直齿面齿轮电解加工技术研究

发布时间：2018-06-06 01:25

本文选题：直齿面齿轮 + 复杂空间型面　；参考：《西安工业大学》2017年硕士论文

【摘要】：直齿面齿轮是一种与直齿圆柱齿轮相啮合的平面齿圈齿轮,凭借其重合度高、传动平稳、噪声低、扭矩分流效果好等传动特点,使得直齿面齿轮被广泛应用在了低速和高速、轻载和重载的众多传动领域中。然而直齿面齿轮的齿面较为复杂,其几何形状已不是传统渐开线齿面或其他常见的齿面,而是一种复杂空间型面,为了解决传统展成法加工直齿面齿轮中存在的周期长、成本高、不适合进行批量生产的问题以及传统成型法加工直齿面齿轮中存在的批量化制造质量精度低的现象。本文提出了一种基于电解加工技术的直齿面齿轮批量化快速制造工艺以实现在质量保证前提下的直齿面齿轮批量化快速制造。首先,利用直齿面齿轮的齿面方程通过对直齿面齿轮的齿面建模点进行合理规划并采用截面放样法构建出用于电解加工的直齿面齿轮齿面三维模型及相应的直齿面齿轮三维模型;其次为了解决传统“减材制造”进行批量生产时存在的技术缺陷,根据直齿面齿轮的三维模型结构依照带有活动成型零部件的注射模具设计方法设计出相应的直齿面齿轮母模三维模型,并利用FDM快速成型技术依次通过三维模型的前处理、设置快速成型工艺参数及制件后处理这3个环节快速制造出用于批量化生产电解加工直齿面齿轮半精制件的直齿面齿轮母模实体,再将此实体作为熔模铸造用的注蜡模具熔模精铸出待电解精加工的批量直齿面齿轮半精制件;最后,基于电解加工技术采用侧面间隙法设计电解精加工直齿面齿轮的阴极头型面并采用电解液反流式方式设计出相应的阴极流道,再结合正交试验法并利用逐步回归分析的思想确定出电解精加工直齿面齿轮的最优工艺参数组合,并按此最优工艺参数设计电解精加工直齿面齿轮的初始阴极,最后通过构建拉格朗日插值函数进行迭代来获取最优修形系数以实现对电解精加工的阴极头进行修形,从而加工出了具有综合精度为IT9级的批量直齿面齿轮制件。研究结果表明,本文提出的基于电解加工技术的直齿面齿轮批量化快速制造工艺不仅实现了较高精度直齿面齿轮的批量化制造,同时通过将“增材制造”技术中的快速成型技术与熔模精铸工艺相结合,还实现了较短时间内、以较低成本的直齿面齿轮半精制件的批量化快速制造,解决了传统批量化“减材制造”技术中存在的成本高、工序复杂、效率低的问题,验证了该工艺方案的正确性与可行性。
[Abstract]:Spur gear is a kind of planar ring gear meshing with straight cylindrical gear. With its characteristics of high coincidence, stable transmission, low noise and good torque diversion effect, spur gear is widely used in low speed and high speed. Light and heavy loads in many fields of transmission. However, the tooth surface of spur gear is more complex, its geometric shape is not traditional involute tooth surface or other common tooth surface, but a complicated spatial surface. The problem of high cost and unsuitable for mass production and the phenomenon of low quality precision of mass manufacturing in traditional forming process of spur gear. In this paper, a batch rapid manufacturing process of spur gear based on ECM is proposed to realize the rapid manufacturing of spur gear with quality assurance. First By using the tooth surface equation of the spur gear, the tooth surface modeling point of the spur gear is reasonably planned, and the three-dimensional model of the tooth surface of the straight tooth gear and the corresponding three-dimensional model of the straight tooth face gear are constructed by using the section lofting method. Secondly, in order to solve the technical defects in batch production of traditional "material reduction manufacturing", According to the 3D model structure of spur gear, according to the design method of injection mould with movable forming parts, the corresponding 3D model of spur gear master die is designed, and the FDM rapid prototyping technology is used to preprocess the 3D model in turn. By setting the process parameters of rapid prototyping and the post-processing of the parts, the master mould entity of the spur gear for batch production of the semi-refined parts of the straight face gear was produced quickly. The solid is then used as a wax injection mould for investment casting to produce a batch of straight gear semi-refined parts to be finished by electrolysis. Based on the electrolytic machining technology, the cathode head profile of the straight gear was designed by side gap method, and the corresponding cathode runner was designed by electrolyte reverse flow. Combining with the orthogonal test method and using the idea of stepwise regression analysis, the optimal process parameters combination of electrolytic finishing straight gear is determined, and the initial cathode of electrolytic finishing straight gear is designed according to the optimum process parameters. At last, the Lagrange interpolation function is constructed to obtain the optimal modification coefficient to realize the modification of the cathode head of electrolysis finishing machining, and then the batch straight gear parts with the comprehensive precision of IT9 class are manufactured. The research results show that the batch rapid manufacturing process of spur gear based on ECM not only realizes the batch manufacturing of gear with higher accuracy. At the same time, by combining the rapid prototyping technology in the "material increasing manufacturing" technology with the investment casting process, the batch rapid manufacturing of spur gear semi-refined parts with lower cost has been realized in a relatively short period of time. It solves the problems of high cost, complex working procedure and low efficiency in traditional batch "material reduction manufacturing" technology, and verifies the correctness and feasibility of the process plan.
【学位授予单位】：西安工业大学
【学位级别】：硕士
【学位授予年份】：2017
【分类号】：TH132.41;TG662

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