Mixture D-Optimal Design of Electrolyte Composition in ECH of Bevel Gears

In Electrochemical Honing (ECH), most of the metal is removed by electrolytic dissolution and therefore, the electrolyte composition plays a crucial role in the study. This paper presents the experimental investigation to find out the optimal electrolyte composition in improving surface quality of gear teeth profile during surfacing finishing of bevel gears by ECH process. In this study, mixture of sodium chloride and sodium nitrate in different ratios were used as input parameter and the percentage improvement in bearing ratio of gear teeth profile was used as response parameters while the experimental runs were designed and planned according to the Mixture D-Optimal design. Analysis of variance was carried out and optimal electrolyte composition was investigated to conduct the confirmation experiment.