Optimization analysis of processing parameters for high efficiency wire cutting of TC4 alloy gear in space transmission mechanism

Abstract

Titanium alloy has many advantages such as high Strength ratio and low density, and is widely used in space transmission mechanism. However, titanium alloy has poor wear resistance, poor high-temperature oxidation resistance and sensitive surface stress concentration, which leads to difficult grinding of titanium alloy gears and easy to destroy the surface. In addition, the space transmission mechanism has high lightweight requirements, and the gear structure has many lightweight treatments such as thin wall and hole digging, resulting in low overall gear stiffness. When machining, the cutting force is large, and the overall structure of the gear is at great risk of deformation. Therefore, it is proposed to use wire cutting to process titanium alloy gears, and to improve the processing efficiency by processing multiple gears at the same time. By means of orthogonal test, the effects of Processing voltage (OV), Discharge time (ON), Quiescent time (OFF) and Line feed (WF) on the tooth surface roughness were studied, and the optimal parameter combination was obtained: Processing voltage (OV) is 90V, Discharge time (ON) is 550ns, Quiescent time (OFF) is 10 μs and Line feed (WF) is level7. This scheme can meet the requirements of the quality of the tooth surface roughness and the machining efficiency at the same time.