Research On Workpiece Vibration-Assisted Wire Electrochemical Micromachining Of Involute Gear Template

High precision involute gear is widely used in modern machinery industry with a large demand,while most of the high precision gears in China still rely on imports.It is of great significance to develop the manufacturing technology of gear involute template and high-precision involute surface for high-precision gear manufacturing.Wire Electrochemical Micromachining technology has been widely concerned by scholars over the world recently as an extension of electrochemical micromachining technology,which unique characteristics can solve problems that is difficult to solve by traditional processing technology.In this paper,the Vibration-Assisted Wire Electrochemical Micromachining technology is introduced into the high-precision involute profile machining,the main contents are as follows:(1)The mechanism of Wire Electrochemical Micromachining technology for involute profile machining was studied.The mathematical model of Wire Electrochemical Micromachining and the compensation equation of machining gap were established.The electric field simulation proved the necessity of improving machining accuracy and gap compensation in involute contour machining.The influence of rotating spiral electrode and vibrating wire electrode with double side flushing was analyzed by the flow field simulation.The electrochemical characteristics of Gcr15 were measured.A vibration assisted electrochemical micromachining platform was designed and built.(2)The cutting experiment of Gcr15 was carried out by using spiral electrode.The influence of processing voltage,pulse frequency,pulse duty cycle and feed rate on the machining accuracy was obtained,a typical micro gear structure with a tip circle diameter of 3.362m and a depth width ratio of 6.25 when cutting was machined by using the optimized parameters.(3)The cutting experiment of Gcr15 with large thickness was carried out by using wire electrode.The effects of different flushing schemes were compared;The influence of vibration frequency and amplitude on machining accuracy was analyzed,which proved that vibration was helpful in improving machining accuracy.In addition,the influence of electrical parameters on the processing efficiency was further studied.It was proved that the increase of voltage,duty cycle and the decrease of frequency can increase the maximum feed rate to some extent and improve the processing efficiency.(4)The involute template was fabricated by using the optimized machining parameters and the compensated machining path.An involute template with 9-level tooth profile accuracy of 13.39mm base circle diameter and 8.39mm span length was obtained,and the aspect ratio reached 40,which proved the feasibility of Vibration-Assisted Wire Electrochemical Micromachining technology in high-precision involute template machining.