Gear lapping is done to improve the gear teeth surface along with geometry and form accuracy. The lapping of gear depends on lap speed, lap time, and applied load. This research aims to study the effects of these input process parameters (lapping speed, lapping time, and braking torque) on gear surface roughness. For this experiment, 20MnCr5 is used as workpiece material which is employed where medium to high strength, wear-resistance, and toughness is required. Taguchi’s L9 orthogonal array is used to optimize the effect of input parameters on surface roughness. The optimization trend shows that lapping speed has maximum impact on surface roughness, followed by lapping time, and braking torque. The results confirm a variation of surface roughness for pinion and crown by 9.30% and 7.00%, respectively.

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