齿轮脉冲电化学光整加工及其控制系统的研究

【作者】 孙雪松；

【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， 2003， 硕士

【摘要】 零件表面质量对零件的耐磨性、抗疲劳强度、抗腐蚀性及接触刚度等使用性能以及寿命、可靠性都有很大的影响。光整加工是改善表面质量的重要手段，近年来新的光整加工工艺方法不断涌现，脉冲电化学光整加工作为一种新的工艺方法已经初步显示出了它的巨大发展潜力。 脉冲电化学光整加工以离子溶解形式去除工件表层金属，加工中因为没有切削力和切削热的作用，所以加工后的工件表面与机械加工表面相比无附加切削痕迹、塑性变形层。平滑的表面形貌降低了在零件表面形成应力集中源的可能性，因此提高了零件的抗疲劳性。 齿轮作为机械传动的关键部件，应用在航空航天、化工、冶金、建筑等各行各业中，如何降低传动噪音、提高使用寿命一直是机械领域内研究的热点问题。研究表明，不同加工方法形成的表面质量对齿轮的噪音、寿命影响差别很大。齿面经过脉冲电化学光整加工后表面粗糙度低、微观几何形貌平滑，不仅使齿轮寿命大幅度提高而且工作噪音也大幅度降低。 本文通过对脉冲电化学光整加工进行基础实验研究与理论分析，总结出该项工艺的电化学特性与工艺特性。结合齿轮脉冲电化学光整加工工艺设计了实验设备，并通过理论分析提出了该项工艺的控制方案，设计了基于PC机与单片机的上下位结构的微机控制系统，在保证齿轮精度的前提下实现对齿面的均匀加工。最后，与模糊逻辑控制技术相结合将脉冲电化学光整加工应用在平缓曲面的光整加工当中，并应用Matlab软件对控制模型进行仿真。 大量的实验结果表明，脉冲电化学光整加工能够显著改善工件的表面质量，对于减小初期磨损、增加抗疲劳性等方面效果显著，对改善我国基础件质量上应用前景广阔。更多还原

【Abstract】 Surface quality of parts has great influence on the operational performance such as wearing quality, figure strength, corrosion resistance and contact stiffness. Finishing is the way to improve the surface quality. In recent years, many new finishing techniques have been developed. Pulse Electrochemical Finishing(PECF), as a new technique, has demonstrated the great potential for development.Pulse Electrochemical Finishing removes the metal of the surface by electrochemical dissolution. Because of no cutting force, cutting heat, there are no cutting mark, plastic deformation layer on the surfaces of the parts. Smooth surface lows the chance of stress concentration, so fatigue strength is enhanced.Gear, as a main part in the mechanical transmission, has been applied in many fields such as aviation industry, chemical industry, metallurgy industry. How to reduce the noise and enhance the life of gear have been one of the most discussed subjects in the mechanical field. The present studies have revealed that the tooth surface produced by different finishing processes influences the noise and life of the gear in different ways. The lower surface roughness and smooth microform by electrochemical finishing not only enhance highly the life of gear, but reduce the noise.This paper studies the Pulse Electrochemical Finishing by experiments and theory, and concludes the electrochemical and technical characteristic of the techniques. In the paper, the technique of gear Pulse Electrochemical Finishing has been developed, and the device has been designed. And a computer-based PC control system base of upper and lower structure has been designed to remove equably the tooth surface, as a result, it improves the dimensional accuracy and surface quality. Finally, a fuzzy logic controller has been introduced in PECF .The experiments show that PECP might improve the lubricity, reduce the wearing , improve the fatigue strength of parts. The techniques can be extended to other polishing process to improve surface quality.更多还原