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2 The calculation method of the electrolytic gap change value is the method cut line of the workpiece surface, P is the contact point between the cathode and the workpiece (the reserved gap is not considered here), n is the unit normal vector of the workpiece tooth surface at point P, C is Center of curvature, n=1kn is the radius of curvature circle, B=PQ is the half length of the cathode, and the maximum gap change is known by differential geometry. Because B is the artificial value when designing the cathode, so long as the curvature of a point on the tooth surface of the workpiece is known, kn , you can know the amount of change in the electrolytic gap.
3 Factors affecting the change of electrolytic gap It is known that the factors affecting the change of electrolytic gap are the length of the cathode and the parameters related to the workpiece.
(1) Cathode length. The length of the cathode has a great influence on the change of the electrolysis gap, which is approximately linear. The longer the cathode, the larger the variation of the electrolysis gap. However, the cathode length is proportional to the productivity, and the cathode is too short to process very low. In designing the cathode, these two factors should be considered comprehensively, and a reasonable cathode length should be determined by calculating the amount of change in the electrolytic gap.
(2) Gear modulus. In the range of medium modulus m=514, it has a great influence on the change of electrolytic gap, and the smaller the modulus, the larger the change of electrolytic gap. When m16, its effect on the change of electrolytic gap is very small.
(3) Number of workpiece teeth. The influence of the number of teeth on the change of the electrolytic gap is basically the same as the influence of the modulus on the change of the electrolytic gap. The larger the number of teeth, the smaller the gap. When the number of teeth increases to Z=40, there is basically no influence.
(4) Workpiece helix angle. The workpiece helix angle is substantially linear and increases significantly.
4 Conclusions (1) Using a linear continuous scan of the cathode will cause unevenness. Using the formula derived in this paper, the amount of change in the electrolytic gap can be quantitatively calculated.
(2) It can be seen from the calculation examples in the above discussion that in general, the amount of change in the electrolytic gap is one to two orders of magnitude smaller than the electrolytic gap reserved in the processing, and there is almost no influence on the processing.
(3) The cathode length should be adjusted according to the parameters of the workpiece when designing the cathode.
1 Electrochemical gap change during helical gear machining When the helical gear is processed, the cathode and the workpiece are driven by a staggered shaft. The cathode is linear, and the tooth surface of the workpiece is an involute spiral surface. The cathode and the workpiece are theoretically in point contact, so the electrolysis gap in the length direction of the cathode during processing is not uniform. Electrolytic gap is an important parameter that affects the amount of metal removal in electrolytic processing. It must be calculated for the degree of change in processing. Only when the amount of change is small relative to the predetermined electrolytic gap, can high processing precision be obtained.