A Study of Influence of Electrolyte Composition on ECH of Bevel Gears using Mixture D-Optimal Design

This paper discusses the experimental investigation to find out the optimal electrolyte composition in improving the surface quality of the gear teeth profile during surfacing finishing of bevel gears by the electrochemical honing process. In this study, AISI 1040 was used as the workpiece material, mixtures of sodium chloride and sodium nitrate in different ratios were used as the input parameter, and the percentage improvement in the surface roughness and material removal rate of the process were used as measures of process performance. The experimental runs were designed according to the Mixture DOptimal design. The analysis of the experimental outcome was carried out and 80% NaCl + 20% NaNO3 was found to be theoptimal electrolyte composition to conduct the confirmation experiments. The finding of the study establishes the process for precision finishing of bevel gears

Role of the Power Supply and Inter-electrode Gap in Electrochemical Honing Process

AbstractThe process performance of electrochemical honing (ECH) is often increased by the use of the appropriate and optimal input process parameters. This study focuses on the types of power supply and inter-electrode gap in ECH of spur gears, with the aim to determine which parameters are most significant for the required output. Based on the experimental findings, pulse assisted ECH gives marginal improvement in surface finish at the cost of three times higher processing time as compared with direct current ECH and higher value of IEG up to 1mm helps to give controlled anodic dissolution in ECH of spur gears

Electrochemo-magneto abrasive flow machine setup fabrication and experimental investigation of the process alongwith mathematical modeling and optimization

In abrasive flow machining, there are two sets of piston-cylinder arrangements, i.e. machine and media. the machine ram pushes the media piston two and fro so that media filled inside it flows past the inner wall of workpiece and the material is removed. The extrusion pressure is the main mechanism of material removal. Various authors have made the process more effective in terms of material removal and surface roughness by providing rotational and magnetic force

Grinding and fine finishing of future automotive powertrain components

The automotive industry is undergoing a major transformation driven by regulations and a fast-paced electrification. A critical analysis of technological trends and associated requirements for major automotive powertrain components is carried out in close collaboration with industry – covering the perspectives of OEMs, suppliers, and machine builders. The main focus is to review the state of the art with regard to grinding, dressing, texturing and fine-finishing technologies. A survey of research papers and patents is accompanied by case studies that provide further insights into the production value chain. Finally, key industrial and research challenges are summarized

Experimental investigation on magnetorheological finishing process parameters

Magneto-rheological polishing (MRP) fluid was developed by MR fluid using a magnetic field, non-magnetic abrasives such as SiC and Al2O3, and carrier medium like oil. A magnetic polishing tool was developed using a super-strong permanent neodymium magnet (Nd2Fe14B) with 0.5-tesla magnetic intensity. This polishing tool was assembled to the vertical milling machine for the finishing workpieces. In the present research, magnetic materials (steel material) and non-ferromagnetic (copper) content were finishing using a developed MRP setup for experimental investigation. This research also investigated the parametric dependencies of different abrasives on the magneto-rheological finishing process. It determined the effect of magnetic particle concentration and abrasives on the surface roughness of ferromagnetic (stainless steel) and non-ferromagnetic material (copper). The final surface roughness value has reached 30 nm from its initial surface roughness of 800 nm for non-ferromagnetic (copper). For the magnetic material (stainless steel), the value is 50 nm from 1300 nm

Notes and laboratory reports on “Technology of Structural materials and Material Science” Part 2

“Technology of Structural materials and Material Science” is one of the basic technical disciplines in the syllabus for “Engineering mechanics” field of study. During the implementation of laboratory work considerable attention is given to the educational and experimental work for the study of materials that are used in different branches of an industry; alloy’s properties dependance on the chemical composition; structure, methods of treatment and external environments. The study of the theory and practice of different methods of materials strengthening is to provide a high reliability and longevity of the machine’s details, devices, tools etc. After every practical class in the laboratory, students will fill the laboratory report. The content of the laboratory class corresponds with the syllabus of the course “Material Science” for students of the “Engineering mechanics” field of study. The purpose of this manual is to provide guidelines for the students in preparation for independent laboratory work and to project its results in the laboratory reports

Rinser Machine and the Dynamics-based Failure Analysis for Spur Gear Fault Detection: A Forensic Review

Gear fault detection and its severity is essential for analyzing the availability, maintainability and reliability of rinser machines. The occurrence of multiple failures of gears and their analysis is becoming more challenging, thereby causing the increased unavailability rinser machines. This study reviewed the rinser machine and its various advantages and disadvantages, including the problems associated with the machine. More so, various types of failures associated with the spur gears were studied, and it was established that the detection and the diagnosis of gear faults would inform a maintenance planner on scheduled maintenance. Thus, the absence of failure detection will cause uncontrolled machine breakdown and, consequently, result in unsafe operation as well as a loss of productivity. The study concludes and recommends grey cast iron as alternative material that could reduce chemical failure and failure resulting from fatigu

Selective electrochemical machining of the steel molds in hot isostatic pressing of Ti6Al4V powder

Anodic dissolution is proven to be an effective method to remove stainless steel molds from Ti6Al4V compacts obtained from powder by hot isostatic pressing. Two different working solutions were studied: 2 M NaCl and 2 M NaCl + 0.05 M Na2EDTA. While both were capable of removing the steel mold, the latter was also capable of removing the diffusional layer made by the intermetallic phases generated between titanium and steel during the compaction process

Remanufacturing technology

Thesis (M.S.)--Massachusetts Institute of Technology, Dept. of Mechanical Engineering, 1983.MICROFICHE COPY AVAILABLE IN ARCHIVES AND ENGINEERING.Vita.Includes bibliographical references.by Tomás Agustin González Laugier.M.S