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GB2162454A - Method of manufacturing internally-toothed bevel gear and apparatus therefor - Google Patents

Method of manufacturing internally-toothed bevel gear and apparatus therefor Download PDF

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Publication number
GB2162454A
GB2162454A GB08419654A GB8419654A GB2162454A GB 2162454 A GB2162454 A GB 2162454A GB 08419654 A GB08419654 A GB 08419654A GB 8419654 A GB8419654 A GB 8419654A GB 2162454 A GB2162454 A GB 2162454A
Authority
GB
United Kingdom
Prior art keywords
electrode
toothed
internally
electrodes
externally
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
GB08419654A
Other versions
GB8419654D0 (en
GB2162454B (en
Inventor
Brian James Daws
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Dowty Rotol Ltd
Original Assignee
Dowty Rotol Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Dowty Rotol Ltd filed Critical Dowty Rotol Ltd
Priority to GB08419654A priority Critical patent/GB2162454B/en
Publication of GB8419654D0 publication Critical patent/GB8419654D0/en
Priority to DE19853527282 priority patent/DE3527282A1/en
Priority to FR8511800A priority patent/FR2568506B1/en
Publication of GB2162454A publication Critical patent/GB2162454A/en
Application granted granted Critical
Publication of GB2162454B publication Critical patent/GB2162454B/en
Expired legal-status Critical Current

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23HWORKING OF METAL BY THE ACTION OF A HIGH CONCENTRATION OF ELECTRIC CURRENT ON A WORKPIECE USING AN ELECTRODE WHICH TAKES THE PLACE OF A TOOL; SUCH WORKING COMBINED WITH OTHER FORMS OF WORKING OF METAL
    • B23H9/00Machining specially adapted for treating particular metal objects or for obtaining special effects or results on metal objects
    • B23H9/003Making screw-threads or gears

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  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Electrical Discharge Machining, Electrochemical Machining, And Combined Machining (AREA)

Abstract

The method comprises producing an internally-bevelled gear blank 6 which forms a first electrode, and a second electrode 7 of externally-bevelled formation so shaped as, by the method, to be capable of providing the first electrode with an internally-bevel- toothed formation intended to mesh, at least approximately, with an externally-toothed bevel pinion subsequently required to co-operate therewith. The two electrodes are mounted on a machine 1 and the second electrode is advanced into close proximity to the first electrode, electrical current then being conducted across the electrodes to cause electric discharge or electro- chemical erosion of the first electrode. A constant gap 22 is maintained between the electrodes until such erosion of the first electrode has occurred that it reaches an internally-toothed shape which is substantially the mirror image of the externally-toothed shape of the second electrode. <IMAGE>

Description

SPECIFICATION Method of manufacturing internallytoothed bevel gear and apparatus therefor This invention relates to a method of manufacturing an internally-toothed bevel gear and to apparatus therefor.
Hitherto it has been found somewhat difficult and in some cases impossible to manufacture such internally-toothed bevel gears by normal machining processes involving mechanical force, for example by conventional gear tooth cutting and/or grinding, and in consequence certain such gears have been formed only from low grade metal or from plastics material in a suitably-shaped mould.
Thus, internal bevel gears made in this way have not been suitable for use in equipment such as gear boxes for aircraft where the gears are required to be subjected to high rotational speeds and/or high tooth loadings.
The invention as claimed is intended to provide a remedy. It solves the problem of how to manufacture an internally-toothed bevel gear from high grade electrically-conductive material without encountering practical difficulties otherwise found with normal gearcutting processes involving mechanical force and employing conventional milling and/or grinding machines.
According to this invention a method of manufacturing an internally-toothed bevel gear comprises the steps of:- (a) producing a gear blank, of required internally-bevelled shape and of electrically-conductive material, which forms a first electrode, (b) producing a second electrode of externally-bevel-toothed formation, said formation being so shaped as, by said method, to be capable of providing said first electrode with an internally-beveltoothed formation intended to mesh, at least approximately, with an externally-toothed bevel pinion subsequently required to co-operate therewith, (c) mounting said first electrode and said second electrode on a machine which is capable of effecting controlled erosion of said first electrode without imparting mechanical force thereon, (d) advancing the second electrode into close proximity to said first electrode, (e) conducting electrical current across said electrodes thereby to cause erosion of said first electrode, and, (f) maintaining a constant gap between said electrodes during continued supply of current across said electrodes until such erosion of said first electrode has occurred that it reaches an internally-toothed shape which is the mirror image of the externally-toothed shape of said second electrode, or substantially so.
The said method may further comprise the steps of:- (a) producing a third electrode similar to said second electrode but having an externally-bevel-toothed formation so shaped as, by said method, to be capable of providing said first electrode with an internallybevel-toothed formation intended to have a precision meshing fit with respect to said externally-toothed bevel pinion, (b) removing said second electrode from said machine and replacing it by said third electrode, (c) advancing said third electrode into close proximity to said first electrode, and (d) conducting electrical current across said first and third electrodes thereby to cause such further erosion of said first electrode that it reaches an internally-toothed shaped which is the mirror image of the externally-toothed shape of said third electrode, or substantially so.
In this way said second electrode is a "coarse" electrode, and said third electrode is a "fine" electrode which can where required apply a precision finish to said internallytoothed bevel gear.
The step of eroding said first electrode by use of said second electrode may be by electrical discharge machining (EDM), or, alternatively by electro-chemical machining (ECM), and the step of final erosion of said first electrode by use of said third electrode may be by electrical discharge machining.
Also according to this invention apparatus, suitable for manufacture of an internallytoothed bevel gear by the process mentioned in the four preceding paragraphs, includes a machine adapted for either electrical discharge machining or electrochemical machining having a work-table for supporting said first electrode, a holder upon which said second or third electrode can be mounted and a mechanism for advancing said second electrode or said third electrode into close proximity to said first electrode and for maintaining a constant gap between said electrodes during continued supply of current across said electrodes.
Preferably said blank or first electrode is of high tensile carburising or nitriding steel and said second and/or third electrodes are of copper.
The advantages offered by the invention are mainly that the internally-toothed bevel gear can be manufactured in a high grade material which enables the gear to be used in applications such as aircraft gear boxes where reliability and long operational life are essential.
One way of carrying out the invention is described in detail below with reference to the accompanying drawing which shows only one specific embodiment.
As diagrammatically shown in the drawing apparatus for manufacturing an internallytoothed bevel gear comprises a ram-type machine 1 adapted for electrical discharge machining. This machine includes a work-table 2 and a holder 3 which is movable in the direction towards the work-table by an hydraulic ram 4. This ram forms part of an electrohydraulic servo mechanism 5.
A gear-blank 6, which is of suitable inter nally-bevelled shape and from which it is intended that the finished gear is produced, is preformed in high tensile carburising steel in readiness for mounting on work-table 2. This blank, being electrically-conductive, forms a first electrode when so mounted on the worktable.
A second electrode 7 and a third electode 8, both of copper, are now produced in suitable manner in readiness for separately mounting in holder 3. These electrodes each have an externally-bevel-toothed formation so shaped as to be capable, by the method of this invention, of providing first electrode 6 with an internally-bevel-toothed formation intended to mesh with an externally-toothed production bevel pinion (not shown) subsequently required to cooperate therewith in service. It is also intended that the formation produced by electrode 7 will be so dimensioned as to be capable of approximate meshing with the pinion, while the formation produced by electrode 8 will be so dimensioned as to be capable of having a precision meshing relationship with respect to the pinion.
Thus, the electrode 7 forms a "coarse" electrode and the electrode 8 forms a "fine" electrode and, as indicated in somewhat exaggerated manner in the drawing by the dotted lines, the toothed profiles of electrode 8 are very slightly larger than those of electrode 7.
The machine 1 includes a reservoir 9 for dielectric fluid 10. The holder 3 and the hydraulic ram 4 are supported above the reservoir and work-table by member 11 which is itself fast with the wall of the reservoir. A pump 1 2 is provided externally of the reservoir adjacent the base thereof and dielectric fluid pumped from the reservoir is passed through a filter 1 3 and then through pipe 14 back into the reservoir.
A conductor 1 5 taken from the positive side of a source of electrical current connects with the work-table 2 and a conductor 1 6 is taken from the portion 1 7 of holder 3, which is electrically insulated at 1 8 from ram 4, to negative.
When the gear blank 6 is fitted to the worktable 2 it forms a first electrode for machine 1. On fitment of the second electrode 7 to holder 3 the two electrodes are coaxially disposed.
Before electrical discharge machining of the gear blank 6, i.e. of the first electrode, can commence the servo mechanism 5 is brought into operation. Accordingly electro-hydraulic servo valve 19, which forms part of servo mechanism 5, is operated so that liquid under pressure from a suitable source (not shown) is directed through pipe 20 to the upper side of ram 4 while the lower side of the ram is placed in communication with reservoir (also not shown) by way of pipe 21. Ram 4 thus lowers holder 3 so that second electrode 7 is positioned in close proximity to first electrode 6 in which a small predetermined gap 22, in this embodiment .006", is provided between the two electrodes. This gap is shown rather exaggerated in the drawing.
Electrical current is now passed through the conductor 1 5 to work-table 2 and thus to electrode 6 which is suitably clamped on the work-table through the intermediary of mounting blocks 23, 24. This current passes across the gap 22 between electrodes 6 and 7 and then through holder 3 and conductor 1 6 to negative. As current passes across gap 22 spark erosion of the steel of the gear blank 6 occurs so that the internally-toothed profiles of the gear take shape. While this shaping progressively takes place the servo mechanism 5 is operable automatically in suitable manner to maintain gap 22 substantially constant.
Simultaneously, dielectric fluid 10 is flushed through the gap from pipe 14, this fluid serving as a coolant and as a spark conductor.
It also serves as a vehicle for flushing small particles or chips of steel removed from the blank as the internally-toothed bevel gear is formed. Also simultaneously, pump 1 2 is operating to pump particle-containing dielectric fluid out from reservoir 9 and through filter 13, whereafter clean fluid passes through pipe 14 back into the reservoir for flushing gap 22. Suitable dielectric fluids are silicone oils, deionized water and hydrocarbon oil of suitable viscosity.
When the electrical discharge machining operation has advanced sufficiently for blank 6 to have reached an internally-toothed condition in which it is the mirror image of the "coarse" second electrode 7, the process is stopped and ram 4 is operated to raise electrode 7 away from blank 6 for removal from holder 3. Electrode 7 is replaced in holder 3 by the "fine" third electrode 8 indicated by dotted lines in the drawing.
The servo mechanism 5 is then re-operated to lower the third electrode into close proximity to blank 6 in which a gap of .0015" is established between them.
Electrical current is now passed through conductor 1 5 to work-table 2 and across electrodes 6, 8 so that further spark erosion of the gear-blank takes place to complete the shaping of the internally-bevelled tooth profiles of the gear. While this final shaping progressively takes place servo mechanism 5 is again operable to maintain gap 22 substantially constant. Also, simultaneously, dielectric fluid 10 is flushed through the gap from pipe 14, and pump 1 2 again pumps fluid from reservoir 9 through filter 1 3.
When this second stage of electrical discharge machining operation has advanced sufficiently for gear-blank 6 to have reached an internally-toothed condition in which it is the mirror image of the "fine" third electrode 8, the process is stopped and the internallytoothed bevel gear is removed from the ma chine.
By this second stage of machining operation only another .012" of material may have been removed from the blank in order to so form the gear.
Also during one or other or both of said electrical discharge machining operations a small amount of orbiting of the second and/or third electrodes may be suitable apparatus be caused to take place.
It will be understood that suitable heat treatment of the gear can be effected at any desired stage during the above manufacturing processes.
In this embodiment the first (coarse) stage of the process continues for approximately 1 + hours, while the second (fine) stage continues for + an hour. Thereafter the internallytoothed bevel gear is lapped by running a special externally-toothed bevel pinion in mesh therewith. This pinion is substantially identical to the production pinion subsequently required to mesh with the bevel gear and is coated with cubic boron nitride to a depth of .004" which acts as an abrasive. In the lapping process the pair of gears are set with correct assembled backlash and are run in opposite directions with predetermined torque applied thereto to achieve best surface finish.During lapping approximately .001" of material (the "re-cast" layer associated with electrical discharge machining) is removed from the flanks of the teeth of the internallytoothed bevel gear.
The internally-toothed bevel gear so formed can now be fitted in a gear box and arranged to mesh with the production bevel pinion.
In an alternative embodiment of the invention instead of the "coarse" stage of the gearshaping operation being effected by an electrical discharge machining operation, it is effected by an electrochemical machining operation in which metal is removed by anodic dissolution in an electrolytic cell in which the workpiece is the anode and the tool is the cathode. Here an electrolyte, for example an aqueous solution of inorganic salts such as sodium chloride, potassium chloride, sodium nitrate or sodium chlorate, or again a sulphuric acid or a sodium hydroxide solution, is pumped through a suitable gap between the workpiece and the tool.
By the invention it is now possible to manufacture high precision internally-toothed bevel gears from a high grade material avoiding the practical difficulties of normal mechanical machining and thus producing such gears very economically, particularly such gears which are required to mesh with bevel pin ions, the shafts of which are each set at an obtuse angle (for example of the order of 160 ) to the rotational plane of the associated internally-toothed bevel gear, and such bevel pinions being of substantially smaller diameter at their externally-bevel-toothed formations than those of the second and third electrodes.

Claims (10)

1. A method of manufacturing an internally-toothed bevel gear comprising the steps of:- (a) producing a gear blank, of required internally-bevelled shape and of electricallyconductive material, which forms a first electrode, (b) producing a second electrode of externally-bevel-toothed formation, said formation being so shaped as, by said method, to be capable of providing said first electrode with an internally-bevel-toothed formation intended to mesh, at least approximately, with an externally-toothed bevel pinion subsequently required to co-operate therewith, (c) mounting said first electrode and said second electrode on a machine which is capable of effecting controlled erosion of said first electrode without imparting mechanical force thereon, (d) advancing the second electrode into close proximity to said first electrode, (e) conducting electrical current across said electrodes thereby to cause erosion of said first electrode, and, (f) maintaining a constant gap between said electrodes during continued supply of current across said electrodes until such erosion of said first electrode has occurred that it reaches an internally-toothd shape which is the mirror image of the externallytoothed shape of said second electrode, or substantially so.
2. A method as claimed in claim 1 and further comprising the steps of:- (a) producing a third electrode similar to said second electrode but having an externally-beveltoothed formation so shaped as, by said method, to be capable of providing said first electrode with an internally-bevel-toothed formation intended to have a precision meshing fit with respect to said externally-toothed bevel pinion, (b) removing said second electrode from said machine and replacing it by said third electrode, (c) advancing said third electrode into close proximity to said first electrode, and (d) conducting electrical current across said first and third electrodes thereby to cause such further erosion of said first electrode that it reaches an internally-toothed shape which is the mirror image of the externally-toothed shape of said third electrode, or substantially so.
3. A method as claimed in either claim 1 or claim 2, wherein the step of eroding said first electrode by use of said second electrode is by electrical discharge machining.
4. A method as claimed in either claim 1 or claim 2, wherein the step of eroding said first electrode by use of said second electrode is by electro-chemical machining.
5. A method as claimed in claim 2, or as claimed in either claim 3 or claim 4 when dependent on claim 2, wherein the step of final erosion of said first electrode by use of said third electrode is by electrical discharge machining.
6. Apparatus, suitable for manufacture of an internally-toothed bevel gear by the method as claimed in any one of the preceding claims, including a machine adapted for either electrical discharge machining or electrochemical machining having a work-table for supporting said first electrode, a holder upon which said second or third electrode can be mounted and a mechanism for advancing said second electrode or said third electrode into close proximity to said first electrode and for maintaining a constant gap between said electrodes during continued supply of current across said electrodes.
7. Apparatus as claimed in claim 6, wherein said blank or first electrode is of high tensile carburising or nitriding steel.
8. Apparatus as claimed in either claim 6 or claim 7, wherein said second and/or third electrodes are of copper.
9. A method of manufacturing an internally-toothed bevel gear substantially as here it before described with reference to the accompanying drawing.
10. Apparatus, suitable for manufacture of an internally-toothed bevel gear, substantially as hereinbefore described with reference to the accompanying drawing.
GB08419654A 1984-08-01 1984-08-01 Method of manufacturing internally-toothed bevel gear and apparatus therefor Expired GB2162454B (en)

Priority Applications (3)

Application Number Priority Date Filing Date Title
GB08419654A GB2162454B (en) 1984-08-01 1984-08-01 Method of manufacturing internally-toothed bevel gear and apparatus therefor
DE19853527282 DE3527282A1 (en) 1984-08-01 1985-07-30 METHOD AND DEVICE FOR MANUFACTURING AN INTERNAL-GEARED BEVEL GEAR
FR8511800A FR2568506B1 (en) 1984-08-01 1985-08-01 PROCESS AND APPARATUS FOR MANUFACTURING CONICAL SPROCKETS WITH INTERNAL TOOTHING

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB08419654A GB2162454B (en) 1984-08-01 1984-08-01 Method of manufacturing internally-toothed bevel gear and apparatus therefor

Publications (3)

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GB8419654D0 GB8419654D0 (en) 1984-09-05
GB2162454A true GB2162454A (en) 1986-02-05
GB2162454B GB2162454B (en) 1988-12-14

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GB08419654A Expired GB2162454B (en) 1984-08-01 1984-08-01 Method of manufacturing internally-toothed bevel gear and apparatus therefor

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DE (1) DE3527282A1 (en)
FR (1) FR2568506B1 (en)
GB (1) GB2162454B (en)

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4793219A (en) * 1986-05-22 1988-12-27 Colt Industries Operating Corporation Method of manufacturing non-slip thread rolling dies
EP0491052A4 (en) * 1990-07-04 1992-12-30 Shizuoka Seiki Co. Ltd. Method of finishing gear by electrolytically machining and method of machining electrode used therein
RU2146581C1 (en) * 1998-10-26 2000-03-20 Институт материаловедения Дальневосточного отделения РАН Apparatus for electric spark alloying
RU2183537C2 (en) * 2000-06-26 2002-06-20 Воронежский государственный технический университет Method of flanking gear wheels
GB2436461A (en) * 2006-03-20 2007-09-26 Aisin Seiki Method of producing a face gear

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE4324271C2 (en) * 1993-05-28 2000-02-10 Rust & Mitschke Entex Method and device for producing the internal teeth on planetary roller extruders
DE102015005532A1 (en) 2015-05-03 2016-11-17 Entex Rust & Mitschke Gmbh Method and device for producing the internal toothing on planetary roller extruders
CN111673380B (en) * 2020-05-28 2022-08-05 贵州龙飞航空附件有限公司 Method for machining rotating shaft triangular spline by utilizing electric spark
FR3159176A1 (en) * 2024-02-08 2025-08-15 Safran Process for manufacturing toothed parts hardened by nitriding, in particular parts for aircraft turbomachines

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB919010A (en) * 1961-10-04 1963-02-20 Rolls Royce Apparatus for removing metal electrically from a workpiece
GB974338A (en) * 1961-06-05 1964-11-04 Rolls Royce Apparatus suitable for forming holes electrolytically in a metallic workpiece
GB1032799A (en) * 1963-12-04 1966-06-15 Beteiligungs & Patentverw Gmbh Apparatus for the electrical treatment of electrically conducting workpieces
GB1505065A (en) * 1974-03-23 1978-03-22 Rolls Royce Methods and apparatus for electrically machining a workpiece
GB2072562A (en) * 1980-03-27 1981-10-07 Japax Inc Displacing a tool electrode in electroerosion machine tools
GB2096518A (en) * 1981-04-15 1982-10-20 Nat Res Dev Method and apparatus for the electrical machining of a workpiece

Family Cites Families (2)

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Publication number Priority date Publication date Assignee Title
GB1486802A (en) * 1973-09-14 1977-09-28 Connor T O Cutting master and method of making a cutting master for abrasion machining
FR2527963A1 (en) * 1982-06-07 1983-12-09 Fiz Tekhn I Ak Finish machining of electroerosion electrodes - for prodn. of stamping tool and die sets

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB974338A (en) * 1961-06-05 1964-11-04 Rolls Royce Apparatus suitable for forming holes electrolytically in a metallic workpiece
GB919010A (en) * 1961-10-04 1963-02-20 Rolls Royce Apparatus for removing metal electrically from a workpiece
GB1032799A (en) * 1963-12-04 1966-06-15 Beteiligungs & Patentverw Gmbh Apparatus for the electrical treatment of electrically conducting workpieces
GB1505065A (en) * 1974-03-23 1978-03-22 Rolls Royce Methods and apparatus for electrically machining a workpiece
GB2072562A (en) * 1980-03-27 1981-10-07 Japax Inc Displacing a tool electrode in electroerosion machine tools
GB2096518A (en) * 1981-04-15 1982-10-20 Nat Res Dev Method and apparatus for the electrical machining of a workpiece

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4793219A (en) * 1986-05-22 1988-12-27 Colt Industries Operating Corporation Method of manufacturing non-slip thread rolling dies
EP0491052A4 (en) * 1990-07-04 1992-12-30 Shizuoka Seiki Co. Ltd. Method of finishing gear by electrolytically machining and method of machining electrode used therein
RU2146581C1 (en) * 1998-10-26 2000-03-20 Институт материаловедения Дальневосточного отделения РАН Apparatus for electric spark alloying
RU2183537C2 (en) * 2000-06-26 2002-06-20 Воронежский государственный технический университет Method of flanking gear wheels
GB2436461A (en) * 2006-03-20 2007-09-26 Aisin Seiki Method of producing a face gear
GB2436461B (en) * 2006-03-20 2008-08-20 Aisin Seiki Method of producing member having face-geared surface
US7426777B2 (en) 2006-03-20 2008-09-23 Aisin Seiki Kabushiki Kaisha Method of producing member having face-geared surface

Also Published As

Publication number Publication date
GB8419654D0 (en) 1984-09-05
FR2568506B1 (en) 1988-06-24
GB2162454B (en) 1988-12-14
FR2568506A1 (en) 1986-02-07
DE3527282A1 (en) 1986-02-06

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PCNP Patent ceased through non-payment of renewal fee

Effective date: 19920801