The Designing Of Process System Of Electrochemical Machining And The Optimization Of Process Parameters For Micro-segment Helical Internal Gear

Micro-segment helical internal gear is mainly used in planetary gear train，which is widely applied in automotive, aerospace engineering and other highpower drive fields. It is very hard to be processed by traditional machining forhis non-standard modulus, large modification coefficient and the thin gear ringwhich is also hard. Electrochemical Machining(ECM) can offer severaladvantage to process Micro-segment helical internal gear, such as hardness andstrength of material play no part in machining, has no mechanical cutting force,fine surface quality.Paper research the processing method of Helical Internal Gear, and designthe process system of Electrochemical Machining. Adding and installing NCrotary table on DJK3150machine tool spindle increase one freedom of rotationaround the Z axis. Designing and manufacturing the sealing technical equipmentwhich ensure the electrolyte flow enough and equably in the process ofmachining, and has certain backpressure. Design cathode components; choose1mm thick stainless steel cathode piece as a work of the head, and the designingand optimization cathode piece of tooth. Choose the pulse power which peakcurrent is2000A and the frequency can up to20KHz. Design and build theelectrolyte system. Install and debug the whole process system. Design theprocess equipment scheme, using the single factor experiment and orthogonalexperiment to optimization of process parameters,According to the microscope and its supporting software internal gearmeasurement, using the range analysis and variance analysis to analyze theexperimental data, paper obtain the optimal combination of process parameters.The machining gear precision meets the requirements of high efficiency, goodsurface quality, no mechanical residual stress, no need for subsequentprocessing.