Abstract: When WEDM machines non-circular gears, electrical parameters are recognized as pivotal factors affecting the tooth profile error of non-circular gears. Orthogonal experiments were designed to analyze WEDM non-circular gears by using the maximum tooth profile errors at the gear tooth root, tooth profile middle and tooth top respectively. Through variance analysis and main effect analysis methods, the influence law of WEDM electrical parameters, including peak current, pulse width, pulse interval, and tracking, on the tooth profile error of non-circular gears at the tooth root, tooth profile middle, and tooth top was studied. At the same time, regression analysis was performed on the tooth profile errors, machining duration, and process parameters to establish regression models. The multi-objective optimization of the regression models was conducted using the Grey Wolf Optimization algorithm. The results of this study obtain the optimal parameter combination for different parts of the WEDM non-circular gear tooth profile, which can provide a reference for actual processing.

Key words: non-circular gear, tooth profile error, process parameters, variance analysis, main effects analysis