CN114473089A - Method for removing large generated electrolytic allowance of high-hardness material face gear and machining device - Google Patents
Method for removing large generated electrolytic allowance of high-hardness material face gear and machining device Download PDFInfo
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- 238000000034 method Methods 0.000 title claims abstract description 49
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- 238000005868 electrolysis reaction Methods 0.000 claims abstract description 33
- 230000033001 locomotion Effects 0.000 claims abstract description 23
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- 229910052802 copper Inorganic materials 0.000 claims description 7
- 239000010949 copper Substances 0.000 claims description 7
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- FAPWRFPIFSIZLT-UHFFFAOYSA-M Sodium chloride Chemical group [Na+].[Cl-] FAPWRFPIFSIZLT-UHFFFAOYSA-M 0.000 description 2
- 238000005260 corrosion Methods 0.000 description 2
- 230000007797 corrosion Effects 0.000 description 2
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- 238000010862 gear shaping Methods 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
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- 238000011160 research Methods 0.000 description 2
- VWDWKYIASSYTQR-UHFFFAOYSA-N sodium nitrate Chemical compound [Na+].[O-][N+]([O-])=O VWDWKYIASSYTQR-UHFFFAOYSA-N 0.000 description 2
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23H—WORKING OF METAL BY THE ACTION OF A HIGH CONCENTRATION OF ELECTRIC CURRENT ON A WORKPIECE USING AN ELECTRODE WHICH TAKES THE PLACE OF A TOOL; SUCH WORKING COMBINED WITH OTHER FORMS OF WORKING OF METAL
- B23H3/00—Electrochemical machining, i.e. removing metal by passing current between an electrode and a workpiece in the presence of an electrolyte
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23H—WORKING OF METAL BY THE ACTION OF A HIGH CONCENTRATION OF ELECTRIC CURRENT ON A WORKPIECE USING AN ELECTRODE WHICH TAKES THE PLACE OF A TOOL; SUCH WORKING COMBINED WITH OTHER FORMS OF WORKING OF METAL
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Abstract
A method for removing large electrolytic allowance generated by high-hardness material face gears and a processing device belong to the technical field of electrolytic processing. The cathode is used as a cutter, the face gear is electrolytically machined by applying a developed roll-to-roll movement electrolysis method, the cathode profile is designed into a cylindrical gear profile, the meshing roll-to-roll movement of the face gear and the cylindrical gear is simulated, and most of the allowance of a face gear blank is removed by controlling process parameters in the face gear electrolysis process. Designing a cathode system, wherein the generating cathode system comprises a cathode cutter and a combined insulating cutter handle. In the electrolytic process, current is led into the cathode tool through the conductive slip ring in the positive direction, and the current is not conducted due to the influence of the insulating ring in the reverse direction, so that the influence of stray current leakage on a spindle system is avoided. The wire is connected to the rotating part, and the electric slip ring device is installed on the anode tooling. High-quality and high-efficiency electrolytic machining is adopted to improve the precision and efficiency of subsequent finish machining. The method has important significance for improving the machining precision and efficiency of the key part face gear of the domestic high-speed high-power aviation driving system.
Description
Technical Field
The invention belongs to the technical field of electrolytic machining, and particularly relates to a method and a device for removing generated electrolytic large allowance of a high-hardness material face gear, which are prepared for finish machining of a subsequent face gear.
Background
The face gear has the advantages of high bearing capacity, stable transmission, low working noise and the like, and is widely applied to energy equipment, transportation, engineering machinery, main reducers of aeroengines and helicopter transmission systems. The traditional face gear machining method comprises gear shaping, gear hobbing and gear grinding machining, the gear shaping and the gear hobbing are used as common rough machining process methods of the face gear, and generating movement of a cutter and the face gear is simulated. However, for the slotting machining of high-hardness difficult-to-machine materials and special face gears with special structures, the problems of low machining efficiency, serious tool abrasion, high machining cost, difficult control of cutting scraps in the machining process, tool sticking phenomenon or formation of accumulated scraps and the like exist, the surface quality of a workpiece is reduced, the workpiece is deformed, and the dimensional accuracy of the workpiece is difficult to ensure.
The electrochemical machining has the advantages of good machining quality and high machining efficiency, and the machining is a machining method for removing surface metal by oxidizing metal on the surface of a workpiece serving as an anode to lose electrons and form free ions which enter electrolyte according to the electrochemical anode dissolution principle. The cathode in the electrolytic machining is equivalent to a cutter, the cathode and a tool system are specially designed according to the characteristics of a machined workpiece, and electrochemical reaction is realized in a process system by means of a power supply system and a medium-pressure electrolyte circulating system to finish the rough machining and forming of the workpiece. The cathode of the electrolytic machining and the anode of the workpiece are not in direct contact, but have a certain gap. Although the electrolytic machining has the above-described advantages, there are problems such as stray corrosion and difficulty in controlling dimensional accuracy.
Disclosure of Invention
The invention aims to provide a method for removing the generated electrolytic large allowance of the high-hardness material face gear, which can realize precise, efficient and low-cost electrolytic machining of the high-hardness and difficult-to-machine face gear and aims to solve the problems of stray corrosion, difficult control of dimensional precision and the like in the prior art.
The second purpose of the invention is to provide a high-hardness material face gear generating electrolysis large-allowance removing and processing device.
The method for removing the large surplus generated by generating electrolysis of the high-hardness material face gear comprises the following specific steps:
the method comprises the steps of taking a cathode as a cutter, electrolytically machining a face gear by applying a developed roll-to-roll movement electrolysis method, designing the cathode profile into a cylindrical gear profile, simulating the meshing roll-to-roll movement of the face gear and the cylindrical gear, obtaining technological parameters through tests in the face gear electrolysis process, and removing most of the allowance of a face gear blank by controlling the technological parameters, wherein the technological parameters comprise electrolyte components, concentration, temperature, feeding speed, working voltage, electrolyte pressure and the like.
The specific steps of the electrolytic machining of the face gear by applying the roll-to-roll movement electrolysis method are as follows: the rotating speed ratio of the cathode tool to the face gear blank is the transmission ratio of the cylindrical gear to the face gear, the cathode tool axially moves to a certain feeding depth along the electrolytic machine tool, and generating movement is carried out between the electrode and the workpiece to complete generating electrolytic machining of the feeding depth; then, the cathode tool moves axially along the electrolytic machine tool by the same feeding depth, and in the same way, multi-step axial feeding is carried out to complete the generating electrolytic machining of the face gear; the cathode is designed according to a gear meshed with a face gear with a finish machining allowance, the reference circle diameter of the cathode is 0.8 multiplied by the number of teeth of a cylindrical gear multiplied by the modulus m of the cylindrical gear, a certain machining gap is kept between the surface of the cathode and a workpiece, and the certain machining gap is about 0.2mm of electrolytic gap plus the finish machining allowance of 0.2-0.3 mm.
The technical parameters are obtained through tests, and specifically, the technical parameters of electrolyte composition, concentration, temperature, feeding speed, working voltage and electrolyte pressure are formulated through the sequence and primary and secondary differences of the technical parameters and combined with the test research on the influence of relevant technical parameters on the processing characteristics.
The large-allowance removal processing device for generating electrolysis of the high-hardness material face gear comprises a generating method electrolysis machine tool and an electrolysis workbench;
the generating electrolysis machine includes: the device comprises a Z-axis sliding seat, a B-axis tailstock, a Y-axis guide rail, a 3R clamp, a stand column of a machine base and an electrolysis machine body; the Y axis is a cathode cutter moving axis, the B axis is a workpiece rotating axis, and the C axis is a cathode cutter rotating axis;
the electrolytic working table comprises an electrolyte inlet, a tool upper cover, a face gear blank, a tool lower cover, a marble base (bottom insulation), a pull nail, a tool shank body (for realizing C-axis rotation), an electro-hydraulic slip ring, a cathode tool, an electrolyte outlet, an electric slip ring, a pulse power supply cathode, a pulse power supply anode and a pulse power supply;
the electrolytic machining of the electrolytic machine tool depends on the Z-axis sliding seat, the Y-axis guide rail, the combined insulating tool shank and the B-axis tail seat to realize the movement of the Z axis, the Y axis, the C axis and the B axis; the 3R clamp is used for realizing rapid positioning of face gear electrolytic machining.
The electrolytic worktable is arranged on a generating method electrolytic machine tool through a fastening device, the electrolytic tank is arranged on a machine body of the generating method electrolytic machine tool, and the B shaft tail seat immerses a workpiece into electrolyte in a cavity of the electrolytic tank through a sealing device; the conductive copper block is arranged on the side surface of the workpiece, and the positive electrode of the pulse power supply is connected with the conductive copper block through an electric slip ring;
the sealing device comprises a locking block, a rubber sealing ring and an insulating screw, wherein the locking block and the rubber sealing ring are connected to the outer end face of the upper cover of the tool through the insulating screw;
the combined insulating tool handle sequentially comprises a blind rivet, a tool handle body, an electro-hydraulic slip ring, an insulating sheet and a nylon screw; the insulating ring is arranged between the knife handle body and the cathode cutter, so that the current in the electrolysis process is prevented from being transmitted to a machine tool through the knife handle body.
The cathode cutter adopts a cylindrical straight gear which is meshed with the face gear;
the electro-hydraulic slip ring is arranged on the anode tool and is used for facilitating the unlimited continuous rotation of the workbench tool.
The 3R clamp, the tool upper cover, the tool lower cover, the electrolytic tank and the marble base form a workpiece clamping system.
The 3R fixture is characterized in that the positioning reference of the 3R fixture is the central position of a base of the 3R fixture, and a one-time high-precision correction continuous use mode is adopted.
The positive pole of the pulse power supply is connected with the conductive copper block through the electric slip ring, so that a workpiece in contact with the positive pole is positively charged, and the negative pole of the pulse power supply is connected with the cathode connecting rod through the electric slip ring, so that the cathode of a tool arranged on the negative pole is negatively charged.
Compared with the prior art, the invention has the following advantages:
1. the cathode of the tool is different from the traditional machining tool, the cathode is a cylindrical straight gear meshed with a face gear, but a cathode system is specially designed aiming at the requirements of electrolysis safety and generating electrolysis motion. The generating method cathode system comprises a cathode cutter and a combined insulating cutter handle. In the electrolytic process, current is led into the cathode tool through the conductive slip ring in the positive direction, and the current is not conducted due to the influence of the insulating ring in the reverse direction, so that the influence of stray current leakage on a spindle system is avoided.
2. During the electrolysis, the rotation of the cathode tool (numerical control C shaft) and the rotation of the face gear blank (numerical control B shaft) are in linkage relation. In the electrical design process, in order to facilitate the unlimited continuous rotation of the worktable tool, a lead needs to be connected to the rotating part, and an electrical slip ring device is arranged on the anode tool.
3. The invention adopts electrolytic method for rough machining to remove a large amount of allowance, and comprises the design of an electrolytic machine tool in the electrolytic machining process, the rapid installation and positioning of electrolytic machining and the design of a combined insulating cutter handle, so that the precision and the efficiency of subsequent finish machining are improved by high-quality and high-efficiency electrolytic machining. The method has important significance for improving the machining precision and efficiency of the key part face gear of the domestic high-speed high-power aviation driving system.
Drawings
FIG. 1 is a schematic view of the structure of a generating electrolysis machine.
FIG. 2 is a schematic structural view of an electrolysis bench.
Fig. 3 is a schematic structural diagram of the combined insulating tool shank.
Fig. 4 is a generating cathode system.
FIG. 5 is a schematic diagram of the electrolytic anode workpiece and cathode tool movement.
Each of the labels in the figure is: the device comprises a Z-axis sliding seat 1, a B-axis tailstock 2, a 3R clamp 3, an electrolytic tank 4, an electrolytic lathe bed 5, a Y-axis guide rail 6, a machine tool upright post 7, an electrolyte inlet 8, a tool upper cover 9, a face gear blank 10, a tool lower cover 11, a marble base 12, a blind rivet 13, a combined insulating tool shank 14, an electro-hydraulic slip ring 15, a cathode tool 16, an electrolyte outlet 17, an electro-hydraulic slip ring 18, a pulse power supply cathode 19, a pulse power supply anode 20, a pulse power supply 21, a tool shank body 23, an insulating ring 26, an insulating sheet 27, a nylon screw 28 and an electrolytic gap 30.
Detailed Description
The following examples will further illustrate the present invention with reference to the accompanying drawings.
The method for removing the large surplus generated by generating and electrolyzing the high-hardness material face gear comprises the following steps:
the cathode in the electrolytic machining is equivalent to a cutter in the mechanical machining, the face gear is electrolytically machined by using a developed paired rolling movement electrolytic method, most of the allowance of a face gear blank is removed, and the rotating speed ratio of the cathode cutter to the face gear blank is the transmission ratio of the cylindrical gear to the face gear. The technological parameters including electrolyte composition, concentration, temperature, feeding speed, working voltage and electrolyte pressure are obtained through experiments.
The specific method for electrolytically machining the face gear by applying the developed paired rolling motion electrolytic method comprises the following steps: the cathode tool moves to a certain feeding depth along the axial direction of the electrolytic machine tool, and the generating movement is carried out between the electrode and the workpiece, so that the generating electrolytic machining of the feeding depth is completed. Then, the cathode tool moves axially along the electrolytic machine tool by the same feeding depth, and in the same way, multi-step axial feeding is carried out to complete the generating electrolytic machining of the face gear. The cathode is designed according to a gear meshed with a face gear with a finishing allowance, the reference circle diameter is 0.8 multiplied by the number of teeth of the cylindrical gear multiplied by the module m of the cylindrical gear, and a certain machining gap (about 0.2mm electrolytic gap + finishing allowance of 0.2-0.3 mm) is kept between the surface of the cathode and a workpiece.
The technological parameters are obtained through tests, and specifically, the technological parameters of electrolyte composition, concentration, temperature, feeding speed, working voltage and electrolyte pressure are formulated through the sequence and primary and secondary differences of the technological parameters and combined with the test research on the influence of relevant technological parameters on the processing characteristics.
The movement device of the electrolytic machining process mainly comprises an electrolytic worktable, a generating method electrolytic machine tool and a generating method cathode system;
as shown in fig. 1, the generating method electrolytic machine mainly comprises a Z-axis slide carriage 1, a B-axis tailstock 2, a 3R clamp 3 (for realizing B-axis rotation), an electrolytic tank 4, an electrolytic machine body 5, a Y-axis guide rail 6 and a machine tool upright 7; the generating method cathode system is arranged on the generating method electrolytic machine tool and can do linear motion and rotary motion along the Z axis and the C axis; the machine tool column 7 and the B-axis tailstock 2 are fixed on the electrolytic lathe body 5.
As shown in fig. 1 and 2, the electrolysis workbench comprises an electrolyte inlet 8, a tool upper cover 9, a face gear blank 10, a tool lower cover 11, a marble base 12 (bottom insulation), a pull nail 13, a combined insulation tool shank 14 (for realizing C-axis rotation), an electrolyte slip ring 15, a cathode tool 16, an electrolyte outlet 17, an electrical slip ring 18, a pulse power supply cathode 19, a pulse power supply anode 20 and a pulse power supply 21. The 3R clamp 3 rapidly clamps the face gear blank 10 on the B-axis tailstock 2, the face gear blank 10 can rotate around the B axis, and the face gear blank 10 is immersed in electrolyte in the electrolytic tank 4. The rivet 13 is arranged at the top end of the combined insulating tool shank 14, and the face gear blank 10 is arranged in the electrolytic tank 4 through the 3R clamp 3 and is immersed in the electrolyte in the electrolytic tank 4; the electrolytic tank 4 is arranged on the marble base 12, and the marble base 12 is fixed on the electrolytic lathe bed 5; the lower cover 11 of the tool is fixedly connected with the marble base 12; the top is provided with a tooling upper cover 9; an electric slip ring 18 is arranged on the face gear blank 10 and used for ensuring that the 3R clamp 3 can rotate continuously to realize the rotation of the B shaft. The electric slip ring 18 is connected with the positive pole 20 of the pulse power supply, and the electric slip ring 15 is connected with the negative pole 19 of the pulse power supply; the 3R clamp 3, the upper tool cover 9, the lower tool cover 11, the electrolytic tank 4 and the marble base (bottom insulation) 12 form a workpiece clamp. In fig. 2, reference numeral 8 denotes an electrolyte inlet, and 17 denotes an electrolyte outlet.
Referring to fig. 3-5, the generating cathode system is composed of a combined insulating tool handle 14 and a cathode tool 16. The combined insulating tool handle 14 comprises a pull nail 13, a tool handle body 23, an electro-hydraulic slip ring 15, a cathode tool 16, an insulating ring 26, an insulating sheet 27 and a nylon screw 28. The cathode cutter 16 is arranged at one end of the combined insulating cutter handle 14, and the cutter handle body 23 and the cathode cutter 16 are separated by an insulating ring 26; the nylon screw 28 is connected with the cathode cutter 16 and the cutter handle body 23, an insulating sheet 27 is arranged below the nylon screw 28, the electro-hydraulic slip ring 15 is connected with the cathode cutter 16, current is led into the cathode cutter 16 in the forward direction through the electro-hydraulic slip ring 15 in the electrolysis process, and the current is not conducted due to the protection of the insulating sheet 27 and the insulating ring 26 in the reverse direction.
In order to position and clamp the face gear blank 10, the face gear blank 10 is fixed by the 3R clamp 3. The cathode cutter 16 is connected with the Z-axis sliding seat 1 through a combined cathode insulation cutter handle 14.
Before electrolytic machining, the axis of a cathode cutter 16 is ensured to be vertical to the axis of a face gear blank 10, the cathode cutter 16 axially moves to a certain depth along the face gear blank 10, a gear set of a 28-tooth face gear and an 11-tooth cylindrical gear is taken as an example (as shown in fig. 5), the generating movement angular speed omega 1: omega 2 of the cathode cutter 16 and the face gear blank 10 is controlled to be 28: 11, the distance between the cathode cutter 16 and the face gear blank 10 is adjusted, a machining gap (about 0.2mm, an electrolytic gap + fine machining allowance is 0.2-0.3 mm), after the electrolytic machining is completed, the same depth is axially fed, a blank material is removed again, multiple times of feeding are performed, and the electrolytic rough machining of the face gear is completed. In fig. 5, reference numeral 30 denotes an electrolytic gap.
In order to determine each speed of generating movement and each electrolytic machining process parameter, a parameter determination test for optimizing the target by machining precision, production efficiency, surface quality and machining stability is established. The following operating parameters were obtained by experiment:
average processing voltage: 30V;
average machining current: 2000A;
cathode feed rate: 8-10 mm/min;
electrolyte flow rate: 300L/min
Inlet pressure: 0.9MPa, outlet back pressure: 0.5 MPa;
concentration of the electrolyte: 1.1-1.3 g/mL, temperature: 25 ℃;
the electrolyte is NaCl, NaNO3、Na2SO4Mixing the solutions according to a certain proportion.
The positive pole 20 of the pulse power supply is connected with the conductive copper block through the electric slip ring 18, so that the face gear blank 10 in contact with the positive pole 20 of the pulse power supply is positively charged, and the negative pole 19 of the pulse power supply is connected with the cathode cutter 16 through the electric slip ring 15, so that the cathode cutter 16 arranged on the negative pole 19 of the pulse power supply is negatively charged.
Claims (10)
1. The method for removing the large surplus generated by generating and electrolyzing the high-hardness material face gear is characterized by comprising the following steps of:
the method comprises the steps of taking a cathode as a cutter, electrolytically machining a face gear by applying a developed roll-to-roll movement electrolysis method, designing the cathode profile into a cylindrical gear profile, simulating the meshing roll-to-roll movement of the face gear and the cylindrical gear, obtaining technological parameters through tests in the face gear electrolysis process, and removing most of the allowance of a face gear blank by controlling the technological parameters, wherein the technological parameters comprise electrolyte components, concentration, temperature, feeding speed, working voltage, electrolyte pressure and the like.
2. The method for removing the generated electrolytic large allowance of the high-hardness material face gear according to claim 1, wherein the specific steps of applying the generated paired rolling motion electrolytic method to electrolytically machine the face gear are as follows: the rotating speed ratio of the cathode to the face gear blank is the transmission ratio of the cylindrical gear to the face gear, the cathode moves to a certain feeding depth along the axial direction of the electrolytic machine tool, and generating movement is carried out between the electrode and the workpiece to complete generating electrolytic machining of the feeding depth; then, the cathode cutter moves axially along the electrolytic machine tool by the same feeding depth, and in the same way, multi-step axial feeding is carried out to complete the generating electrolytic machining of the face gear.
3. The method for removing the generated electrolytic large allowance of the face gear with the high hardness material according to claim 2, wherein the cathode is designed according to a gear meshed with the face gear with a finishing allowance, the reference circle diameter of the cathode is 0.8 x the number of teeth of the cylindrical gear x the module m of the cylindrical gear, a certain machining gap is kept between the surface of the cathode and the workpiece, and the certain machining gap is about 0.2mm plus the electrolytic gap with the finishing allowance of 0.2-0.3 mm.
4. The method for removing the generated electrolytic large allowance of the high-hardness material face gear according to claim 1, wherein the process parameters of electrolyte composition-concentration-temperature-feeding speed-working voltage-electrolyte pressure are determined by acquiring the process parameters through experiments, specifically by sequentially and primarily distinguishing the process parameters and researching the influence of the relevant process parameters on the processing characteristics through experiments.
5. The high-hardness material face gear generating electrolysis large-allowance removing and processing device is characterized by comprising a generating method electrolysis machine tool and an electrolysis workbench;
the generating electrolysis machine includes: the device comprises a Z-axis sliding seat, a tailstock, a 3R clamp, an electrolysis workbench and an electrolysis lathe bed;
the electrolytic working table comprises an electrolyte inlet, a tool upper cover, a face gear blank, a tool lower cover, a marble base, a rivet, a tool handle body, an electrolyte slip ring, a cathode tool, an electrolyte outlet, an electrical slip ring, a pulse power supply cathode, a pulse power supply anode and a pulse power supply;
the electrolytic machining of the electrolytic machine tool is realized by means of a Z-axis sliding seat, a Y-axis guide rail, a combined insulating tool handle and a tailstock to realize the movement of a Z axis, a Y axis, a C axis and a B axis; the 3R clamp is used for realizing the quick positioning of the face gear electrolytic machining;
the electrolytic worktable is arranged on the generating method electrolytic machine tool through a fastening device, the workpiece is arranged in a cavity of an electrolytic tank, the electrolytic tank is arranged on a lathe bed of the generating method electrolytic machine tool, and the side tailstock immerses the workpiece into electrolyte through a sealing device; the conductive copper block is arranged on the side face of the workpiece, and the positive pole of the pulse power supply is connected with the conductive copper block through the electric slip ring.
6. The high-hardness material face gear generating electrolysis large-allowance removing machining device as claimed in claim 5, wherein the sealing device comprises a locking block, a rubber sealing ring and an insulating screw, and the locking block and the rubber sealing ring are connected to the outer end face of the upper cover of the tool through the insulating screw.
7. The high-hardness material face gear generating electrolysis large-allowance removing machining device as claimed in claim 5, wherein the combined type insulation tool shank sequentially comprises a blind rivet, a tool shank body, an electro-hydraulic slip ring, an insulation sheet and a nylon screw; the insulating ring is arranged between the knife handle body and the cathode cutter, so that the current in the electrolysis process is prevented from being transmitted to a machine tool through the knife handle body; the electro-hydraulic slip ring is arranged on the anode tool and is used for facilitating the unlimited continuous rotation of the workbench tool.
8. The apparatus for generating electrolytic large allowance removal processing of a face gear of high hardness material according to claim 5, wherein the cathode cutter employs a spur gear in meshing relationship with the face gear.
9. The high-hardness material face gear generating electrolysis large-allowance removing machining device according to claim 5, wherein the 3R clamp, the tool upper cover, the tool lower cover, the electrolysis box and the marble base form a workpiece clamping system;
the 3R fixture is characterized in that the 3R fixture positioning reference is the center position of a base of the 3R fixture, and a one-time high-precision correction continuous use mode is adopted.
10. The device for generating, electrolyzing and removing large allowance of face gear with high hardness material as claimed in claim 5, wherein the positive pole of the pulse power supply is connected with the conductive copper block through an electric slip ring to make the workpiece contacting with the positive pole positively charged, and the negative pole of the pulse power supply is connected with the cathode connecting rod through an electric slip ring to make the tool cathode mounted on the negative pole negatively charged.
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