直齿面齿轮高精度电解加工阴极整体结构设计方法研究

Study on Design Method of Integral Structure of Cathode for High Precision Electrochemical Machining of Straight Teeth Face Gear

针对传统展成法加工直齿面齿轮周期长、成本高及成形法批量生产存在的质量精度低等现象,提出一种高精度直齿面齿轮电解加工阴极整体结构设计方法。首先,根据直齿面齿轮的齿面方程,利用截面放样法对齿面建模点进行合理规划,并基于网格划分方式,利用平衡间隙设计理论建立相应的阴极刀具型面模型;其次,采用反流式设计阴极流道以提高工作效率及加工精度;最后,在设计阴极刀具型面和流道型腔结构的基础上,设计了一体化电解加工装夹系统。通过电解加工直齿面齿轮的加工实验,获得了表面粗糙度值小于Ra1.6μm、综合精度为IT9级的直齿面齿轮制件,从而验证了该设计方法的可行性。

Aiming at the phenomenon of long processing period,high cost and low quality precision in the production of straight tooth surface gear,a cathode electrochemical machining（ECM） of high precision straight teeth face gear structure design method is proposed. First of all,according to the section lofting surface equation of straight tooth surface of gear tooth surface modeling of straight tooth gear and the reasonable planning of mesh clearance design using the equilibrium theory to establish the corresponding tool cathode surface model based on the second. The cathode flow channel design using reverse flow type design has to improve work efficiency and processing the accuracy of ECM clamping system. Integration design based on the cathode tool surface and flow structure of the cavity. The ECM straight tooth gear machining test,the surface roughness below Ra1.6 μm,with accuracy of IT9 level of face gear parts,which verifies the feasibility of the design method.