Abstract
Abrasive flow finishing (AFF) is a non-traditional nano-finishing process for radiusing, polishing, surface stress reliving, geometry optimization and deburring. This paper reports on finishing of straight bevel gear by using AFF. Experimental setup of AFF and a special fixture for holding workpiece straight bevel gear were developed. Finishing result produced by AFF is significantly influenced by two process parameters, namely finishing duration and extrusion pressure. Eleven experiments for AFF of straight bevel gear were conducted in two phases by varying extrusion pressure and finishing time using one factor at a time approach. The outcome showed high improvement in maximum surface roughness and average surface roughness of gear which will further improve their service life and operating performance. Surface morphology study of AFF finished straight bevel gears revealed that their flank surfaces are free from cutter marks, burrs, nicks, micro-cracks, micro-chips, and micro-pits. Result produced establishes the feasibility AFF for precision finishing of straight bevel gear.
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