Electrochemical machining device for small-size curved end face gear and method of use

Abstract

The application discloses a small-size curved end face gear electrolytic machining device, which comprises a cathode clamp, a tool cathode, an electrolyte through cavity, a workpiece axial positioning cavity I and a workpiece axial positioning cavity II, the cathode clamp is provided with an electrolyte rectification area, an electrolyte output channel and a communication hole, the lower end of the cathode clamp is used for connecting the tool cathode, the lower end of the tool cathode is provided with an end face tooth, and the upper end of the cathode clamp is used for being connected with a machine tool driving device; the upper end of the workpiece axial positioning cavity II is sequentially provided with the workpiece axial positioning cavity I and the electrolyte through cavity, the electrolyte through cavity is used for abutting against the cathode clamp and the tool cathode and inserting a workpiece blank, and the workpiece axial positioning cavity I is used for clamping the workpiece blank; and the side wall of the electrolyte through cavity is provided with an electrolyte input channel. The workpiece is formed by the tool cathode end face tooth, and defects such as tool wear in traditional mechanical cutting machining are avoided.

Description

An electrolytic machining device for small-sized curved end face gears and its usage method Technical Field

[0001] This invention relates to the field of high-precision transmission system processing and manufacturing, specifically to an electrolytic machining device and method for small-sized curved end face gears. Background Technology

[0002] Face gears, distributed on the same end face, possess advantages such as high load-bearing capacity, high overlap ratio, and high reliability, making them suitable for a wide range of applications, especially in the military and aerospace fields. Face gear machining is a type of profile machining, which traditional machining methods struggle to achieve within the narrow space between teeth. Furthermore, traditional methods suffer from problems such as easy tool wear and poor workpiece surface finish, severely impacting their performance and service life. The lack of high-precision, high-surface-quality machining methods for special face gear structures hinders the development of advanced mechanical transmission technology. Therefore, it is necessary to research new technologies for machining small-sized curved face gears to address issues such as improving the transmission strength, fatigue strength, and safety of transmission systems.

[0003] Currently, electrolytic machining is a non-contact, stress-free, and melt-free machining technology that can provide a solution to problems. Therefore, there is an urgent need for an electrolytic machining device for small-sized curved end face gears to solve the problems of tool wear and poor surface quality that occur in the machining of small-sized curved end face gears. Summary of the Invention

[0004] This invention addresses the shortcomings of existing technologies by providing an electrolytic machining device and method for small-sized curved end face gears, thereby solving the problems of tool wear and poor surface quality that occur during the machining of small-sized curved end face gears.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] An electrolytic machining device for small-sized curved end face gears is characterized by comprising a cathode chuck, a tool cathode, an electrolyte flow chamber, a workpiece axial positioning chamber I, and a workpiece axial positioning chamber II. The cathode chuck has an electrolyte rectification zone inside and an electrolyte output channel communicating with the electrolyte rectification zone. A connecting channel extends downwards from the electrolyte rectification zone inside the cathode chuck. The lower end of the cathode chuck is used to connect to the tool cathode. A flow chamber communicating with the connecting channel is located in the middle of the tool cathode. The lower end of the tool cathode is provided with end face teeth for machining the workpiece blank. The upper end of the cathode chuck is used for fixed connection to a machine tool drive device.

[0007] The upper end of the workpiece axial positioning cavity II is connected to the workpiece axial positioning cavity I. The upper end of the workpiece axial positioning cavity I is connected to the electrolyte passage cavity. The center of the electrolyte passage cavity is provided with a groove for the integral insertion of the cathode chuck and the tool cathode. The center of the groove is provided with a through hole for the insertion of the workpiece blank. The workpiece axial positioning cavity I is used to clamp and fix the workpiece blank extending from below the electrolyte passage cavity. The side wall of the electrolyte passage cavity is provided with an electrolyte input channel communicating with the groove.

[0008] To optimize the above technical solution, the specific measures also include:

[0009] Furthermore, the lower end face of the cathode chuck is provided with a positioning hole and a threaded connection hole, and the outer ring of the end face teeth of the tool cathode is provided with a positioning through hole for communicating with the positioning hole and a threaded through hole for communicating with the threaded connection hole.

[0010] Furthermore, a baffle plate is provided in front of the port where the electrolyte input channel communicates with the groove.

[0011] Furthermore, there is a gap between the lower end of the baffle and the bottom end of the groove that allows the electrolyte to flow, and the lower end of the baffle is provided with a rounded chamfer.

[0012] Furthermore, the workpiece axial positioning cavity I includes two detachable sub-workpiece axial positioning cavities I, which can fit together, and the fitting area is symmetrically provided with clamping grooves for clamping the workpiece blank; one sub-workpiece axial positioning cavity I is fixedly connected to the upper end of the workpiece axial positioning cavity II, and the other sub-workpiece axial positioning cavity I can be movably inserted between the electrolyte passage cavity and the workpiece axial positioning cavity II to clamp the workpiece blank.

[0013] Furthermore, an annular workpiece positioning groove is provided on the upper end face of the workpiece axial positioning cavity II, which is located directly below the clamping groove; an annular insert block that can be inserted into the annular workpiece positioning groove is provided on the lower end of the workpiece blank.

[0014] Furthermore, the upper half of the clamping groove is used to surround and clamp the workpiece blank, and the lower half of the clamping groove is used to fix the workpiece blank by line contact.

[0015] Furthermore, a second sealing groove is formed on the end face of the tool cathode that is in contact with the cathode chuck. The second sealing groove is located on the periphery of the flow cavity and is used to embed a sealing ring.

[0016] Furthermore, a first sealing groove is formed on the side wall that contacts the tool cathode within the groove, and the first sealing groove is used to embed a sealing ring.

[0017] Furthermore, a method of using an electrolytic machining apparatus for small-sized curved end face gears includes the following steps:

[0018] Step 1: After aligning the cathode chuck with the machine tool drive unit using hex socket screws, make a detachable and fixed connection.

[0019] Step 2: Place the workpiece axial positioning cavity II as a circular base horizontally on the machine tool operating table, and align it with the cathode chuck using a pair of cylindrical pins, and fix it to the machine tool operating table using multiple hexagonal screws;

[0020] Step 3: Place the workpiece axial positioning cavity I horizontally on the upper surface of the circular base of the workpiece axial positioning cavity II. Then, embed the workpiece blank into the through hole of the electrolyte passage cavity, and make the inner wall of the workpiece positioning groove tightly fit with the lower outer cylindrical surface of the workpiece blank. The upper outer cylindrical surface is tightly fitted through the triangular prism-shaped inner wall of the workpiece axial positioning cavity I and the workpiece axial positioning cavity II. The large cylindrical bottom surface of the upper end of the workpiece blank is tightly fitted with the upper surface of the electrolyte passage cavity. During the clamping process, the axial positioning is achieved by combining with the vertically downward external force. After the operation is completed, the workpiece blank clamping work is finished.

[0021] Step 4: After aligning the tool cathode with the cathode chuck using a pair of cylindrical pins, use hex socket screws for detachable fixing. Once the operation is completed, the tool cathode assembly installation is finished.

[0022] Step 5: Connect the cathode chuck to the negative terminal of the machine tool power supply, and connect the workpiece axial positioning cavity II to the positive terminal of the machine tool.

[0023] Step Six: Inspect and clean any debris generated during installation from the electrolyte output channel on the cathode clamp and the electrolyte input channel in the electrolyte passage.

[0024] Step 7: Insert the dryer supply and return pipes of the machine tool into the electrolyte input channel of the electrolyte passage chamber and the electrolyte output channel corresponding to the cathode chuck, respectively.

[0025] Step 8: After all installation work is completed, check whether the machine tool power supply and electrolyte circulation system are normal, and check whether there are any abnormalities on the outside of the machine tool; after the inspection, test the electrolyte and check the sealing.

[0026] Step 9: Input the electrolytic machining process parameters on the machine tool operation interface and adopt the cathode vibration and pulse power supply coupled machining mode;

[0027] Step 10: Turn on the power. The tool cathode will be continuously fed towards the workpiece blank by the machine tool drive device. After the electrolyte flows into the machining gap in the reverse flow form, the workpiece machining surface will undergo anodic dissolution. The electrolysis products and Joule heat will be carried away by the high-speed flowing electrolyte, and the workpiece blank will be gradually machined.

[0028] Step 11: After completing the electrolytic machining of the small-sized curved end face gear, disconnect the power supply, raise the machine tool spindle a certain distance, remove the machined part, and rinse it with clean water;

[0029] Step 12: Measure and record the processed sample using a coordinate measuring machine, analyze the normal error between each point and the theoretical surface, and further correct and optimize multiple parameters through multiple experiments until the processing meets the design requirements.

[0030] The beneficial effects of this invention are:

[0031] 1. This invention uses electrolytic machining to process multiple teeth simultaneously, which improves processing efficiency compared to tooth-by-tooth machining. At the same time, this process uses ion form to remove excess material, which does not generate mechanical cutting force compared to traditional mechanical cutting, and therefore does not produce defects such as deformation and burrs.

[0032] 2. The tool cathode of the present invention is detachably fixed to the cathode chuck using an internal hexagon screw, and is fixedly connected to the cathode chuck via the machine tool spindle. This not only enables the tool cathode to move up and down during processing, but also facilitates installation and disassembly.

[0033] 3. The flow field used in this invention is a reverse flow mode, which has good flow field uniformity, does not produce cavitation, and has better processing accuracy and stability compared with other flow field forms;

[0034] 4. The tool cathode of the present invention does not dissolve during processing and does not short-circuit erosion under normal processing conditions. Therefore, the tool cathode does not suffer any loss and can be used for a long time, reducing the manufacturing cost of the cathode. Secondly, the tool cathode is a separate part in the whole device. If the process test requires optimization and correction of the tool cathode, only the cathode needs to be remanufactured, which greatly reduces the manufacturing cost of the device.

[0035] 5. This invention uses a low-frequency vibration feed mode with a tool cathode to process small-sized curved end face gears, so that the processing gap is always in a periodic fluctuation state during the processing, which can effectively promote the timely discharge of electrolytic products in the processing gap. Attached Figure Description

[0036] Figure 1 is a schematic diagram of the overall structure of an electrolytic machining device for small-sized curved end face gears proposed in this invention;

[0037] Figure 2 is a schematic diagram of the tool cathode structure of a small-size curved end face gear electrolytic machining device proposed in this invention;

[0038] Figure 3 is a schematic diagram of the electrolyte passage chamber of a small-size curved end face gear electrolytic machining device proposed in this invention;

[0039] Figure 4 is a schematic diagram of the cathode chuck of a small-sized curved end face gear electrolytic machining device proposed in this invention;

[0040] Figure 5 is a schematic diagram of the installation of the workpiece blank in the small-size curved end face gear electrolytic machining device proposed in this invention;

[0041] Figure 6 is a schematic diagram of the processing circuit connection of an electrolytic machining device for small-sized curved end face gears proposed in this invention.

[0042] Reference numerals in the attached drawings: 1. Electrolyte output channel; 2. Cathode chuck; 2-1. Threaded connection hole; 2-2. Positioning hole; 3. First sealing groove; 4. Electrolyte inlet cavity; 5. Electrolyte inlet channel; 5-1. Bolt hole; 6. Workpiece positioning groove; 7. Electrolyte rectification zone; 8. Second sealing groove; 9. Tool cathode; 9-1. Threaded through hole; 9-2. Positioning through hole; 10. Workpiece blank; 11. Workpiece axial positioning cavity I; 11-1 Bottom threaded hole; 12. Workpiece axial positioning cavity II. Detailed Implementation

[0043] The invention will now be described in further detail with reference to the accompanying drawings.

[0044] As shown in Figures 1, 2, and 3, an embodiment of the present invention provides an electrolytic machining device for small-sized curved end face gears, including a cathode chuck 2, a tool cathode 9, an electrolyte passage chamber 4, a workpiece axial positioning chamber I 11, and a workpiece axial positioning chamber II 12. The cathode chuck 2 has an electrolyte rectification zone 7 inside, and an electrolyte output channel 1 communicating with the electrolyte rectification zone 7 is also provided on the cathode chuck 2. An electrolyte output channel 1 is respectively provided on the left and right sides of the electrolyte rectification zone 7. The cathode chuck 2 internally... The electrolyte rectification zone 7 has a connecting channel extending downwards. The lower end of the cathode chuck 2 is used to connect to the tool cathode 9. The tool cathode 9 has a flow cavity in the middle that communicates with the connecting channel. The lower end of the tool cathode 9 has end face teeth for machining the workpiece blank 10. The upper end of the cathode chuck 2 is used to fix it to the machine tool drive device. Before connection, in order to avoid excessive force on the cathode chuck 2 per unit area by the hexagonal screw and cause it to deform, a rigid metal block is used to transmit force so that the cathode chuck 2 is subjected to uniform force.

[0045] The upper end of the workpiece axial positioning cavity II12 is connected to the workpiece axial positioning cavity I11, and the upper end of the workpiece axial positioning cavity I11 is connected to the electrolyte passage cavity 4. The center of the electrolyte passage cavity 4 is provided with a groove for the entire insertion of the cathode chuck 2 and the tool cathode 9. The center of the groove is provided with a through hole for the insertion of the workpiece blank 10. The workpiece axial positioning cavity I11 is used to clamp and fix the workpiece blank 10 extending from below the electrolyte passage cavity 4. The side wall of the electrolyte passage cavity 4 is provided with several electrolyte input channels 5 that are evenly spaced in a ring and communicate with the groove.

[0046] In use, the device of this invention places the workpiece axial positioning cavity II12 as a circular base horizontally on the machine tool operating table, and uses a pair of cylindrical pins and cathode chuck 2 for angular positioning to avoid subsequent installation errors between the tool cathode 9 and the workpiece blank 10. It is then fixed to the machine tool operating table with hexagonal screws. The lower surface of the workpiece axial positioning cavity I11 is tightly fitted with the upper surface of the workpiece axial positioning cavity II12. Next, the electrolyte flow cavity 4 is horizontally placed at the upper end of the workpiece axial positioning cavity I11, and then the workpiece blank 10 is axially... Insert the tool cathode 9 into the through hole of the electrolyte passage chamber 4, so that the lower surface of the large cylinder at the upper end of the workpiece blank 10 is in close contact with the upper surface of the electrolyte passage chamber 4; after aligning the tool cathode 9 and the cathode chuck 2 through the pin hole, fix them in a detachable manner with screws. When connecting, the tool cathode 9 can be angularly positioned with the cathode chuck 2 through a pair of pin holes of different angles but the same diameter, and then fixed with hexagonal screws. The lower end of the tool cathode 9 is provided with end face teeth corresponding to the workpiece. During the processing, the end face teeth correspond to the tooth grooves of the workpiece blank 10. After the electrolytic machining device is installed, the machine tool electrolyte inlet pipe is connected to the corresponding electrolyte inlet and outlet channels, and the power is turned on. The tool cathode 9 is continuously fed towards the workpiece blank 10 by the drive device, and the end face of the workpiece blank 10 is gradually machined into a gear. During machining, the electrolyte is input through the electrolyte inlet channel 5 and wraps around the end face teeth of the tool cathode 9 and the tooth groove of the workpiece blank 10. The electrolyte will flow along the flow cavity of the tool cathode 9 from the connecting hole of the cathode chuck 2 to the electrolyte rectification zone 7. After the electrolyte merges in the electrolyte rectification zone 7, it flows out of the entire machining device from the electrolyte outlet channel 1 to form a reverse flow.

[0047] During installation, the cathode chuck 2 can be detachably fixed to the machine tool spindle after horizontal alignment. During the connection process, excessive force may cause some damage to the cathode chuck 2. Therefore, before using hexagon socket screws for fixing, a high-strength metal part can be added to ensure that the cathode chuck is subjected to uniform force during installation, which can prevent its deformation.

[0048] The tool cathode 9 has a cathode curve end face tooth with the same number of teeth as the workpiece blank 10, and it corresponds to the tooth groove of the workpiece blank 10 during the machining process. Due to the complex tooth profile, narrow channel, and large curvature changes of tooth root and tooth tip, the electrochemical dissolution law of each position of the gear is different. In order to ensure that the tool cathode 9 has the same dissolution rate at each point of the workpiece blank 10 under different feed depths, the end face tooth of the tool cathode 9 adopts an unequal clearance design.

[0049] Both the cathode chuck 2 and the tool cathode 9 are made of metal. Therefore, the lower end face of the cathode chuck 2 and the upper end face of the tool cathode 9 have a high degree of overlap when they are in close contact, ensuring that the profile of the tool cathode 9 is always parallel to the machining surface of the workpiece blank 10. The machining edge of the tool cathode 9 is a curved end face gear, and during the machining process, the cathode curve teeth correspond to the tooth grooves of the workpiece blank 10, and the cathode curve profile teeth adopt an unequal clearance design.

[0050] As shown in Figure 4, in another embodiment, the lower end face of the cathode chuck 2 is provided with a positioning hole 2-2 and a threaded connection hole 2-1. The outer ring of the end face teeth of the tool cathode 9 is provided with a positioning through hole 9-2 for communicating with the positioning hole 2-2, and a threaded through hole 9-1 for communicating with the threaded connection hole 2-1. This facilitates the positioning and connection of the cathode chuck 2 and the tool cathode 9.

[0051] In another embodiment, a baffle is provided in front of the port where the electrolyte input channel 5 communicates with the groove.

[0052] The lower end of the baffle plate and the bottom end of the groove have a gap that allows the electrolyte to flow, and the lower end of the baffle plate is provided with a rounded chamfer.

[0053] In this embodiment, multiple electrolyte inlet channels 5 are radially and evenly distributed on the outer wall of the electrolyte inlet cavity 4. After the electrolyte is introduced, it flows into the electrolyte inlet channel 5 and contacts the baffle plate, thereby helping to increase the pressure of the electrolyte. At the same time, a rounded chamfer is provided at the lower end of the baffle plate, which has a certain guiding effect and can reduce the pressure loss of the electrolyte along the process.

[0054] As shown in Figure 5, in another embodiment, the workpiece axial positioning cavity I 11 includes two detachable sub-workpiece axial positioning cavities I. The two sub-workpiece axial positioning cavities I can fit together, and symmetrical clamping grooves for clamping the workpiece blank 10 are provided at the center of the fitting area. One sub-workpiece axial positioning cavity I is fixedly connected to the upper end of the workpiece axial positioning cavity II 12, and the other sub-workpiece axial positioning cavity I can be movably inserted between the electrolyte passage cavity 4 and the workpiece axial positioning cavity II 12 to clamp the workpiece blank 10. Thus, in use, positioning is achieved by the fixed connection of one sub-workpiece axial positioning cavity I to the workpiece axial positioning cavity II 12, and the workpiece blank 10 is clamped by the movable insertion of the other sub-workpiece axial positioning cavity I between the electrolyte passage cavity 4 and the workpiece axial positioning cavity II 12. Several connecting holes are provided on each of the two sub-workpiece axial positioning cavities I for bolt connection and fixation.

[0055] The upper end face of the workpiece axial positioning cavity II12, located directly below the clamping groove, has an annular workpiece positioning groove 6. The lower end of the workpiece blank 10 is correspondingly provided with an annular insert that can be inserted into the annular workpiece positioning groove 6. Thus, by setting the workpiece positioning groove 6 and the annular insert, the annular insert at the lower end of the workpiece blank 10 can be tightly fitted against the inner wall of the annular workpiece positioning groove 6, restricting the workpiece blank 10 from moving radially.

[0056] The upper half of the clamping groove is used to surround and clamp the workpiece blank 10, while the lower half of the clamping groove provides line contact to secure the workpiece blank 10. In this embodiment, the upper half of the clamping groove is a cylindrical structure, and the lower half is a triangular prism structure. During clamping, since the axial dimension of the workpiece blank 10 is much larger than its radial dimension, triangular and circular facets are used for limiting the upper part of the workpiece blank 10. This, combined with a downward external force, serves as axial positioning to ensure the perpendicularity of the workpiece during installation and processing. During clamping, the outer cylindrical surface at the upper end of the workpiece blank 10 is tightly fitted by the triangular prism structure and the inner wall of the cylindrical structure, jointly restricting the radial displacement of the workpiece blank 10, and is fixedly connected using hexagonal socket head cap screws.

[0057] In another embodiment, the electrolyte passage cavity 4 has a through bolt hole 5-1, and the workpiece axial positioning cavity I11 has a corresponding bottom threaded hole 11-1 for communicating with the bolt hole 5-1. This facilitates the positioning and fixed connection between the electrolyte passage cavity 4 and the workpiece axial positioning cavity I11.

[0058] In another embodiment, a second sealing groove 8 is formed on the end face of the tool cathode 9 that contacts the cathode chuck 2. The second sealing groove 8 is located around the flow channel and is used to embed a sealing ring. The second sealing groove 8 can prevent electrolyte from seeping out through the connection gap between the cathode chuck 2 and the tool cathode 9 during the machining process, thereby affecting the stability and accuracy of the machining process.

[0059] In another embodiment, a first sealing groove 3 is formed on the sidewall that contacts the tool cathode 9 within the groove. The first sealing groove 3 is used to embed a sealing ring. Thus, during normal processing, the first sealing groove 3 ensures that the electrolyte will not splash outwards. Furthermore, the use of insulating plastic material in the manufacturing process of this part reduces the overall weight of the device.

[0060] The tool cathode 9 of this invention features an unequal clearance design on its end face tooth profile. The machining edge has cathode curved end face teeth with the same number of teeth as the workpiece, and these teeth correspond to the workpiece tooth grooves during machining. During installation, its upper end is detachably fixed to the cathode chuck 2, while its lower end is kept at a certain distance from the workpiece blank machining surface, allowing the electrolyte to flow quickly. Machining is performed using a low-frequency vibration feed mode of the tool cathode 9, ensuring that the machining gap remains in a periodic fluctuation state during machining. This effectively promotes the timely discharge of electrolytic products within the machining gap, ensuring the stability of the flow field. The tool cathode 9 continuously feeds towards the workpiece blank 10 along with the machine tool spindle, and the workpiece curved end face gear is formed based on the principle of electrochemical dissolution.

[0061] The present invention adopts a reverse flow method of electrolyte. The electrolyte flows into the machining gap through multiple electrolyte input channels 5 that are radially evenly distributed on the annular outer wall of the electrolyte passage cavity 4, and finally flows out through two electrolyte output channels 1 provided in the cathode chuck 2. This flow method can effectively improve the uniformity of the flow field and significantly improve the machining accuracy.

[0062] This invention addresses the challenges of precision and efficient manufacturing of small-sized curved end-face gears in traditional machining processes, which include easy tool wear, poor workpiece surface quality, and failure to meet design requirements for tooth profile and direction. These issues lead to uneven load distribution during actual operation, resulting in severe gear wear and even tooth breakage.

[0063] As shown in Figure 6, the method of using the device of the present invention includes the following steps:

[0064] Step 1: After aligning the cathode chuck 2 with the machine tool drive unit using hex socket screws, make a detachable fixed connection. During the connection process, excessive force may cause some damage to the cathode chuck. Therefore, before using hex socket screws for fixing, a high-strength metal part can be added to ensure that the cathode chuck is subjected to uniform force during installation, which can prevent its deformation.

[0065] Step 2: Place the circular base of the workpiece axial positioning cavity II12 horizontally on the machine tool operating table, and align it with the cathode chuck 2 using a pair of cylindrical pins, and fix it to the machine tool operating table using multiple hexagonal screws;

[0066] Step 3: Place the workpiece axial positioning cavity I11 horizontally on the upper surface of the circular base of the workpiece axial positioning cavity II12. Then, insert the workpiece blank 10 into the through hole of the electrolyte passage cavity 4, and make the inner wall of the workpiece positioning groove tightly fit with the lower outer cylindrical surface of the workpiece blank 10. The upper outer cylindrical surface is tightly fitted through the triangular prism-shaped inner wall of the workpiece axial positioning cavity I11 and the workpiece axial positioning cavity II12. The large cylindrical bottom surface at the upper end of the workpiece blank 10 is tightly fitted with the upper surface of the electrolyte passage cavity 4. During the clamping process, the workpiece blank is axially positioned by combining with the vertically downward external force. After the operation is completed, the workpiece blank clamping work is finished.

[0067] Step 4: After aligning the tool cathode 9 with the cathode chuck using a pair of cylindrical pins, use hexagon socket screws for detachable fixing. Before connecting, check whether the electrolyte discharge channel in the gap provided in the tool cathode 9 and the cathode chuck 2 is aligned, and insert the sealing ring into the second sealing groove 8 between the cathode chuck and the tool cathode. After the operation is completed, the tool cathode assembly installation is finished.

[0068] Step 5: Connect the cathode chuck 2 to the negative terminal of the machine tool power supply, and connect the workpiece axial positioning cavity II 12 to the positive terminal of the machine tool.

[0069] Step 6: Insert the sealing ring into the first sealing groove 3 opened in the inner wall of the center hole of the electrolyte passage cavity 4;

[0070] Step 7: Inspect and clean the electrolyte output channel 1 and electrolyte inlet channel 4 at both ends of the cathode clamp to remove any debris generated during installation.

[0071] Step 8: Insert the dryer supply and return pipes of the machine tool into the electrolyte input channel 5 of the electrolyte passage chamber 4 and the electrolyte output channel 1 corresponding to the cathode chuck 2, respectively.

[0072] Step 9: After all installation work is completed, check whether the machine tool power supply, electrolyte circulation system and other equipment are normal, and check whether there are any abnormalities on the outside of the machine tool; after the inspection, test the electrolyte and check the sealing.

[0073] Step 10: Input the electrolytic machining process parameters on the machine tool operation interface and adopt the cathode vibration and pulse power supply coupled machining mode;

[0074] Step 11: Turn on the power. The tool cathode 9 will be continuously fed towards the workpiece by the machine tool drive device. After the electrolyte flows into the machining gap in the reverse flow form, the workpiece machining surface will undergo anodic dissolution. The electrolysis products and Joule heat will be carried away by the high-speed flowing electrolyte, and the workpiece will be gradually machined.

[0075] Step 12: After completing the electrolytic machining of the small-sized curved end face gear, disconnect the power supply, raise the machine tool spindle a certain distance, remove the machined part, and rinse it with clean water;

[0076] Step 13: Measure and record the processed sample using a coordinate measuring machine, analyze the normal error between each point and the theoretical surface, and further correct and optimize multiple parameters through multiple experiments until the processing meets the design requirements.

[0077] This invention relates to an electrolytic machining apparatus and method for small-sized curved end face gears, belonging to the field of high-precision transmission system manufacturing. The tool cathode 9 is continuously vibrated and fed towards the workpiece blank 10 by a machine tool drive device to complete the machining of the small-sized curved end face gear. The tooth profile of the tool cathode 9 adopts an unequal clearance design, and the machining edge has cathode curved end face teeth with the same number of teeth as the workpiece, corresponding to the tooth grooves of the workpiece blank 10 during machining. This invention shapes the workpiece through the end face teeth of the tool cathode 9, avoiding defects such as easy tool wear, poor workpiece surface quality, and failure to meet design requirements for tooth shape and direction parameters in traditional mechanical cutting. The reverse flow method effectively improves the uniformity of the flow field and significantly improves machining accuracy.

[0078] It should be noted that the terms such as "upper", "lower", "left", "right", "front", and "back" used in the invention are only for clarity of description and are not intended to limit the scope of the invention. Changes or adjustments to their relative relationships, without substantially altering the technical content, should also be considered within the scope of the invention.

[0079] The above are merely preferred embodiments of the present invention. The scope of protection of the present invention is not limited to the above embodiments. All technical solutions falling within the scope of the present invention's concept are within the scope of protection of the present invention. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principle of the present invention should be considered within the scope of protection of the present invention.

Claims

1. A method of using an electrolytic machining device for small-sized curved end face gears, characterized in that: The structure includes: The device includes a cathode chuck (2), a tool cathode (9), an electrolyte flow chamber (4), a workpiece axial positioning chamber I (11), and a workpiece axial positioning chamber II (12). The cathode chuck (2) has an electrolyte rectification zone (7) inside, and an electrolyte output channel (1) communicating with the electrolyte rectification zone (7) is also provided on the cathode chuck (2). A connecting channel extends downwards from the electrolyte rectification zone (7) inside the cathode chuck (2). The lower end of the cathode chuck (2) is used to connect to the tool cathode (9). A flow chamber communicating with the connecting channel is provided in the middle of the tool cathode (9). The lower end of the tool cathode (9) is provided with end face teeth for machining the workpiece blank (10). 2) The upper end is used to be fixedly connected to the machine tool drive device; the upper end of the workpiece axial positioning cavity II (12) is connected to the workpiece axial positioning cavity I (11), the upper end of the workpiece axial positioning cavity I (11) is connected to the electrolyte passage cavity (4), the center of the electrolyte passage cavity (4) is provided with a groove for the cathode chuck (2) and the tool cathode (9) to be inserted as a whole, the center of the groove is provided with a through hole for the workpiece blank (10) to be inserted downwards, the workpiece axial positioning cavity I (11) is used to clamp and fix the workpiece blank (10) extending from below the electrolyte passage cavity (4); the side wall of the electrolyte passage cavity (4) is provided with an electrolyte input passage that communicates with the groove. The method includes: Step 1: After aligning the cathode chuck (2) with the machine tool drive device using hexagonal screws, a detachable fixed connection is made; Step 2: The workpiece axial positioning cavity II (12) is placed horizontally on the machine tool operating table as a circular base, and aligned with the cathode chuck (2) using a pair of cylindrical pins, and fixed with the machine tool operating table using multiple hexagonal screws; Step 3: The workpiece axial positioning cavity I (11) is placed horizontally on the upper surface of the circular base of the workpiece axial positioning cavity II (12), and then the workpiece blank (10) is embedded in the through hole of the electrolyte passage cavity (4), and the inner wall of the workpiece positioning groove (6) is tightly fitted with the lower outer cylindrical surface of the workpiece blank (10), and the upper outer cylindrical surface is... The cylindrical surface is tightly fitted with the triangular prism-shaped inner wall of the workpiece axial positioning cavity I (11) and the workpiece axial positioning cavity II (12). The bottom surface of the large cylindrical part at the top of the workpiece blank (10) is tightly fitted with the upper surface of the electrolyte passage cavity (4). During the clamping process, it is axially positioned by combining with the vertically downward external force. After the operation is completed, the workpiece blank clamping work is finished. Step 4: After aligning the tool cathode (9) with the cathode chuck (2) through a pair of cylindrical pins, it is detachably fixed by using hexagonal screws. After the operation is completed, the tool cathode (9) assembly is installed. Step 5: Connect the cathode chuck (2) to the negative terminal of the machine tool power supply and connect the workpiece axial positioning cavity II (12) to the positive terminal of the machine tool.Step Six: Inspect and clean the electrolyte output channel (1) on the cathode chuck (2) and the electrolyte input channel (5) on the electrolyte flow chamber (4) to remove any debris generated during installation; Step Seven: Insert the dry supply and return pipes of the machine tool into the electrolyte input channel (5) of the electrolyte flow chamber (4) and the corresponding electrolyte output channel (1) of the cathode chuck (2), respectively; Step Eight: After all installation work is completed, check whether the machine tool power supply and electrolyte circulation system are normal, and check whether there are any abnormalities on the outside of the machine tool; after the inspection, test the electrolyte flow and check the sealing condition; Step Nine: Input the electrolytic machining process parameters on the machine tool operation interface and adopt the cathode vibration and pulse power coupling machining mode; Step 10: Turn on the power. The tool cathode (9) will continuously feed towards the workpiece blank (10) with the machine tool drive device. After the electrolyte flows into the machining gap in the reverse flow form, the workpiece machining surface will undergo anodic dissolution, and the electrolysis products and Joule heat will be carried away by the high-speed flowing electrolyte, gradually machining the workpiece blank (10); Step 11: After completing the electrolytic machining of the small-size curved end face gear, turn off the power, raise the machine tool spindle a certain distance, take out the machined part, and rinse it with clean water; Step 12: Use a coordinate measuring machine to measure and record the machined sample, analyze the normal error between each point and the theoretical surface, and further correct and optimize multiple parameters through multiple experiments until the machining meets the design requirements.

2. The method of using the electrolytic machining device for small-sized curved end face gears according to claim 1, characterized in that: The lower end face of the cathode chuck (2) is provided with a positioning hole (2-2) and a threaded connection hole (2-1). The outer ring of the end face tooth of the tool cathode (9) is provided with a positioning through hole (9-2) for communicating with the positioning hole (2-2) and a threaded through hole (9-1) for communicating with the threaded connection hole (2-1).

3. The method of using the electrolytic machining device for small-sized curved end face gears according to claim 1, characterized in that: A baffle is provided in front of the port where the electrolyte input channel (5) connects to the groove.

4. The method of using the electrolytic machining device for small-sized curved end face gears according to claim 3, characterized in that: There is a gap between the lower end of the baffle and the bottom end of the groove to allow the electrolyte to flow, and the lower end of the baffle is provided with a rounded chamfer.

5. The method of using the electrolytic machining device for small-sized curved end face gears according to claim 1, characterized in that: The workpiece axial positioning cavity I (11) includes two detachable sub-workpiece axial positioning cavities I. The two sub-workpiece axial positioning cavities I can fit together, and the center of the fitting area is symmetrically provided with a clamping groove for clamping the workpiece blank (10). One sub-workpiece axial positioning cavity I is fixedly connected to the upper end of the workpiece axial positioning cavity II (12), and the other sub-workpiece axial positioning cavity I can be movably inserted between the electrolyte liquid passage cavity (4) and the workpiece axial positioning cavity II (12) to clamp the workpiece blank (10).

6. The method of using the electrolytic machining device for small-sized curved end face gears according to claim 5, characterized in that: The upper end face of the workpiece axial positioning cavity II (12), and located directly below the clamping groove, is provided with an annular workpiece positioning groove (6); the lower end of the workpiece blank (10) is provided with an annular insert block that can be inserted into the annular workpiece positioning groove (6).

7. The method of using the electrolytic machining device for small-sized curved end face gears according to claim 5, characterized in that: The upper half of the clamping groove is used to surround and clamp the workpiece blank (10), and the lower half of the clamping groove is used to press and fix the workpiece blank (10) in line contact.

8. The method of using the electrolytic machining device for small-sized curved end face gears according to claim 1, characterized in that: A second sealing groove (8) is formed on the end face of the tool cathode (9) that is in contact with the cathode chuck (2). The second sealing groove (8) is located on the periphery of the flow cavity and is used to embed a sealing ring.

9. The method of using the electrolytic machining device for small-sized curved end face gears according to claim 1, characterized in that: A first sealing groove (3) is formed on the side wall that contacts the tool cathode (9) in the groove. The first sealing groove (3) is used to embed the sealing ring.

Images