The Development Of Electrochemical Machining Technology And Equipment For Micro-segment Helical Internal Gear

Micro-segment helical internal gear is mainly used in automatic transmission planetary gear train. It is very difficult to be processed by conventional machining for his non-standard modulus, large modification coefficient and the thin gear ring which is also hard. Electrochemical Machining (ECM) is suitable to process Micro-segment helical internal gear, because of no mechanical cutting force after processing, and attaining fine surface quality.Add NC rotary table on DJK3150machine tool spindle to increase one freedom of rotation around the Z axis. Develop the electrochemical frock and1mm thick disc-form cathode. Choose the pulse power whose peak current is2000A, which the frequency can reach to20KHz. Select centrifugal pump, devise electrolytic cell and filter to finish electrolyte system. Use the technology of PLC and design the control system combined the movement of NC rotary table with machine tool spindle. Non-linear electrolyte and its compound electrolyte are used in experiment. Finally, the entire equipment is installed and tested. Choose appropriate machining parameter to process gear.The experiment results indicate that sealed frock well which can exactly locate workpiece has good flow field and electrical conductivity. The control system can accurately control the movement of the machine tool. The machine tool would be stopped immediately to protect workpiece and cathode when short-circuit happen. The gear profiler meets the requirement. When the gear work with Micro-segment helical external gear, they rotate flexibly and their backlash is well distributed.