Theoretical and experimental study on LV-WECM of gear involute artifact with high aspect ratio
Theoretical and experimental study on LV-WECM of gear involute artifact with high aspect ratio
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DOI：
10.1007/s00170-022-10752-9
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发表时间：
2023-01
期刊：
影响因子：
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通讯作者：
Li Liuxin;Liu Yong;Ling Siying;Wang Kan;Li Chenxin
中科院分区：
文献类型：
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作者：
Li Liuxin;Liu Yong;Ling Siying;Wang Kan;Li Chenxin
在高精度齿轮检测中，精密渐开线工件是不可缺少的工具。提出了一种低频振动辅助线电解加工（LV-WECM）的新方法来加工高深宽比齿轮渐开线工件。首先，建立了WECM的数学模型，分析了齿轮渐开线伪影的形成机理。其次，通过电场仿真对加工过程进行了仿真。根据仿真结果分析了WECM的偏差。通过流场模拟分析了低频振动和冲洗对加工的影响，结果表明振动和冲洗能有效地促进差距内的传质。最后，通过实验研究了外加电压、脉冲参数和振动参数对加工精度的影响。经过多组对比实验，在8 mm厚的GCr 15工件上成功加工出了高宽比为40：1的渐开线齿轮毛坯，最大齿形偏差为17.6 µm，平均表面粗糙度Sa约为2.370 µm。实践证明，LV-WECM是一种加工高深宽比渐开线样板的可靠方法。
Precision involute artifact is an indispensable tool in the detection of high precision gears. In this paper, a new method of low-frequency vibration-aided wire electrochemical machining (LV-WECM) is proposed to fabricate gear involute artifact with high aspect ratio. First, a mathematical model of WECM is established to analyze forming principle of gear involute artifact. Second, the machining process is simulated by electric field simulation. The deviation of WECM is analyzed according to the simulation results. And then, the effects of low-frequency vibration and flushing on machining are analyzed by flow field simulation, which shows that vibration and flushing can effectively promote mass transfer in the gap. Finally, the effects of applied voltage, pulse parameters, and vibration parameters on machining accuracy were discussed experimentally. After several groups of contrast experiments, a gear involute artifact blank with aspect ratio of 40:1 is successfully machined on 8-mm-thick GCr15 workpiece, the max profile deviation is 17.6 µm, and the average surface roughness Sa is about 2.370 µm. It is proved that LV-WECM is a reliable method for machining involute template with high aspect ratio.