Investigations on precision finishing of space curve meshing wheel by electrochemical brushing process

In this study, a novel finishing process named electrochemical brushing (ECB) is proposed, which integrates the merits of electrochemical polishing (ECP) and mechanical finishing (MF). It executes finishing for the space curve meshing wheel (SCMW), which was manufactured by the selective laser melting (SLM) rapid prototyping process. First, finishing experiments of ECP and ECB were carried out with optimal parameters, including an applied voltage of 10 V, a cathode and workpiece gap of 1 mm, and an ingredient electrolyte of NaNO₃ (10 %)?+?Al₂O₃ (0.1 %)?+?H₂O. Advantages of the ECB process were shown by analyzing the machining mechanism and comparing the experimental results. Furthermore, the cathode tools and finishing experimental rigs were designed to process SCMW samples. Finally, kinematics experiments were carried out, and the relation between the transmission ratio and the surface roughness of meshing tines is discussed. After ECB, as the surface roughness of meshing tines was reduced from 34 to 0.5 μm, the average transmission ratio of SCMW samples was improved from 3.922 to 3.993 and approached the theoretical value of 4, and its standard deviation was improved from 0.0317 to 0.0077. Therefore, the ECB process could be a feasible process to finish the SCMW to be able to perform precision meshing transmission.