In gear manufacturing industry, the fine finishing of gear teeth profile in gear boxes is an essential factor for defining quality of the manufactured products. Fine finished gear teeth profile is used in highly precise manufacturing processes, scientific instruments, aircraft, and military equipment. The finished gear teeth performance rests on the shape precision that increases the service life, reliability and reduces the noise and vibrations at higher speed. For obtaining the required shape accuracy of gear teeth, various finishing processes are developed. In this work, a recently developed magnetorheological gear profile finishing (MRGPF) process is used for the surface finish of the gear teeth profile of hardened EN24 steel material. The hardened EN24 steel material is extremely useful in industry for the manufacturing of spur gears, bevel gears, and helical gears. Response surface methodology is utilized for the parametric study of the MRGPF process. The outcomes of different process parameters variables on the percentage change in surface roughness of hardened EN24 steel spur gear is investigated and optimized. The optimized process parameters are utilized for improving the gear shape accuracy through fine finishing. The surface morphology of the ground surface and finished surface after the MRGPF process has been analyzed using the scanning electron microscopy. It reveals that the present magnetorheological (MR) finishing process removes the grinding burn, grinding lays and surface cracks from the initial gear surface. The value of surface roughness reduces from 220 nm to 20 nm in 40 min of finishing cycle with the optimized parameters. Also, the improvement in gear shape accuracy after MR finishing with the optimized parameters is measured in DIN standards to check the accuracy and precision of the gear dimensions.

在齿轮制造行业中，齿轮箱中齿轮齿廓的精加工是定义制成品质量的重要因素。精加工的齿轮齿廓用于高精度制造工艺，科学仪器，飞机和军事装备。最终的齿轮齿性能取决于形状精度，从而提高了使用寿命，可靠性并降低了高速时的噪音和振动。为了获得所需的轮齿形状精度，开发了各种精加工工艺。在这项工作中，最近开发的磁流变齿轮轮廓精加工（MRGPF）工艺用于硬化EN24钢材的齿轮齿轮廓的表面精加工。硬化的EN24钢材在工业上对正齿轮的制造极为有用，锥齿轮和斜齿轮。响应面方法被用于MRGPF过程的参数研究。研究和优化了不同工艺参数变量对硬化EN24钢正齿轮表面粗糙度变化百分比的影响。优化的工艺参数用于通过精加工提高齿轮形状的精度。使用扫描电子显微镜分析了MRGPF工艺之后的地面和最终表面的表面形态。结果表明，目前的磁流变（MR）精加工工艺消除了初始齿轮表面的磨痕，磨痕和表面裂纹。在优化的参数下，在40分钟的精加工周期中，表面粗糙度的值从220 nm降低至20 nm。也，