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Affiliation of Author(s):Shandong University, Weihai

Journal:The International Journal of Advanced Manufacturing Technology

Key Words:Wire electrochemical machining · Gear involute artifact · Numerical simulation · Low-frequency vibration · High aspect ratio

Abstract: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.

All the Authors:Ling Siying, Wang Kan, Li Chenxin

First Author:Li Liuxin

Indexed by:Research Paper

Correspondence Author:Yong Liu

Document Code:10.1007/s00170-022-10752-9

Document Type:Journal article

Volume:124

Page Number:3453-3469

ISSN No.:0268-3768

Translation or Not:no

Date of Publication:4493-01-01