直齿面齿轮高精度电解加工阴极型面设计方法研究

直齿面齿轮的齿面是一种复杂空间曲面,为了实现难切削材料的复杂曲面产品的批量加工,目前主要以电解加工技术为主;考虑到电解加工在复杂异面类产品的加工中存在阴极设计效率低,精度难以保证等问题,提出一种基于标准阴极特性的阴极型面智能设计方法。首先,基于复杂齿面网格规划原则对直齿面齿轮的齿面点进行合理规划,并采用截面放样法计算各采样齿面点坐标;其次,通过分析各齿面采样点所在型面的曲率半径,利用电解加工平衡间隙理论构建针对不同曲率情况下的相应阴极刀具型面设计方案;最后,利用Matlab中的GUI人机交互界面构建直齿面齿轮的智能化阴极刀具型面设计系统。通过加工实验可知,利用该系统设计出的阴极型面,其加工精度可达IT8。

Research on Design Method of Cathode Profile for High Precision Electrolytic Machining of Spur Face Gear

The tooth surface of the spur face gear is a kind of complex space curved surface, in order to realize the batch machining of complex space curved surface products with difficult cutting materials, the main technology of electrolytic machining is mainly used at present. Considering that electrolytic machining has some problems such as low efficiency of cathode design and difficult to guarantee the design accuracy in the machining of complex dissimilar surface products, an intelligent design method of cathode profile based on the characteristics of standard cathode is presented. Firstly, based on complex tooth surface grid planning principle, the coordinate of each sampling tooth surface is calculated by section lofting method. Secondly, by analyzing the curvature radius of each tooth surface sampling point, the design scheme of the corresponding cathode tool profile is constructed based on the theory of electrolytic machining equilibrium gap theory. Finally, using the GUI humancomputer interface in Matlab, the intelligent cathode profile design system for spur face gear is constructed.Meanwhile the experimental shows that the machining accuracy of the cathode surface designed by the system is up to IT8.