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Title: Design of gear-form electrode and ultrasonic-aid in electrochemical finishing of SNC236 surface
Authors: Pa, P S
Issue Date: Jun-2007
Publisher: CSIR
IPC Code: B23F19/00
Abstract: It is very difficult to execute the finishing process of the complex surface of gears. The current study offers a design of gear-form electrode and a new area-finishing process using ultrasonic energy transmitted into the electrolyte to assist in the process of electrochemical finishing on the surface of nickel chromium steels beyond traditional process of gear machining instead of conventional hand or machine polishing. The surface of the gears is electrochemically finished by different types of feeding electrodes as a finishing operation. In the experiment, three types of electrodes are used with continuous direct current and axial electrode feed applied. The controlled factors include the chemical composition and concentration of the electrolyte, die material, initial gap width, and flow rate of electrolyte. The experimental parameters are current rating, feed rate of electrode, frequency and power level of ultrasonics, and electrode geometry. To feed gear-form electrodes, an electrode with one-side borer tip with a small base area yields the best polishing effect in the current investigation. For the design electrodes, a thin plate with small end radius and small wedge angle are associated with higher current density and provides larger discharge space and better polishing effect. The electrode with a spherical head performs the best. The higher current rating with ultrasonic assistance can avoid the difficulty of dreg discharge, thus reducing the finishing time. It is a great contribution that the ultrasonic-aided electrochemical finishing after gear machining needs a much shorter time than manual or machine polishing to make the surface of gears smooth and bright. An effective and low-cost finishing of the surface of castings is presented.
Page(s): 202-208
ISSN: 0971-4588
Appears in Collections:IJEMS Vol.14(3) [June 2007]

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