Study on the Electrochemical Deburring for the External Surface of the Microhole Caused by Mechanical Drilling Process

Abstract

To improve the performance of electrochemical deburring for microhole drilling (MD-ECD), the distribution and dynamic change of the current density in the machining area during the electrolysis process were analyzed, and the synchronous change relationship between the current density and the burr profile was studied. The effects of process parameters, such as machining voltage U, initial machining gap d, electrolyte concentration C, and electrode radius r1 on the deburring process, were studied. The results show that the magnitude of the current density value in the burr area reflects the MD-ECD’s deburring performance. The current density near the burr tip is high, and the material is preferentially removed. The non-processed area has a low current density and slow material removal. As the machining progresses, the burr tip becomes blunt and the current in the burr area gradually transfers to the non-machining area, resulting in the transfer of the material removal area from the burr area to the adjacent non-machining area. Then, a chamfer is formed at the orifice; the chamfer width is larger than the chamfer height. When U = 4 V, d = 0.35 mm, C = 12%, and r1 = 0.4 mm, the burr removal efficiency and accuracy can be guaranteed. The chamfer width and chamfer height obtained from the test are 29 μm and 17 μm, and the burr removal effect is good.

Non-Traditional Machining Techniques in Manufacturing Industries – An Overview

“…Electrochemical deburring as depicted in Figure 8 is a precise finishing process used in high-precision manufacturing and machining [28]. Unlike traditional drilling methods, electro-chemical deburring (ECD) focuses on localized burr removal [29]. The deburring process involves positioning the workpiece on a non-metallic locator, which precisely aligns an electrode with the burr(s) on the surface.…”

“…Before the application of current, the electrolyte stream flushes out any loose chips that may hinder the process. As the burr undergoes anodic metal dissolution, a controlled radius is formed, resulting in consistent deburring from part to part and lot to lot [28][29][30]. Proper fixturing is crucial in ECD.…”

Selection of Robotic Machining Parameters with Pneumatic Feed Force Progression

“…In the case of vibratory-abrasive machining, various types of abrasive shapes are used, with the hardness depending on the type of workpiece material. In addition to the aforementioned methods, chemical, electrochemical, and thermal deburring are well suited for automation [7][8][9][10][11].…”