Non-contact flank modifications of spur gears using cathodic gear tools and mechanisms: an experimental study

Abstract

ABSTRACT This paper introduces cathodic gear tools designed for non-contact modification of spur gears through pulsed electrochemical flank modification. Operating with continuous rotary motion, these tools achieve profile crowning, lead crowning, tip relieving, root relieving, and end relieving. Anodic workpiece gears experience constant or variable reciprocating velocity based on the modification type. Experimental investigations confirm that the tools not only achieve the intended flank modification but also reduce flank surface roughness, eliminating hob cutter marks and cracks from the modified spur gear surfaces. The magnitude of intended modifications increases with higher voltage and longer modification duration. Notably, root relieving requires a longer duration (20 minutes) compared to other modifications (12 minutes). Details of variation in surface roughness and surface morphology using scanning electron microscopy are also presented to validate the developed mechanism.