DAAAM INTERNATIONAL SCIENTIFIC BOOK 2013 pp. 697-710 CHAPTER 41 HIGH QUALITY FINISHING OF BEVEL GEARS BY ELECTROCHEMICAL HONING SHAIKH, J. H. & JAIN, N.K. Abstract: This chapter presents the development of an innovative experimental setup for finishing the bevel gears by Electro-chemical honing (ECH) process and experimental investigations on the effects of electrolyte composition and finishing time on surface roughness of straight bevel gears with an objective to improve their overall surface quality. A novel concept of using twin complementary cathode gears has been envisaged to meet the challenge of finishing the complex conical geometry of the bevel gears by ECH without providing reciprocating motion and to ensure high quality finishing of bevel gears by ECH. Average surface roughness (R a ) and maximum surface roughness (R max ) have been considered to evaluate the effects of the chosen input parameters. The experiments were designed and conducted using full factorial approach of experimental design. The experimental results have shown significant improvement in surface finish of the bevel gears. The analysis of finished surface through SEM images has shown improvement in the surface integrity of the workpiece gears. This work establishes ECH a productive and economical alternative finishing process for the bevel gears giving high quality surface finish. Key words: ECH, Bevel Gears, High Quality Finishing, Surface Roughness Authors´ data: Shaikh, J[aved] H[abib]; Jain, N[eelesh] K[umar]*, Discipline of Mechanical Engineering, Indian Institute of Technology Indore, 453 446, MP, INDIA, shaikhjaved1@gmail.com, nkjain@iiti.ac.in This Publication has to be referred as: Shaikh, J[aved] H[abib] & Jain, N[eelesh] K[umar] (2013) High Quality Finishing of Bevel Gears by Electrochemical Honing, Chapter 41 in DAAAM International Scientific Book 2013, pp. 697-710, B. Katalinic & Z. Tekic (Eds.), Published by DAAAM International, ISBN 978-3-901509-94-0, ISSN 1726-9687, Vienna, Austria DOI: 10.2507/daaam.scibook.2013.41