螺旋锥齿轮脉冲电化学及电化学机械光整加工技术研究
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摘要
螺旋锥齿轮是实现相交轴传递的基础元件,由于具有重合度大、传动平稳、噪音小、承载能力高等优点,被广泛应用于汽车、飞机、机床及工程机械等领域。螺旋锥齿轮在汽车行业的应用尤为广泛,几乎所有汽车的传动系统都包含螺旋锥齿轮副。因此,螺旋锥齿轮的制造精度、质量直接影响到汽车传动系统的效率、噪声、运动精度和寿命。大量研究证实,提高齿轮表面质量可以有效改善齿轮各方面使用性能并可提高其使用寿命。对齿轮齿面进行光整加工是改善齿轮齿面质量、提高齿轮精度的有效途径。
脉冲电化学光整加工(PECF)和电化学机械光整加工(ECMF)是近年来得到快速发展的两种非传统光整加工工艺,其突出优点是能以高效率光整加工任意硬度的金属零件表面,并可获得优良的表面形貌,目前已应用于多种零件表面的光整加工,将其应用于螺旋锥齿轮齿面光整加工对于提高锥齿轮质量具有重要意义。
在螺旋锥齿轮加工原理方面,主要研究了螺旋锥齿轮的啮合原理和加工方法,给出了成形法加工螺旋锥齿轮大轮的调整计算公式,为脉冲电化学和电化学机械两种工艺在螺旋锥齿轮大轮齿面光整加工上的应用提供了理论依据。
在脉冲电化学光整加工方面,从加工过程中工件阳极表面形貌的微观轮廓变化入手,研究了齿轮表面微观轮廓随加工参数的变化过程。以法拉第定律理论为基础,建立了脉冲电化学光整加工过程中工件阳极表面粗糙度和去除量随加工时间变化的理论模型,并通过实验验证了模型的正确性,解释了脉冲电化学光整加工的整平机理；在电化学机械光整加工方面,由于工件阳极表面发生电化学溶解会生成钝化膜,且钝化膜的特性是影响电化学机械光整加工质量的关键,因此,我们对钝化膜的厚度、电阻和成分做了研究,分析了钝化现象对于阳极整平过程的影响。
在上述研究基础上,针对螺旋锥齿轮的结构特点,研究了脉冲电化学和电化学机械两种工艺在螺旋锥齿轮大轮齿面光整加工上的应用模式、关键技术及工艺特点。
在螺旋锥齿轮脉冲电化学光整加工方面：通过对比脉冲电化学光整加工在螺旋锥齿轮大轮上应用的不同模式,确定比较合理的齿廓成形法加工方式。结合脉冲电化学光整加工原理,在现有Gleason No.16铣齿机床上建立了螺旋锥齿轮脉冲电化学光整加工的实验装置。重点研究了加工参数对螺旋锥齿轮齿面质量和齿轮精度的影响。实验结果表明,脉冲电化学光整加工不仅可以使锥齿轮表面粗糙度Rz从7.13μm降低到4.32μm,而且使锥齿轮凸面精度从原来的10级提高到8级,凹面精度从9级提高到7级。鉴于脉冲电化学光整加工过程的复杂性,将最小二乘支持向量机的方法引入脉冲电化学光整加工螺旋锥齿轮加工参数的优选。结果表明,所建立的模型具有较好的加工参数优选能力。
在螺旋锥齿轮电化学机械光整加工方面：根据螺旋锥齿轮铣齿加工原理,在立式铣床ZX50F上建立了螺旋锥齿轮电化学机械光整加工实验装置。重点研究了阴极和阴极盘的设计、螺旋锥齿轮夹具设计和机床参数的调整。采用正交实验的方法分析了加工参数对齿轮表面质量和精度的影响。实验结果表明：在优选的工艺参数条件下,锥齿轮齿面粗糙度值可以从Ra 1.6μm降低到Ra 0.05μm,同时齿轮精度基本保持不变。
将电化学机械光整加工引入螺旋锥齿轮齿面的光整加工中,可以替代螺旋锥齿轮齿面传统的磨削精加工。获得的齿轮表面均匀、光滑,具备较低的摩擦系数、较高的抗疲劳强度。提高螺旋锥齿轮产品的加工质量,对提高螺旋锥齿轮的使用寿命,降低啮合噪声,进而提高我国汽车、飞机、机床等设备传动系统的效率和使用寿命具有积极意义。
As a basic component in the driving of intersecting axes, spiral bevel gear (SBG) has been widely applied in the transmission system of automobiles, airplanes and many other machine tools since it has many advantages such as the big overlap ratio, the stability, lower noises and high loading capacity. The application of SBG in automobiles is particularly wide, and every transmission of automobile contains a pair of spiral bevel gear at least. The manufacturing accuracy and quality of SBG have direct influence on the efficiency, noise, precision and lifespan of the automobile transmission. A large number of studies show that the service performance has been improved and the lifespan has been increased by improving surface quality of gear. Finishing provides an effective method for improving gear surface quality and then improving gear accuracy.
Pulse Electrochemical Finishing (PECF) and Electrochemical Mechanical Finishing (ECMF) are two kinds of nontraditional finishing process, which could finish the workpiece surface with any hardness efficiently and have been used as the finishing process of various parts. So, applying PECF and ECMF to SBG tooth surfaces is of great significance to the improvement of its quality.
In PECF, the variation of workpiece surface micro-topography has been studied. Based on the Faraday's law, the theoretical models about the variation of the surface roughness and the removal thickness with the finishing time have been developed. The validity of developed models has been verified through experiments. The effects of processing parameters on surface profile have been investigated and the smoothing mechanism of PECF is explained. In ECMF, the characteristic of passive film formed on the workpiece surface by anodic dissolution is the key for workpiece surface smoothing in ECMF. The thickness, resistance and composition of the passive film have been determined through experiments in order to make a further analysis about the effects of passive state on the anodic smoothing.
Based on the above discussion and according to the structure features of SBG, the applications of PECF and ECMF to the SBG are discussed.
In the study of PECF's application to the SBG tooth surfaces finishing, different application schemes are compared. It has been found that PECF with a tooth profile shaped cathode is a preferable scheme. Combined with the principle of PECF, an experimental setup for the SBG tooth surfaces finishing has been established based on Gleason No.16 cutting machine. The experimental results show that the SBG tooth surface roughness Rz is reduced from 7.13μm to 4.32μm. According to Din3965, the precision of the SBG convex side is improved form 10 to 8, and the precision of the SBG concave side is improved from 9 to 7. Because the PECF is complicated and non-linear process, least square support vector machine (LSSVM), an intelligent model is adopted for optimizing the processing parameters. The results indicate that the model has reasonable accuracy.
In the study of ECMF's application to the SBG tooth surface finishing, an experimental setup for the SBG tooth surfaces finishing has been established based on ZX50F vertical milling machine. The cathode design, the cutter head design, the gear fixture design and the parameters adjustment of vertical milling machine are especially studied. The experimental results show that the SBG tooth surface roughness Ra is reduced from 1.6μm to 0.05μm and the precision of the SBG is maintained.
The conventional grinding methode can be insteaded by ECMF in tooth surfaces finishing of SBG. The tooth surfaces after ECMF are uniform and smooth, which has many advantages such as small friction coefficient, high contact rigidity and high fatigue resistance. ECMF can improve the lifespan and decrease the meshing noise of SBG pair. In order to improve the efficiency and lifespan of transmission system of automobiles, airplanes and many other machine tools, the quality of SBG products should be improved.
脉冲电化学光整加工(PECF)和电化学机械光整加工(ECMF)是近年来得到快速发展的两种非传统光整加工工艺,其突出优点是能以高效率光整加工任意硬度的金属零件表面,并可获得优良的表面形貌,目前已应用于多种零件表面的光整加工,将其应用于螺旋锥齿轮齿面光整加工对于提高锥齿轮质量具有重要意义。
在螺旋锥齿轮加工原理方面,主要研究了螺旋锥齿轮的啮合原理和加工方法,给出了成形法加工螺旋锥齿轮大轮的调整计算公式,为脉冲电化学和电化学机械两种工艺在螺旋锥齿轮大轮齿面光整加工上的应用提供了理论依据。
在脉冲电化学光整加工方面,从加工过程中工件阳极表面形貌的微观轮廓变化入手,研究了齿轮表面微观轮廓随加工参数的变化过程。以法拉第定律理论为基础,建立了脉冲电化学光整加工过程中工件阳极表面粗糙度和去除量随加工时间变化的理论模型,并通过实验验证了模型的正确性,解释了脉冲电化学光整加工的整平机理；在电化学机械光整加工方面,由于工件阳极表面发生电化学溶解会生成钝化膜,且钝化膜的特性是影响电化学机械光整加工质量的关键,因此,我们对钝化膜的厚度、电阻和成分做了研究,分析了钝化现象对于阳极整平过程的影响。
在上述研究基础上,针对螺旋锥齿轮的结构特点,研究了脉冲电化学和电化学机械两种工艺在螺旋锥齿轮大轮齿面光整加工上的应用模式、关键技术及工艺特点。
在螺旋锥齿轮脉冲电化学光整加工方面：通过对比脉冲电化学光整加工在螺旋锥齿轮大轮上应用的不同模式,确定比较合理的齿廓成形法加工方式。结合脉冲电化学光整加工原理,在现有Gleason No.16铣齿机床上建立了螺旋锥齿轮脉冲电化学光整加工的实验装置。重点研究了加工参数对螺旋锥齿轮齿面质量和齿轮精度的影响。实验结果表明,脉冲电化学光整加工不仅可以使锥齿轮表面粗糙度Rz从7.13μm降低到4.32μm,而且使锥齿轮凸面精度从原来的10级提高到8级,凹面精度从9级提高到7级。鉴于脉冲电化学光整加工过程的复杂性,将最小二乘支持向量机的方法引入脉冲电化学光整加工螺旋锥齿轮加工参数的优选。结果表明,所建立的模型具有较好的加工参数优选能力。
在螺旋锥齿轮电化学机械光整加工方面：根据螺旋锥齿轮铣齿加工原理,在立式铣床ZX50F上建立了螺旋锥齿轮电化学机械光整加工实验装置。重点研究了阴极和阴极盘的设计、螺旋锥齿轮夹具设计和机床参数的调整。采用正交实验的方法分析了加工参数对齿轮表面质量和精度的影响。实验结果表明：在优选的工艺参数条件下,锥齿轮齿面粗糙度值可以从Ra 1.6μm降低到Ra 0.05μm,同时齿轮精度基本保持不变。
将电化学机械光整加工引入螺旋锥齿轮齿面的光整加工中,可以替代螺旋锥齿轮齿面传统的磨削精加工。获得的齿轮表面均匀、光滑,具备较低的摩擦系数、较高的抗疲劳强度。提高螺旋锥齿轮产品的加工质量,对提高螺旋锥齿轮的使用寿命,降低啮合噪声,进而提高我国汽车、飞机、机床等设备传动系统的效率和使用寿命具有积极意义。
As a basic component in the driving of intersecting axes, spiral bevel gear (SBG) has been widely applied in the transmission system of automobiles, airplanes and many other machine tools since it has many advantages such as the big overlap ratio, the stability, lower noises and high loading capacity. The application of SBG in automobiles is particularly wide, and every transmission of automobile contains a pair of spiral bevel gear at least. The manufacturing accuracy and quality of SBG have direct influence on the efficiency, noise, precision and lifespan of the automobile transmission. A large number of studies show that the service performance has been improved and the lifespan has been increased by improving surface quality of gear. Finishing provides an effective method for improving gear surface quality and then improving gear accuracy.
Pulse Electrochemical Finishing (PECF) and Electrochemical Mechanical Finishing (ECMF) are two kinds of nontraditional finishing process, which could finish the workpiece surface with any hardness efficiently and have been used as the finishing process of various parts. So, applying PECF and ECMF to SBG tooth surfaces is of great significance to the improvement of its quality.
In PECF, the variation of workpiece surface micro-topography has been studied. Based on the Faraday's law, the theoretical models about the variation of the surface roughness and the removal thickness with the finishing time have been developed. The validity of developed models has been verified through experiments. The effects of processing parameters on surface profile have been investigated and the smoothing mechanism of PECF is explained. In ECMF, the characteristic of passive film formed on the workpiece surface by anodic dissolution is the key for workpiece surface smoothing in ECMF. The thickness, resistance and composition of the passive film have been determined through experiments in order to make a further analysis about the effects of passive state on the anodic smoothing.
Based on the above discussion and according to the structure features of SBG, the applications of PECF and ECMF to the SBG are discussed.
In the study of PECF's application to the SBG tooth surfaces finishing, different application schemes are compared. It has been found that PECF with a tooth profile shaped cathode is a preferable scheme. Combined with the principle of PECF, an experimental setup for the SBG tooth surfaces finishing has been established based on Gleason No.16 cutting machine. The experimental results show that the SBG tooth surface roughness Rz is reduced from 7.13μm to 4.32μm. According to Din3965, the precision of the SBG convex side is improved form 10 to 8, and the precision of the SBG concave side is improved from 9 to 7. Because the PECF is complicated and non-linear process, least square support vector machine (LSSVM), an intelligent model is adopted for optimizing the processing parameters. The results indicate that the model has reasonable accuracy.
In the study of ECMF's application to the SBG tooth surface finishing, an experimental setup for the SBG tooth surfaces finishing has been established based on ZX50F vertical milling machine. The cathode design, the cutter head design, the gear fixture design and the parameters adjustment of vertical milling machine are especially studied. The experimental results show that the SBG tooth surface roughness Ra is reduced from 1.6μm to 0.05μm and the precision of the SBG is maintained.
The conventional grinding methode can be insteaded by ECMF in tooth surfaces finishing of SBG. The tooth surfaces after ECMF are uniform and smooth, which has many advantages such as small friction coefficient, high contact rigidity and high fatigue resistance. ECMF can improve the lifespan and decrease the meshing noise of SBG pair. In order to improve the efficiency and lifespan of transmission system of automobiles, airplanes and many other machine tools, the quality of SBG products should be improved.
引文
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