Research on the Tooth Surface Integrity of Non-Circular Gear WEDM Based on HPSO Optimization SVR

Non-circular gears have the characteristics of gear ratio accuracy, good dynamic performance, and wide application prospects but are difficult to manufacture. Wire electrical discharge machining (WEDM) can process almost all kinds of non-circular gear. In order to solve the problem that the process parameters are mainly adjusted using the operator’s experience and to improve the surface quality of non-circular gears machined using WEDM, this research took Pascal gears processed with a fast-walking WEDM machine as the object, conducted orthogonal tests, and used hybrid particle swarm optimization (HPSO) to optimize support vector regression (SVR) with different kernel functions, to predict various surface integrity indicators. The results showed that the rbf kernel function had a better performance in the prediction model of surface integrity indicators, which can provide a reference for the parameter selection of non-circular gear machining using WEDM. The final predicted results were R2 = 0.9978, MAPE = 0.4534 for surface roughness, R2 = 0.9483, MAPE = 3.1673 for surface residual stress, and R2 = 0.9786, MAPE = 0.4779 for surface microhardness.