Finishing of Bevel Gears using Abrasive Flow Machining

Venkatesh, Gudipadu; Sharma, Apurbba Kumar; Singh, Nitish Kumar; Kumar, Pradeep

doi:10.1016/j.proeng.2014.12.255

Cited by 30 publications

(6 citation statements)

References 6 publications

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“…Since the gear tooth profile is found in a 3-D shape, therefore, the MFD at the gear tooth profile point P is a function of the three magnetic field intensity vectors H xij , H yjk , and H zik in x, y, and z-direction respectively as reported in equation (12). The MFD (B) at any point in any direction in free space due the magnetic field strength (H) produced by the electromagnet coil is given by equation (13).…”

Section: Calculation Of Number Of Abrasive Particles Eips and Chain Structure Of Eips In Working Gapmentioning

confidence: 99%

“…To overcome these defects, from the past few decades, many researchers are working on the nonconventional methods like electrochemical grinding (ECG), 9 electrochemical honing (ECH), 10,11 abrasive flow machining (AFM), 12 chemically accelerated vibratory surface finishing (CAVSF), 13 and ultrasonic assisted abrasive flow machining (UAFFM). 14 These developed processes provide the fine finish of the gear tooth's profile surface.…”

Section: Introductionmentioning

confidence: 99%

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Modeling of surface roughness in a novel magnetorheological gear profile finishing process

Yadav

Singh

Arora

2020

Proceedings of the Institution of Mechanical Engineers, Part C:

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Fine finishing of spur gears reduces the vibrations and noise and upsurges the service life of two mating gears. A new magnetorheological gear profile finishing (MRGPF) process is utilized for the fine finishing of spur gear teeth profile surfaces. In the present study, the development of a theoretical mathematical model for the prediction of change in surface roughness during the MRGPF process is done. The present MRGPF is a controllable process with the magnitude of the magnetic field, therefore, the effect of magnetic flux density (MFD) on the gear tooth profile has been analyzed using an analytical approach. Theoretically calculated MFD is validated experimentally and with the finite element analysis. To understand the finishing process mechanism, the different forces acting on the gear surface has been investigated. For the validation of the present roughness model, three sets of finishing cycle experimentations have been performed on the spur gear profile by the MRGPF process. The surface roughness of the spur gear tooth surface after experimentation was measured using Mitutoyo SJ-400 surftest and is equated with the values of theoretically calculated surface roughness. The results show the close agreement which ranges from −7.69% to 2.85% for the same number of finishing cycles. To study the surface characteristics of the finished spur gear tooth profile surface, scanning electron microscopy is used. The present developed theoretical model for surface roughness during the MRGPF process predicts the finishing performance with cycle time, improvement in the surface quality, and functional application of the gears.

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Section: Calculation Of Number Of Abrasive Particles Eips and Chain Structure Of Eips In Working Gapmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Modeling of surface roughness in a novel magnetorheological gear profile finishing process

Yadav

Singh

Arora

2020

Proceedings of the Institution of Mechanical Engineers, Part C:

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“…Unfortunately, for a long duration after its inception, AFF was not used for gear finishing. More recently, AFF has been explored by some researchers for finishing the helical gears, 8 straight bevel gears, 9 and ultrasonic vibration-assisted AFF (UVA-AFF) process for finishing the straight bevel gears. 10 Xu et al 8 used AFF to reduce surface roughness values at addendum, leftside flank, and right-side flank of helical gears and found that AFF reduced these values from 2.73 µm, 1.10 µm, and 1.42 µm to 1.75 µm, 0.22 µm, and 0.21 µm, respectively.…”

Section: Introductionmentioning

confidence: 99%

“…They also reported that AFF improved contact stiffness, surface quality, and fatigue strength of the helical gears in a very less time. Venkatesh et al 9 used AFF to improve surface finish the bevel gears and studied interaction of the abrasive particles with bevel gear flank regions using computational fluid dynamics (CFD). They observed that extrusion pressure contributed about 73% to surface finish improvement and 83% to material removal, and that surface morphology improved with increase in extrusion pressure.…”

Section: Introductionmentioning

confidence: 99%

Simultaneous improvement of microgeometry and surface quality of spur and straight bevel gears by abrasive flow finishing process

Petare

Jain

Palani

2021

Journal of Micromanufacturing

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This article reports on influence of extrusion pressure, abrasive particle size and volumetric concentration on simultaneous reduction of surface roughness and microgeometry errors of spur and straight bevel gear by abrasive flow finishing (AFF) process. A vertical configured experimental apparatus was developed for two-way AFF and developed fixtures for finishing gears. Experimental investigations were conducted to identify optimum parametric combination, using response surface methodology, based on Box–Behnken design approach. Results revealed that higher values of abrasive particle size and volumetric concentration yield more percentage decrease in surface roughness and microgeometry error. Roughness profile, bearing area curve, microhardness, surface morphology, and wear resistance of the gear having best quality finishing were studied. Surface morphology analysis of the flank regions of the best finished spur and straight bevel gears found them to be smooth and free from cracks and burrs. Reciprocating wear test results revealed higher wear resistance of the AFF finished gears as compared to the unfinished gears. AFF also enhanced microhardness of the finished gears, which would enhance their operating performance and service life. This study shows that AFF is a flexible, economical, productive, easy to operate, and sustainable nontraditional process for precision finishing of gear that can simultaneously improve microgeometry, surface finish, microhardness, surface morphology, wear resistance, and residual stresses of the finished gears. Gear manufacturers and users will be benefited by the outcome of this study. JEL codes: C00, C20

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“…The authors of Kenda, Pusavec and Kopac (2014) found that the AFM polishing process novelty study having movable mandrels in order to obtain improved performance of the product manufactured in the process. In the paper of AFM process, bevel gears are micro manufactured using special tools in (VENKATESH et al, 2014).…”

Section: Introductionmentioning

confidence: 99%

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

Dhull

Walia

Murtaza

et al. 2019

Ind. Jour. Manag. & Prod.

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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.

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Finishing of Bevel Gears using Abrasive Flow Machining

Cited by 30 publications

References 6 publications

Modeling of surface roughness in a novel magnetorheological gear profile finishing process

Modeling of surface roughness in a novel magnetorheological gear profile finishing process

Simultaneous improvement of microgeometry and surface quality of spur and straight bevel gears by abrasive flow finishing process

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

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