高精度直齿面齿轮电解加工阴极结构设计研究

Research on High Precision Straight Tooth Surface Gear Electrolytic Machining Cathode Structure Design

针对传统展成法加工直齿面齿轮存在加工周期长、成本高以及批量生产精度低的现象,提出一种高精度直齿面齿轮电解加工阴极结构设计方法。利用截面放样法对直齿面齿轮齿面建模点进行合理规划并基于此网格划分方式利用平衡间隙设计理论建立相应阴极刀具型面模型;其次采用反流式方式设计阴极流道,提高工作效率及加工精度;最后设计一体化电解加工装夹系统。通过电解加工试验,获得了表面粗糙度在1.6μm以下、具有综合精度为IT9级的直齿面齿轮制件,验证了该设计方法的可行性。

To solve the problems such as long machining cycle,high cost and low precision in mass production existed in traditional machining of straight tooth gear,a method of designing high precision straight tooth surface gear cathode structure was present.Using the section lofting method,the tooth surface modeling points were reasonably planned;the corresponding cathode surface model was established based on the equilibrium clearance theory.The cathode channel was designed using the reflux mode to improve the work efficiency and the processing precision.Finally an integrated ECM clamping system was designed.Through the electrochemical machining experiment,the straight tooth face gear part with the surface roughness below 1.6μm and the comprehensive accuracy of IT9 level are obtained,which verify the feasibility of the design method.