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ABSTRACT This paper describes tip relieving of spur gears by pulsed electrochemical flank modification （PECFM） process by a novel designed cathodic gear tool and apparatus. This work reports experimental findings on tip relieving and surface finish by varying the concentration, flow rate, and temperature of the electrolyte, modification duration, and cathodic gear rotational speed at four levels each and using predetermined values of voltage, pulse-on time, pulse-off time, and anodic gear reciprocating speed. The amount of tip relief is found to increase considerably with modification duration and electrolyte concentration. Identified optimum values of modification duration, cathode gear rotational speed, concentration, flow rate, and electrolyte temperature are 20?minutes, 45 rpm, 2 Molarity, 30 lpm, and 40°C, respectively. Scanning electron microscopy images of the tip-relieved spur gear revealed that PECFM effectively eliminates the hob cutter marks from its flank surfaces. This work will be helpful to gear manufacturers seeking productive tip relieving.
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