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In view of the difficulty of cathode modification, this paper proposes a new method based on the theory of equilibrium gap and cathode modification. Firstly, the mathematical model of cathode modification of face gear is established and different normal vectors of cathode surface are selected. Then in the process of electrolytic machining, the selecting method of modification coefficients is put forward. Compared with conventional technology, the proposed method can reduce the repair cycle and cost. Introduction Face gear is a kind of plane gear meshing with cylindrical gear. Due to its capacities of high speed and heavy load transmission, it is widely used in the field of aerospace and other high-speed precise transmission [1, 2]. The tooth flank of face gear is a kind of complex surface. Furthermore traditional face gear processing method is not only high cost but also time consuming. However as a non-contact special processing technology, electrolytic machining has the advantages such as high efficiency, better quality and the lossless of cathode tool. Therefore it can solve the problems existed in the process of traditional method [3, 4]. Conventional cathode modification method is not able to deal with the mapping problem (i.e. modification coefficient) of theory gap and actual gap. Thus in this paper, a mathematical model of cathode modification is established and different normal vectors of cathode surface are selected. Meanwhile, the method of calibrating multiple modification coefficients is also proposed. Modification Principle With the improvement of the accuracy requirement of face gear, the processed workpiece of initial cathode is always not able to meet the requirements of actual engineering application. It needs to be modified with the cathode. The purpose of cathode modification is to check the tooth surface errors of the processed anode (specimen). If the accuracy is not satisfied, it is fed into the modification model and the correction of cathode surface (compensation amount of machining gap) is calculated. Then the cathode model is regenerated, and electrochemical machining process is implemented until the precision of the product meets the requirement [5]. The repair process of cathode is shown in Fig. 1. The design of the cathode Basic operating examinations of ECM Measuring surface error

Cathode Modification method for electrolytic machining of face gear