Gui Bing Pang

Gear Finishing and Modification Compound Process by Pulse Electrochemical Finishing with a Moving Cathode

Gears’ surface quality and modification characteristic have an important influence on its working performance. Pulse Electrochemical Finishing (PECF) could get excellent surface topography. In this project, PECF with a scanning cathode is used to finishing the cylinder gear. Tooth profile modification is realized by PECF with an uneven interelectrode gap distribution along the tooth profile and tooth lead modification is realized by PECF with a variable moving velocity of the cathode. The experimental results show that the tooth surface roughness could be decreased from Ra 3.9μm to Ra 0.35μm, which means that the PECF process possesses the finishing ability for the raw surface tooth, and the difference of material removal of PECF with an uneven interelectrode gap distribution could be 46μm and the material removal could be controlled by regulating the moving velocity of the cathode, which means tooth profile and lead modification could be realized by PECF.

Mathematical Modeling of Electrochemical Deburring

The drilling burr is taken as the research object. A mathematical model of electrochemical deburring (ECD) is established and the effects of main influencing factors, such as inter-electrode gap, applied voltage and deburring time, on burr height have been analyzed. The results show that the deburring time increases with the increase of initial burr height, inter-electrode gap, with the decrease of volume of electrochemical equivalent of the workpiece material, conductivity of electrolyte and applied voltage. The deburring time for various burr heights can be predicted by the mathematical model. The calculated results obtained from the mathematical model are approximately consistent with the experimental results. The results show that initial burr height h0=0.722mm is removed, and the fillet radius R=0.211mm is obtained.

A Basic Study on Precision in Electrochemical Abrasive Lapping of Plate

Taking plate as the example, this paper studies the effect of tool’s shape and movement on the electrochemical as well as mechanical lapping characteristics in Electrochemical Abrasive Lapping (ECAL). It is assumed that the removal size of electrochemical action at a random point is in direct proportion to the electrical amperage through this point and the removal size of the lapping action is in direct proportion to the relative frictional distance. Based on the assumption above, electrochemical and mechanical lapping characteristics with different tools shape are studied theoretically. The results show that the diameter of the tool should be larger than the width of the workpiece when a discal tool is used and the inner diameter of the tool should be larger than the width of the workpiece when a ringed tool is used, on the other hand the ratio of the revolving radius of the tool to the diameter of the tool as larger as possible avails to improve the precision and so does the ratio of the angular velocity of the workpiece to the rotating angular velocity of the tool.

Modeling and Experiment of Pulse Electrochemical Deburring on Inclined Exit Surface of Drilling Hole

In this paper the characteristics of pulse electrochemical deburring (PECD) is analyzed through a developed mathematical model and main influencing factors such as applied voltage, pulse duty factor, deburring time, initial burr height and initial interelectrode gap on burr height have been analyzed. The paper also highlights the scheme of the developed PECD system designed to operate within the parametric limits. The calculated results obtained from the mathematical model are found to be approximately consistent with the experimental results. The results show that initial burr height h0=0.057mm is removed, and the fillet radius R=0.248mm is obtained. The present paper through various parametric studies will act as a guideline for the operation of a PECD system.

Crown Modification of Cylinder-Roller Bearing Raceway Using Electrochemical Abrasive Belt Grinding

This paper researches on the theory of the crown modification of cylinder-roller bearing raceway using electrochemical abrasive belt grinding (ECABG) technology, and establishes relevant experimental device. The range of processing parameters with a better surface roughness can be obtained through experiments. On this basis, a mathematics model of distribution of material removal of electrochemical machining bearing is set up. Considering the controllability of processing parameters and demand of the surface quality, the processing parameters such as interelectrode voltage, electrolyte, interelectrode gap and cathode geometry are invariable in the experiment, and processing time is changed to control the crown value. The experimental results show that ECABG can enhance the surface quality of raceway to a great degree, and obtain the ideal forming crown at the same time under the optimum technological parameters. This paper developed a new method for the crown processing and finishing of bearing raceway.

A Mapping Framework between Design Information and Energy Information

Product design, energy consumption and carbon emission belong to different domain. For the purpose of achieving low carbon and energy conservation design, the relation between design information and energy information must be established. This paper employs bond graph theory for extracting and expressing basic energy characteristics and presents a mapping framework between design information and energy information.

Automated design of mechanical system for generating alternate mechanism concepts

An automated design approach for combined mechanical system is presented in this paper. The mechanical system can be generated by combining mechanical units, in particularly, generate alternate mechanism concepts. Beginning with kinematic functions as the input and output of mechanism unit, which are presented as the input and output vectors. And then, equations are defined according to the input and output functional characteristic vectors. Meanwhile, the functional transition can also be established by motion relationship between the inputs and the outputs of combined system. And then, the combination models (series and parallel combined patterns) are provided from the different combination patterns. Additionally, the properties of the different combination are intensively researched and the decomposition rules. By manipulating the matrices and the vectors, a given task can be decomposed into sub-functions. An example is given to show the application of the concept.

On Technologies of Electrochemical Finishing with Pulsed Current

Electrochemical finishing with pulsed current (ECFP) is introduced in this paper. The main process parameters, such as electric parameter and inter-electrode gap, etc., were investigated. The results show that the ECFP is an effective finishing method for improving the machining quality as the result of the machining mechanism. The related experimental results show that the obtained surface quality and dimensional accuracy are improved significantly as the result of the application of the pulsed current. Moreover, machining quality is increased with shorter pulses.

Study on the Design Method of Testing Fixture for Bent Tube Based on UG

According to the analysis of the bent tubes characteristics and the problems existing in the testing fixture design, the design method of testing fixture for bent tube based on UG are presented. The detail steps of the design and the use method for the testing fixture is described by a designing example. With this method, the designer can achieve new testing fixture just through partly modifying the parameters of the existing designing example owing to UG software possessing the feature of parameterized modeling. The design process of testing fixture design becomes easier, more reliable and efficient.

Theoretic and Experimental Study on the Accuracy of Gears by Generative Electrochemical Mechanical Finishing

Gears’ accuracy has important influences on its working performance and life. Electrochemical mechanical finishing (ECMF) was applied to finish cylindrical gears. The influence of the generative type of ECMF was studied theoretically and experimentally on the shape of gear teeth, and on the dimensional accuracy between teeth, and that in the tooth thickness direction. The results indicate that the generative type of ECMF can improve the accuracy between teeth, as well, the dimensional accuracy of gear tooth and that in the thickness direction may be also improved.