Design And Experimental Study Of Multi-station Internal Gear Electrochemical Machining Machine With Electrolyte Current Sharing Control

The internal gear has the advantages of stable transmission,accurate transmission ratio,compact structure,etc,and has an irreplaceable role in related industries such as automobiles,ships,aerospace,instrumentation and other related industries.For the small diameter gear processing in the blind hole,the traditional insertion process is inefficient and the tool loss is large;the cost of plastic forming process equipment is extremely high and the process is not easy to master;electrolytic processing has the advantages of high efficiency,high surface quality,no tool loss,no burr and internal stress,etc.In the internal tooth processing,the existing electrolytic processing of the internal tooth tooling is complex and the efficiency is low.On the basis of the new electrolytic cutting method of flat jet feeding liquid proposed by the research group.In this thesis,a multi-piece synchronous machining scheme is developed around the new method.The machine tool design,control system design,electrolyte current sharing control system design and multi-station electrochemical machining experimental research are carried out.The main work accomplished in the as follows:(1)Machine design.According to the multi-station gear electrolysis processing process,comprehensive consideration of the workpiece size,liquid supply,drainage,energization and anti-corrosion requirements,the machine tool structure scheme is formulated,and the machine tool prototype is actually manufactured.(2)Control system development.The machine tool control system based on PLC is developed to realize the high-precision feed control of the spindle.The specific work includes device selection,circuit design,programming and human-computer interaction interface formulation.(3)Design of electrolyte current sharing control system.The shunt device is analyzed and designed by COMSOL simulation software,and the flow control system of "PLC-flowmeter-solenoid valve" is built by PID control principle to ensure the uniform supply of electrolyte in each station.(4)Design and experimental study of multi-station gear electrolysis processing fixtures.A special fixture is designed,and through the experimental analysis of single station,multi-station processing experiments are carried out to compare the processing effect with or without electrolyte current sharing control.