【作者】 宋晓兵；

【导师】 周锦进；

【作者基本信息】 大连理工大学 ， 机械设计及理论， 2003， 硕士

【摘要】 齿轮作为应用量大面广的基础件产品，其质量直接影响我国相关机电产品的质量和在国际市场的竞争力。从总体水平上看，我国的齿轮在承载能力、使用寿命和噪音水平等技术指标与国外产品都有较大差距。另一方面，改善齿轮性能的重点仍然是齿形，对齿轮进行适当修形是优化齿轮传动、提高使用寿命和运动精度的关键技术。所以对齿轮进行修形研究具有重大的现实意义。 国内外的学者一直在对齿轮进行修形理论的探讨和加工工艺的研究，其中修形理论渐已成熟，本文从当前国内外齿轮修形加工方法的研究现状出发，结合大连理工大学特种加工研究所近年来对脉冲电化学加工工艺的研究和应用，试图将脉冲电化学加工工艺应用到齿轮修形加工中，并就齿轮修形阴极设计、过程控制和加工间隙的控制等方面做了大量的研究，得到了一些很有应用价值和指导意义的结果。 脉冲电化学加工是用脉冲电源代替传统的直流电源，尤其是高频、窄脉冲电流的引入，使脉冲电化学加工中间隙过程的电化学特性、流场特性和阳极溶解特性等都得到了很大的改善，其加工精度、表面质量和加工效率都有了很大的提高。本文通过对脉冲电化学加工机理的探讨，将脉冲电化学加工工艺应用到齿轮修形当中，探讨了加工过程中一些具有指导意义的规律。 间隙、流场和电流密度是影响脉冲电化学加工精度和表面质量的三大要素，本文的研究重点是阴极设计和过程控制。由于脉冲电化学加工可以允许微小的稳定加工间隙，这给脉冲电化学齿轮修形的阴极设计提供了不同于传统电化学齿轮修形阴极设计的新思路，本文以应用广泛的渐开线圆柱直齿轮为加工对象，提出了多种阴极设计方案并论述了各自的优缺点；开发了齿轮修形的加工模拟软件，实现了对加工过程进行模拟和对阴极进行辅助设计，对优化阴极设计、降低实验成本、缩短开发周期起到了良好的作用。 针对齿轮修形的特点，本文设计了基于单片机控制的脉冲电化学齿轮修形控制系统，实现了加工过程的自动化。该系统主要由步进电机控制模块、人机交互模块和单片机与PC通信模块组成，其抗干扰能力强，能很好地满足实验要求，而且灵活性大，通过与PC机的通信，人机交互更为方便直观。 根据法拉第定律，金属的去除量由电流强度和加工时间决定，因此，根据加工要求与加工规律确定出脉冲电流的大小和实时控制齿轮齿面上各点的加工时间，是脉冲电化学齿轮修形所研究的中心内容。本文结合实验室的条件，基于保证齿轮修形量，提高加工效率的思想，以加工时间和极间间隙为控制量，用两种阴极设计方案对脉冲电化学齿轮修形加工进行了实验，并对实验结果进行了认真的分析。在实验的基础上，对影响加工质量的各因素进行了详细的分析，提出了改善加工质量的方法。此外，为了提高工艺的稳定性，作者对脉冲电化学齿轮修形加工中的间隙进行了建模分析和在线控制的探讨。 本文的工作说明基于单片机控制的脉冲电化学齿轮修形工艺是可行的，不仅能满足修形量的要求，还能提高齿轮的齿形精度和表面质量，而且工艺简单，易于实现自动化，具有良好的应用前景。更多还原

【Abstract】 The quality of gear, which is used widely as a basic product, directly influences the quality of relative electromechanical products of our country and their competition in the international market. On the whole, there are big differences comparing our country’s gears with foreign gear products on such technological standards as load capacity, service life and noise level etc. What’s more, the focal point to improve gear properties is still the form of gear tooth. Gear modification is the critical technology to improve gear transmission, raise its service life and motion precision. Therefore, to develop researches on gear modification is practically significant.Scholars at home and abroad have been developing many researches on theories and machining technologies of gear modification. Theories of gear modification have been mature by now. In this paper, attempts to apply pulse electrochemical machining technology (PECM) to gear modification machining were carried out after studying the methods of gear modification machining nowadays at home and abroad and researches on PECM technology and its applications that Nontraditional Machining Institute of Dalian University of Technology has been engaged in recently. A series of researches have been developed on cathode design, process control and machining gap control etc. Several results that are valuable to applications and instructively significant have been gained.PECM is a new technology that the pulse power, especially the high frequency and short pulse current power, is applied and the traditional direct current power is replaced instead. Compared with traditional electrochemical machining, the characteristics of electrochemistry, flowing field and anode dissolution of this new technology are improved and its machining precision, surface quality and machining efficiency are enhanced greatly. In this paper, through researches on the theory of PECM, the PECM technology is applied to gear modification machining and a series of instructive rules during machining process are studied. Gap, flowing field and current density are three important factors that influence the machining precision and surface quality of PECM. In this paper, the research emphasizes on cathode tool design and process control. Because the tiny and steady machining gap is allowed in PECM, new ideas and methods that differ from traditional electromechanical gear modification can be used to design the cathode of PECM gear modification. So this paper develops several schemes of cathode design and their merits and demerits are analyzed and compared. The author also develops the simulation software of gear modification machining, through which the machining process can be simulated and the design of cathode can be aimed so that the cathode design can be optimized, the experimental expense can be reduced and the developing cycle time can be shortened.In this paper, aimed at the character of gear modification, the control system of PECM gear modification has been designed based on singlechip to realize the automation of the machining process. The system consists of stepper motor control module, human-computer interaction module and communication module between singlechip and PC. It has strong ability in anti-jamming and good flexibility and can satisfy the experimental demand. What’s more, human-computer interaction can be convenient and easy through the communication with PC.According to Faraday Law, the eroded quantity of metal depends on current density and machining time. So deciding the pulse current magnitude and real-time controlling the machining time of each point on the gear tooth surface according to the demand and rule of machining are important contents of PECM gear modification research. In this paper, combined with lab conditions and based on the thought that ensuring the modification quantity of gear and improving machining efficiency, experiments of gear modification bymeans of PECM using two schemes of cathode design are carried out. The experimental results are analyzed t更多还原