Basic Research On Finishing Of Spiral Bevel Gear Using Pulse Electrochemical Finishing

Spiral bevel gear is the basic element for carrying out the transfer of intersecting shafts. It is widely used in automobiles, airplanes, machine tools and other kinds of mechanism products, due to those merits in transmission such as high degree in superposition, high carrying capacity, high efficiency in transmission, steady and low noise etc. Currently, the main processing technology of spiral bevel gear is mainly held by few developed nations, falling into different systems and concealed from each other. There is an obvious disparity between our nation and other developed nations in the field of hard surface finish machining of the spiral bevel gear. Therefore, it will be of significant importance for promoting the overall manufacturing level of the spiral bevel gear in our nation to research the hard surface finish machining process of the spiral bevel gear.PECF has great worthiness on researching and high development potential for greatly reducing the surface roughness and improving the surface quality of the parts. Accordingly, PECF is being applied in hard surface finishing of spiral bevel gear in this thesis.It is stressed much importance on the macro and micro smoothing mechanism and process characteristic on the basis of analyzing the status quo of PECF comprehensively from home and abroad, and made an in-depth research of the influence on the processing quality by the process parameters such as the current consistency, electrolyte composition, workpiece material, process clearance, pulse frequency, pulse width and micro-structure of cathode and so on.It is discussed the application mode of PECF on the spiral bevel gear based on the research above and the principle and characteristic of precision cutting of spiral bevel gear. Meantime, it is researched the design of the key parts such as cathode, cathode holder of PECF on the spiral bevel. The experiment was carried out on the spiral bevel gear by PECF, The result shows that PECF could reduce the surface roughness obviously.The machine tool which carries out the PECF on the spiral bevel gear is the Gleason No. 16 multifunctional mill works after alteration. For the complexity in its structure, the clamp and the principal axis are partially exposed in the electrolyte in the process of PECF. So the antisepsis and the electric characteristic of the electrolyte are researched, and the comparatively reasonable antisepsis and its concentration are ascertained.The research on the PECF of spiral bevel aims at opening up the application field of PECF, and promoting the development of PECF to improve the lag-behind situation in the field of gear manufacturing in our nation, which has great significance in the practical production.