Study On Surface Integrity Of Non-circular Gear By WEDM

As a widely used complex part,the machining and manufacturing of non-circular gear have always been the focus of research.Wire electrical discharge machining(WEDM)is a commonly used non-circular gear machining method with many advantages.With the continuous development of modern manufacturing technology,the requirements for the surface integrity of non-circular gear are increasing day by day.The current situation of using only surface roughness as the main parameter and technical index to control product quality cannot meet practical needs,and the surface integrity of non-circular gear has a significant impact on various aspects of gear performance.Therefore,studying the surface integrity of non-circular gear from the perspective of machining methods is of great significance to improve the surface quality and service performance of non-circular gear.This article takes Pascal worm gear as the research object,and studies the surface integrity of non-circular gear during WEDM machining.The main contents are as follows:(1)Simulation analysis of temperature field in WEDM.The simulation analysis of single pulse discharge process in WEDM was carried out,and the temperature field distribution and the depth of discharge pits were obtained under different peak currents and pulse-on time.(2)Non-circular gear WEDM test and data analysis.Taking surface morphology,surface roughness,surface residual stress,and surface microhardness as indicators,orthogonal test methods were used to conduct WEDM machining experiments.Variance analysis and range analysis were used to obtain the primary and secondary order and optimal parameter combinations that affect the surface integrity parameters of non-circular gear.(3)Comprehensive evaluation of surface integrity of non-circular gear.The weights of surface roughness,surface residual stress,and surface microhardness in the surface integrity evaluation system of non-circular gear are calculated using a combination of analytic hierarchy process(AHP)and entropy weight method.The orthogonal test results are evaluated using a gray comprehensive evaluation method,and the group of parameters with the largest correlation value is selected as the optimal parameter combination.(4)Prediction and multi-objective parameter optimization of surface integrity indicators for non-circular gears.Based on orthogonal experimental data,a surface integrity prediction model was constructed using multivariate nonlinear analysis and BP neural network methods,and the snake optimizer was used to optimize multi-objective parameters.obtaining an optimization parameter set.