Research On The Electrochemical Deburring Of Small Mechanical Components

Burrs are the local defects in the process of machining.During the machining of small mechanical components,the burrs that remained locally are very small and are often invisible or difficult to observe to the human eye.However,the local presence of small burrs is not allowed in most of the production assembly process.Therefore,for those small mechanical components,the process of removing small burrs is particularly important,but the removal of these small burrs is a tricky problem.Recently,for many companies,manual scraping under microscope is commonly employed for deburring,but it has some shortcomings,including low removal efficiency,high labor intensity and easy to cause visual fatigue,etc.On the contrary,with non-contact procession and making the cathode very small,electrochemical deburring is suitable for removing the burrs in small mechanical components.So,the removal of burrs of the inner hole of the medical guide tube and on the hole of the back cover of the 3C camera by electrochemical method was researched in this thesis.Based on the theories of electrochemical machining,this thesis firstly introduces the principle of the electrochemical deburring.Then,according to the characteristics of electrochemical deburring,the distribution of current density during the processing was simulated by using the analysis software ANSYS through simulating the rule of burr dissolution in electrochemical machining.Next,the corresponding two-dimensional mathematical model of electrochemical deburring has been established.And the numerical simulation is carried out on the model to analyze that the time required for electrochemical deburring varies with the change of initial burr height and initial machining gap of the electrochemical deburring.Then,according to the features described above,two sets of electrochemical deburring devices were designed.Based on those devices,sufficient electrochemical deburring procession on the medical guide tube and the 3C camera back cover were performed separately,and the optimal parameters are got by comparing the experimental results under different processing parameters.Finally,it can be proved by inspection sample that the electrochemical method can remove the burrs in the inner hole of the medical guide tube and the hole on the back cover of the 3C camera,which is high-quality and effective.Also,the size and morphology of the sample will not be damaged.