基于标准阴极特性的面齿轮阴极设计方法

Design Method of Face Gear Cathode Based on Standard Cathode Characteristics

目的解决电解加工过程中,简单曲面阴极设计方法不能保证面齿轮加工精度的问题。方法利用标准阴极进行正交试验,得出钢制面齿轮的最优电解工艺参数。利用该工艺参数对阴极重新设计,加工试件,根据试件的测量结果对原始阴极进行修形,得出最终阴极形状。结果通过对正交试验数据进行处理,得出钢制面齿轮的最优电解工艺参数为K=20,U=10 V,v=0.6 mm/min;根据试件的误差测量结果,推导出最优修形数为0.4602。结论此阴极设计方法所设计的阴极能保证面齿轮的加工精度,而且能够加工出IT7级精度制件,同时为复杂型面的高精度电解加工方案提供了一种可行的阴极设计方法。

The paper aims to solve problem that simple surface cathode design method can not guarantee the machining precision in the process of ECM. A orthogonal test was carried out with standard cathode to obtain the optimal electrolysis process parameters of steel face gears. Then, those parameters were used to redesign the cathode. Finally, the original cathode was modified by measurement results of the specimen to obtain final cathode shape. The optimal electrolysis process parameters obtained for the steel face gear are K=20, U=10 V, v=0.6 mm/min. The optimal shape correction value derived according to the result of error measurement of samples was 0.4602. The cathode design could guarantee the process thickness of the face gear and can process parts with IT7 grade precision. Also, it presents a feasible cathode design method for high precision electrolytic machining of complex facets.