【作者】 阿达依·谢尔亚孜旦；

【导师】 周锦进；

【作者基本信息】 大连理工大学 ， 机械制造及其自动化， 2007， 博士

【摘要】 螺旋锥齿轮所具有的良好使用性能使其得到了日益广泛的应用，并已成为汽车制造业中的关键基础件之一；但与此同时，螺旋锥齿轮齿面的加工质量对其使用性能的影响也日益突出。大量的研究与实践证实，利用光整加工方法在稳定或提高零件加工精度的同时，通过改善零件的表面质量也可有效提高零件的使用性能。因此，对螺旋锥齿轮的齿面实施光整加工无疑会提高螺旋锥齿轮的使用性能。作为一种先进的、非传统的、非接触式的光整加工方法，电化学光整加工方法因其具有高效、不受零件表面硬度影响以及可使零件表面获得良好的微观几何形貌等优势而得到迅速发展，并在多种机械基础件中得到应用。实践表明，电化学光整加工不仅可大幅度改善零件的表面质量，而且还可不同程度地提高零件的加王精度。因此，将电化学光整加工方法作为螺旋锥齿轮的终加工工艺方法对于提高其加工质量具有十分重要的意义。针对国产汽车驱动桥螺旋锥齿轮加工质量的现状，应长春一汽集团公司的要求，本文在分析国内外螺旋锥齿轮终加工工艺方法及其应用现状的基础上，结合国内外对电化学光整加工的研究与应用，尤其是大连理工大学光整加工课题组多年来在电化学光整加工研究及应用方面所取得的成果，提出了螺旋锥齿轮电化学光整加工工艺方法以提高螺旋锥齿轮齿面的加工质量。螺旋锥齿轮齿面几何结构的特殊性、螺旋锥齿轮齿面的加工质量现状以及电化学光整加工的机理，决定了对螺旋锥齿轮齿面实施电化学光整加工将面临诸多难点问题。这些难点问题主要是既提高加工精度，又如何大幅度降低表面粗糙度的值以及电化学光整加工工艺方法的实施。前者不仅与电化学光整加工的整平机理有关，而且还与电化学光整加工工艺方法的选择有关；后者则主要涉及到工具阴极几何结构确定、极间流场设计以及工具阴极的移动方式等技术问题。在电化学光整加工的整平机理方面，依据法拉第电解定律和对实验结果的分析，在分析电化学光整加工整平过程的同时，建立了小间隙条件下阳极表面微观几何轮廓电化学阳极溶解的数学模型，从微观几何的角度研究了电化学光整加工整平过程中工件阳极表面微观几何轮廓的变化及其影响。研究结果表明：电化学光整加工的整平是小间隙条件下的电化学阳极溶解，其特点是电化学阳极溶解速度沿工件阳极表面微观几何轮廓分布不均；电化学光整加工的整平过程是工件阳极表面微观几何轮廓的圆角化过程；工件阳极表面微观几何轮廓的圆角化不仅影响整平效果的提高，而且也使工件阳极自身表面微观几何轮廓产生记忆效应；减小极间间隙以及使工件阳极表面微观几何轮廓尖峰化可提高电化学光整加工的整平效果。在此基础上，针对螺旋锥齿轮电化学光整加工可能的工艺方法，研究了其涉及到的若干关键基础问题，主要包括工具阴极的表面质量、脉冲电流的作用、机械单元的作用以及工件阳极原始表面质量状况对整平效果的影响。研究结果表明：经电化学光整加工整平后，所获得的工件阳极表面微观几何轮廓是工件阳极自身表面微观几何轮廓、工具阴极表面微观几何轮廓以及工件阳极材质分布不均共同作用复合的结果；工具阴极与工件阳极之间相对运动的存在及其与电流脉冲特性的结合不仅有助于利用工具阴极表面高点扫描改善表面质量，而且也有利于提高工件阳极的加工精度；电化学机械复合光整加工方法中的机械单元不仅具有刮膜作用，而且还具有使工件阳极表面微观几何轮廓尖峰化的作用；依据工件阳极的原始表面质量状况，合理强化电化学机械复合光整加工中机械单元的作用可大幅度提高整平效果。在螺旋锥齿轮电化学光整加工工艺实施方面，结合螺旋锥齿轮齿面的几何结构特点，通过对比移动式工具阴极脉冲电化学光整加工工艺方法与电化学机械复合光整加工工艺方法各自所具有的优势，确定了利用移动式工具阴极脉冲电化学光整加工工艺方法对螺旋锥齿轮齿面实施光整加工；与此同时，通过对螺旋锥齿轮的构形分析，确定了移动式工具阴极的平面几何结构及其移动方式，并对与极间流场相关的极间流场建立的方式以及极间流道等问题进行了设计。实施了面向机械式螺旋锥齿轮铣齿机的螺旋锥齿轮脉冲电化学光整加工工艺方法。实验结果表明：利用旋转扫描式工具阴极脉冲电化学光整加工工艺方法不仅可使成形法加工的螺旋锥齿轮齿面之表面粗糙度达Ra0.1μm的水平，而且还使其加工精度可由DIN10级提高到DIN7级。这一实验结果表明：课题的研究是先进的，工艺方法是有效可行的。更多还原

【Abstract】 Having favorable working performances, spiral bevel gear (SBG) has been more and more used, and also becomes one of the key parts in automobile manufacturing. Meanwhile, it is increasingly shown that the influence of the machining quality of the gear on its working performances. Lots of studies and practices have demonstrated that part’s working performances could be enhanced greatly by improving its quality of the surface, which is obtained by the finishing method. Therefore, if the surface of SBG is finished, its service performances will be enhanced undoubtedly.As an unconventional and noncontact finishing method, the electrochemical finishing (ECF) method has been developed rapidly as a result of its advantages such as regardless of material hardness, high material removal rate and smooth micro-profile of the obtained surface, and thus the method has been used in finishing some key parts to achieve better surface quality. The finishing practice has indicated that ECF not only can improve the surface quality largely, but also can reach good dimensional accuracy. Hence, it is of great significance to apply ECF to finish the teeth surface of SBG for improving its machining quality.Aimed at the domestic machining condition of SBG, which is used in automobile’s driving axle in our country, and for the requirements of Changchun FAW (First Automobile Works), this paper has analyzed the finishing methods of SBG both in home and abroad, combined the condition in application and research of ECF both in home and abroad, especially in the achievement of DLUT in ECF, and then put ECF forward as finishing method for better machining quality of SBG.Because of the factors such as SBG’s geometry structure, the machining quality of SBG and the finishing mechanism of ECF, there are many difficult problems on utilizing ECF to advance the machining quality of SBG. These difficult problems not only relate to the mechanism of ECF and a good selection of the ECF methods, but also relate to the application of the selected ECF process.Considering the difficult problems in the finishing surface of SBG with ECF, the research, focusing on the finishing mechanism of ECF, has been carried out, and the mathematic model, explaining the electrochemical dissolution (ECD) of anodic surface micro-profile in the condition of small gap, has been brought forward according to Faraday’s law. Based on the analysis of theory and experiment, it has been discussed that the influence of the change in anodic micro-profile on finishing effect during the process of ECF from the view of the micro-geometry. The research results show as follows: the ECF is just the ECD in the condition of the small gap, and its characteristic is that the rate of ECD is uneven distribution along with the anodic mico-profile; the finishing process of ECF is the process of blunting the anodic surface micro-profile, which does not only influence the improvement of finishing effect, but also leads to the memory effect of the anodic micro-profile; it can improve the smooth effect of ECF that decreasing the distance between electrodes and making anodic surface micro-profile sharp.Based on this, taking optional methods of ECF for SBG into account, this paper has analyzed the related key processing problems such as the cathodic surface quality, the effect of pulse electricity, the function of mechanical role and the anodic original surface quality.The research result indicates that after the smooth process of ECF, the achieved anodic surface micro-profile is related to the anodic surface micro-profile, the cathodic surface micro-profile, and the uneven distribution of anodic materials as well. The existence of relative movement between the electrodes and its combination with the pulse current are helpful for applying the cathodic high-point-scanning to improve the surface quality and better accuracy of anode also. The mechanical role, which exists in the electrochemical mechanical finishing (ECMF), can not only contribute to the function of scratching, but also sharpen the anodic surface micro-profile. According to the anodic original surface quality, it can improve the smooth effect obviously that enhancing the action of the mechanical role of ECMF properly.Combing the characters of SBG’s geometry structure, through comparing the different advantages of pulse electrochemical finishing (PECF) with moving cathode and ECMF, the former one has been chosen to finish the surface of SBG. At the same time, through the analysis of SBG structure, it has been discussed that the application model of cathode with moving in the finishing process of SBG, and then the flow-field between the electrodes has been also designed.According to above-mentioned analysis, the chosen method has been carried out by using the mechanical machining tool of SBG. The experimental result reveals that the SBG with the surface roughness Ra0.1μm and machining accuracy DIN7, which was machined with forming shape method, can be achieved by using the PECF with moving cathode.The experiment result shows that the topic of the dissertation is an advanced, and the ECF process can improve the machining quality of SBG effectively.更多还原