An Efficient Method to Fabricate the Mold Cavity for a Helical Cylindrical Pinion

Abstract

An efficient method was proposed to fabricate the mold cavity for a helical cylindrical pinion based on a plastic torsion forming concept. The structure of the spur gear cavity with the same profile as the end face of the target helical gear cavity was first fabricated by low-speed wire electrical discharge machining (LS-WEDM). Then, the structure of the helical gear cavity could be obtained by twisting the spur gear cavity plastically around the central axis. In this way, the fabrication process of a helical cylindrical gear cavity could be greatly simplified, compared to the fabrication of a multi-stage helical gear core electrode and the highly difficult and complex spiral EDM process in the current gear manufacturing method. Moreover, several experiments were conducted to verify this novel processing concept, and a theoretical model was established to show the relationship between the machine torsion angle and the helical angle of a helical gear. Based on this theoretical model, the experimental results showed that it is feasible to precisely control the shape accuracy of a helical cylindrical pinion mold cavity by adjusting the machine torsion angle.