Title: Precision microfinishing by electro-chemical honing

Authors: A.K. Dubey, H.S. Shan, N.K. Jain

Addresses: Department of Mechanical and Industrial Engineering, Indian Institute of Technology, Roorkee 247 667, India. ' Department of Mechanical and Industrial Engineering, Indian Institute of Technology, Roorkee 247 667, India. ' Department of Mechanical and Industrial Engineering, Indian Institute of Technology, Roorkee 247 667, India

Abstract: Surface condition and shape deviations produced by manufacturing processes have pronounced influence on the functional performance of engineering components. This paper reports a comprehensive study on the influence of several key process parameters of Electro-Chemical Honing (ECH), a precision microfinishing technology, on dominant machining criteria the surface roughness improvement. The current intensity, electrolyte concentration, stick-out pressure and stick grit-size are found to be the major players influencing the response significantly. With distinct coordination of electrolytic dissolution and mechanical scrubbing, ECH can be utilized as a precision microfinishing process for critical components of tribological significance. More than 90% improvement in surface finish with precisely controlled shape deviations can be achieved. Important features of the ECH setup that was designed and developed indigenously are also highlighted.

Keywords: electro-chemical honing; rotary-to-reciprocating speed ratio; surface roughness; analysis of variance; ANOVA; bearing ratio; precision microfinishing; current intensity; electrolyte concentration; stick-out pressure; stick grit size; tribology; surface finish.

DOI: 10.1504/IJMTM.2009.023953

International Journal of Manufacturing Technology and Management, 2009 Vol.17 No.4, pp.364 - 372

Published online: 22 Mar 2009 *

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