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传统的齿轮模具型腔电铸方法存在着许多问题,如:铸层质量差、沉积速度低、铸层厚度分布非常不均匀,严重时某些局部无金属沉积,不适用于小模数齿轮模具型腔的制造。分析认为,这些弊端主要是阴极上电流密度分布不均匀所致。本文在进行试验研究后,提出了一种新的齿轮模腔电铸成形方法。这种方法采取特殊的电极配置方式,用一绝缘材料齿轮对平板阴极进行选择性屏蔽,从而获得所需形状的铸层。这一方式保证了阴极上电流密度均匀分布,铸层无任何尖角缺陷、均匀致密。采取的强烈冲刷、脉冲供电等措施更进一步提高了沉积速度和铸层质量。这种方法既可用于直接电铸镍模具型腔,也可用于电铸电火花加工模腔用铜电极。已经采用了这种方法制造了模数在0.25～0.40mm之间的齿轮模具型腔近百个,均获得满意结果。
There are many problems in traditional electroforming of gear die cavity, such as poor quality of casting layer, low deposition speed, very uneven distribution of thickness of casting layer, some localized metal-free deposition in severe condition, not suitable for small modulus gear die Cavity manufacturing. Analysis, these drawbacks are mainly due to uneven distribution of cathode current density. After the experimental research, a new gear die cavity electroforming method is proposed. This method uses a special electrode configuration, with an insulating material gear plate cathode selective shielding, so as to obtain the desired shape of the casting. This method ensures uniform distribution of current density on the cathode, the casting without any sharp corner defects, uniform and compact. Taking strong erosion, pulse power supply and other measures to further improve the deposition rate and quality of the casting. This method can be used not only for direct electroforming nickel mold cavity, but also for electroforming EDM copper electrode. This method has been used to produce a mold modulus of 0.25 ~ 0.40mm between the gear mold cavity nearly 100, have been satisfactory results.