For the problem of forming stable arc discharge on the complex surface of the TC4 titanium alloy gears treated by liquid plasma electrolytic saturation (LPES)

a simulation model of the gear surface strengthening system was established

the electric field and flow field were simulated based on simulation analysis and experimental verification methods. The discharge mechanism on the complex surface of the gear was determined. The effects of electrode system parameters and inlet velocity on the formation of the strengthening layer were studied. Results indicated that the fundamental reason for the difficulty of effective discharge on the gear surface was attributable to the uneven electric field. The uniformity of the electric field and the strengthening layer were better when the meshing anode was used. Too small electrode distance was likely to cause short circuit of strengthening system

and too large electrode distance could reduce uniformity and thickness of strengthening layer. Appropriate electrolyte flow rate is important for both the stability of the discharge and the thickness of the strengthening layer. Compared with the untreated substrate

the surface wear resistance of the strengthened titanium alloy gear has been significantly improved.