Study On Electrochemical Machining Technology Of Straight Teeth Face Gear

The straight teeth face gear is a kind of planar gear which is meshed with spur gear,with its high coincidence degree,calm transmission,low noise and efficient torque diversion characteristics makes straight teeth face gear be widely used in numerous transmission fields in low and high speed,and in light and heavy load.Since the tooth surface of straight teeth face gear is much more sophisticated,and its geometry is a complex spatial curved surface instead of traditional involute flank or other common tooth surfaces,in order to solve the traditional generating method problems of long period,high cost and not suitable for batch production in the process of machining straight teeth face gear and the phenomenon of low precision of batch production in the process of machining straight teeth face gear by traditional forming method.In this paper,a rapid manufacturing process of straight teeth face gear based on electrochemical machining technology is proposed to achieve the mass rapid manufacturing of straight teeth face gear under the premise of quality assurance.Firstly,the tooth facial points of straight teeth face gear are rationally planned which is based on the tooth surface equation of straight teeth face gear,and then the three-dimensional model of the tooth surface and the corresponding three-dimensional model of the straight teeth face gear are constructed by using the method of section lofting;secondly,in order to solve the technical defects of the traditional " reduction of material manufacturing " in batch production,according to the three-dimensional model structure of the straight teeth face gear and based on injection mold design method with movable forming parts,the corresponding three-dimensional model of the straight teeth face gear master mold is designed,meanwhile the three parts of rapid prototyping process that included pretreatement of three-dimensional,rapid prototyping process parameters and post processing are set up by FDM rapid prototyping technology to rapid machining of straight teeth face gear master mold that is used for produce the semi-finished product of straight teeth face gear for mass production of electrochemical machining,and the entity of straight teeth face gear master mold is used as a wax casting mould for investment casting to produce a batch of semi-finished straight teeth face gear product which are waiting for electrolytic finishing;finally,according to electrochemical machining technology,this paper presents a method for designing the cathode head surface of an electrolytic finishing straight teeth face gear by the side clearance method and the cathode flow channel was designed by the reverse flow of electrolyte,combing with the orthogonal test method and the idea of stepwise regression analysis,the optimal process parameters combination of the electrolytic finishing straight teeth face gear is determined,according to the optimum process parameters,the initial cathode of electrolytic finishing straight teeth face gear is designed,in the end,the Lagrange interpolation function is used to obtain the optimal modification coefficient to realize the modification of the cathode head of the electrolytic finishing process,therefore,it has produced a batch straight teeth face gear with comprehensive accuracy of IT9.The study show that this paper introduced a rapid manufacturing process of straight teeth face gear which is based on the electrochemical machining technology can not only realizes the batch manufacturing of high precision straight teeth face gear,but also can combining the rapid prototyping technology with the investment casting process that belongs to additive material manufacturing technology,so the semi-precision parts of the straight teeth face gears are manufactured in a low cost and in the short time,it solves the problems of high cost,complex process and low efficiency in the traditional batch “reduction of material manufacturing” technology,this method is proved to be correct and feasible.