Electrochemical ultra-precision machining device and method with controllable surface track of steel ball

Abstract

The invention provides a steel ball surface track controllable electrochemical ultra-precision machining device and method. The steel ball surface track controllable electrochemical ultra-precision machining device comprises an upper flat plate, a lower flat plate, a double-layer electrochemical electrode device and a transmission device. The upper flat plate and the lower flat plate are arranged in parallel; the steel ball is placed between the upper flat plate and the lower flat plate; the double-layer electrochemical electrode device is positioned between the upper flat plate and the lower flat plate and surrounds the steel ball; the transmission device is connected with the double-layer electrochemical electrode device and drives the double-layer electrochemical electrode device to move; during machining, the upper flat plate serves as a driving part and moves parallel to the lower flat plate according to a preset track, and the steel balls are driven to do pure rolling motion between the upper flat plate and the lower flat plate; the movement track of the double-layer electrochemical electrode device is completely the same as the mass center track of the steel ball; and the double-layer electrochemical electrode device comprises a plurality of electrode tips and liquid flushing heads, is arranged around the steel ball and is used for performing electrochemical machining and liquid flushing on the steel ball. Through the machining device, the steel ball movement track and the electrode polishing process are controlled, and the steel ball surface machining quality and precision are improved.

Description

Technical Field

[0001] This application relates to the field of precision manufacturing technology, specifically to an electrochemical ultra-precision machining device and method for controllable surface trajectory of a steel ball. Background Technology

[0002] In the precision manufacturing industry, the ultra-precision manufacturing process of steel ball surfaces is one of the key processes affecting product quality. Traditionally, ultra-precision manufacturing of steel ball surfaces mostly employs grinding processes to reduce surface roughness. These grinding processes typically involve polishing with grinding discs or by mixing and stirring abrasive particles with the steel ball to polish its surface.

[0003] The basic principles of grinding and polishing with a grinding disc and polishing with abrasive mixed with steel balls are as follows: A. Grinding with a grinding disc involves clamping a steel ball (or more) between two parallel plates. One plate has (hypothetically) left-handed spiral grooves radiating from the center to the edge, and abrasive powder is laid in the grooves. The other plate may not have grooves. When the two parallel plates rotate in opposite directions (the plate without grooves must rotate in the direction of the left-handed grooves), the abrasive powder generates relative sliding friction with the surface of the steel ball, "removing" the micro-protrusions on the surface of the steel ball, thus achieving the polishing process; B. The polishing principle of mixing abrasive with steel balls is to "remove" the micro-protrusions on the surface of the steel ball by generating relative sliding friction between the abrasive and the steel ball through mixing, thus achieving the polishing process.

[0004] However, in the aforementioned polishing process, due to the varying sizes of micro-protrusions on different parts of the steel ball surface at different times, including differences in the friction conditions and range of each micro-protrusion, and the significant differences in the coefficients of friction between different materials even under the same operating conditions, the amount of excess material removed from the steel ball surface through relative sliding friction is unstable and variable depending on the specific point or location on the steel ball surface. Therefore, the processing is essentially probabilistic. Furthermore, the surrounding environment for grinding one steel ball differs from that for subsequent steel balls, and the size and surface roughness of different batches of steel balls may also differ or be unstable.

[0005] To reduce these differences, it's necessary to increase the number of grinding passes or the grinding time to decrease processing errors and make the probability of processing all parts of the surface more uniform, thus reducing production efficiency. The problem with steel balls polished by friction is that steel balls processed from the same grinding disc can vary in size and surface roughness between batches; this is a quality issue inherent in the processing principle. Therefore, especially in applications with high requirements, steel balls must be classified and sorted according to different requirements. Summary of the Invention

[0006] In view of the deficiencies in the prior art, the purpose of this application is to provide an electrochemical ultra-precision machining device and method for controllable steel ball surface trajectory, which solves the problems of uncontrollable steel ball trajectory, poor machining dimensional consistency, and surface roughness that does not meet high-end requirements.

[0007] In a first aspect, this application provides an electrochemical ultra-precision machining device with controllable steel ball surface trajectory, comprising: an upper plate, a lower plate, a double-layer electrochemical electrode device, and a transmission device; The upper plate and the lower plate are arranged parallel to each other, and the steel ball is placed between the upper plate and the lower plate; The double-layer electrochemical electrode device is located between the upper plate and the lower plate, and is arranged around the steel ball with equal gaps; The transmission device is connected to the double-layer electrochemical electrode device and is used to drive the double-layer electrochemical electrode device to move; During processing, the upper plate acts as a driving component, moving parallel to the lower plate according to a preset trajectory, driving the steel ball to perform pure rolling motion between the upper plate and the lower plate; The trajectory of the double-layer electrochemical electrode device is exactly the same as the trajectory of the center of mass of the steel ball. The double-layer electrochemical electrode device includes multiple electrode heads and flushing heads, which are arranged around the steel ball and maintain equal gaps, for electrochemical processing and flushing of the steel ball.

[0008] Optionally, when the upper plate drives the steel ball to perform a pure rolling motion without slippage, a set pressure is applied to the top of the upper plate to press down the steel ball, so that the steel ball only performs a pure rolling motion between the upper plate and the lower plate. The set pressure includes the weight of the upper plate.

[0009] Optionally, the double-layer electrochemical electrode device is a double-layer ring structure, and the plurality of flushing heads and the plurality of electrode heads can be combined to form a double-layer ring structure or uniformly spaced on the double-layer ring structure; The flushing head is disposed on the upper layer of the double-ring structure, and the electrode head is disposed below the double-ring structure; During processing, the multiple electrode heads are kept at equal intervals with the steel ball.

[0010] Optionally, it also includes a driving device connected to the upper plate for driving the upper plate to move; The drive device includes a servo motor and a transmission component; The speed of the servo motor can be adjusted within a preset range; The transmission component is connected to the servo motor and the upper plate, and is used to transmit the motion of the servo motor to the upper plate, thereby controlling the movement trajectory and speed of the upper plate.

[0011] Optionally, according to claim 4, the electrochemical precision machining device for controllable steel ball surface trajectory is characterized in that at least one of the upper plate and the lower plate is a metal plate; The upper plate moves relative to the lower plate via the driving device. The metal plate is connected to the positive terminal of the power supply, while the lower plate is fixedly installed.

[0012] Optionally, the preset trajectory is characterized by being a spiral trajectory or a planetary motion trajectory. A second aspect of this application provides a processing method for an electrochemical ultra-precision machining apparatus with controllable surface trajectory of a steel ball, comprising: Set up a processing device, fix the lower plate, connect both the lower plate and the upper plate to the positive terminal of the power supply, connect the electrode head to the negative terminal of the power supply, connect the flushing head to the flushing pump, and connect the double-layer annular electrochemical electrode device to the transmission device. One steel ball corresponds to one of the double-layer annular electrochemical electrode devices. When more than one steel ball is processed between the upper plate and the lower plate, more than one double-layer annular electrochemical electrode device can be connected in parallel to form a whole, so that all the steel balls are located in the middle of the double-layer electrochemical electrode device; The electrode head and the flushing head are activated, and the movement trajectory of the double-layer electrochemical electrode device is controlled to be exactly the same as the trajectory of the center of mass of the steel ball, so as to perform electrochemical electrode polishing on the surface of the steel ball.

[0013] Optionally, the step of activating the electrode head and the flushing head, and controlling the movement trajectory of the double-layer electrochemical electrode device to be exactly the same as the trajectory of the steel ball's center of mass, and performing electrochemical electrode polishing on the surface of the steel ball, includes: Turn on the flushing pump and align the flushing port of the flushing head with the processing gap between the steel ball and the electrode head, and perform a powerful flushing with electrochemical special processing fluid; The motion trajectory of the double-layer electrochemical electrode device is controlled to be exactly the same as the trajectory of the center of mass of the steel ball; Turn on the processing power supply to connect the electrode head to the negative electrode. Apply a certain voltage between the electrode and the steel ball. Through the conductivity of the electrochemical special processing fluid, anodic dissolution electro-corrosion is generated on the surface of the steel ball opposite the electrode. Under the action of strong flushing fluid, the dissolved electro-corrosion material is blown away, thereby realizing the processing of the surface of the steel ball. According to the preset trajectory, the continuous rotation of the steel ball surface washes away the anodic dissolution and electro-corrosion substances, and performs continuous electrochemical electrode polishing on the steel ball surface.

[0014] Optionally, controlling the motion trajectory of the double-layer electrochemical electrode device to be exactly the same as the trajectory of the center of mass of the steel ball includes: The lower plate is fixed, and the upper plate is driven to move parallel to the lower plate according to a preset motion trajectory. The steel ball, driven by the upper plate, performs a pure rolling motion without slippage between the upper plate and the lower plate. The transmission device controls the movement of the double-layered annular electrochemical electrode device according to the trajectory of the center of mass of the steel ball.

[0015] Optionally, the transmission device controls the double-layer annular electrochemical electrode device to move according to the trajectory of the steel ball's center of mass, and the transmission device is controlled by the steel ball's center of mass trajectory tracking drive system; The trajectory tracking drive system controls the real-time acquisition of the position signal of the center of mass of the steel ball, and drives the transmission device to operate according to the position signal. The transmission device drives the double-layer electrochemical electrode device to move synchronously, so that the motion trajectory of the double-layer electrochemical electrode device is consistent with the motion trajectory of the steel ball.

[0016] This application provides an electrochemical ultra-precision machining device for controllable steel ball surface trajectory. It employs a combination of upper and lower parallel plates and a double-layer electrochemical electrode device. By utilizing multiple flushing heads and electrode heads, it achieves multi-point machining and multi-point powerful flushing during processing. The upper plate drives the steel ball in pure rolling motion, and combined with the double-layer electrochemical electrode device, it performs omnidirectional, dead-angle-free machining of the steel ball surface, avoiding the problem of insufficient local machining and realizing an electrochemical machining process that involves machining while the ball is in motion. Simultaneously, by controlling the electrode device to align with the steel ball's center of gravity trajectory to maintain an equidistant gap, the trajectory is controllable, enabling precise control of the electrochemical polishing process. This improves the machining accuracy and uniformity of the steel ball surface, further achieving ultra-precision machining of the steel ball surface. This meets the stringent requirements for steel ball surface quality in high-precision fields and helps improve the machining quality and accuracy of steel ball surfaces.

[0017] Other technical effects resulting from the additional features will be further illustrated in the corresponding embodiments. Attached Figure Description

[0018] Other features, objects, and advantages of this application will become more apparent from the following detailed description of non-limiting embodiments with reference to the accompanying drawings: Figure 1 This is a flowchart illustrating an electrochemical ultra-precision machining method for controllable surface trajectory of a steel ball according to an exemplary embodiment; Figure 2 This is a diagram of a processing apparatus for electrochemically processing the surface of a steel ball according to an exemplary embodiment; Figure 3 This is a processing effect diagram showing a processing time of 70 seconds according to an exemplary embodiment; Figure 4 This is a processing effect diagram showing a processing time of 240 seconds according to an exemplary embodiment; Figure 5 This is a schematic diagram illustrating the motion trajectory of the upper plate according to an exemplary embodiment; Figure 6 This is a schematic diagram illustrating the trajectory of a flat plate at another angle according to an exemplary embodiment; Figure 7 This is a dense point distribution diagram for analyzing the uniformity of the machining trajectory on the surface of a steel ball according to an exemplary embodiment. Figure 8 This is a schematic diagram illustrating the verification results of a pure rolling drive processing device according to an exemplary embodiment; Figure 9 This is a percentage distribution diagram of the density of each unit trajectory point, according to an exemplary embodiment.

[0019] In the diagram: 1. Steel ball; 2. Electrode head; 3. Flushing head; 4. Upper plate; 5. Lower plate. Detailed Implementation

[0020] The present application will now be described in detail with reference to specific embodiments. These embodiments will help those skilled in the art to further understand the present application, but do not limit the present application in any way. It should be noted that those skilled in the art can make several modifications and improvements without departing from the concept of the present application, and these all fall within the protection scope of the present application. Parts not described in detail in the following embodiments can be implemented using existing technology.

[0021] In existing technologies, methods for removing excess material from the surface of steel balls through relative sliding friction are inherently unstable and variable, with the amount of excess material removed varying depending on the specific point or location on the steel ball's surface. This makes the processing essentially probabilistic. To mitigate these variations, it's necessary to increase the number of grinding passes or the processing time to reduce errors and make the probability of processing different parts of the surface more uniform, thereby reducing production efficiency. The problem with steel balls polished using this method is that the same steel ball can exhibit differences in size and surface roughness depending on its location—a quality issue stemming from the processing principle itself. Based on these problems, this application provides an electrochemical ultra-precision machining apparatus with controllable steel ball surface trajectory to solve the aforementioned issues.

[0022] Reference Figure 2 As shown in one embodiment of this application, an electrochemical ultra-precision machining device with controllable steel ball surface trajectory includes: an upper plate 4, a lower plate 5, a double-layer electrochemical electrode device, and a transmission device.

[0023] The upper plate 4 and the lower plate 5 are arranged in parallel, and the steel ball 1 is placed between the upper plate 4 and the lower plate 5; the double-layer electrochemical electrode device is located between the upper plate 4 and the lower plate 5 and is arranged around the steel ball 1; the transmission device is connected to the double-layer electrochemical electrode device and is used to drive the double-layer electrochemical electrode device to move.

[0024] During processing, the upper plate 4 acts as a driving component, moving parallel to the lower plate 5 according to a preset trajectory, driving the steel ball 1 to perform pure rolling motion between the upper plate 4 and the lower plate 5; the motion trajectory of the double-layer electrochemical electrode device is exactly the same as the trajectory of the center of mass of the steel ball 1; the double-layer electrochemical electrode device includes multiple electrode heads 2 and flushing heads 3, which are arranged around the steel ball 1 and are used to perform electrochemical processing and flushing on the steel ball 1.

[0025] Specifically, the processing device has an upper plate 4 and a lower plate 5 arranged parallel to each other. A double-layer electrochemical electrode device is arranged between the two, surrounding a steel ball 1. The lower layer consists of multiple electrochemical processing electrode heads 2, and the upper layer consists of multiple flushing heads 3. Next, a steel ball 1 is placed in the middle of the double-layer electrochemical electrode device between the upper plate 4 and the lower plate 5, maintaining an equal gap between the steel ball 1 and the multiple electrochemical processing electrode heads in the double-layer electrochemical electrode device. Then, the lower plate 5 is fixed, and the upper plate 4 is electrically connected to the positive terminal of the power supply, driving the upper plate 4 to move parallel to the lower plate 5 in a preset trajectory in the horizontal plane, thereby causing the steel ball 1 to roll purely on the surface of the lower plate 5. Finally, the movement trajectory of the double-layer electrochemical electrode device is controlled to be consistent with the trajectory of the center of mass of the steel ball 1, maintaining an equal distance between the electrode heads 2 and the steel ball 1. At the same time, liquid is flushed into the processing gap between the steel ball 1 and the electrode heads 2 through the flushing heads 3. The power is turned on, causing electrochemical corrosion on the surface of the steel ball 1, realizing ultra-precision polishing of the surface of the steel ball 1.

[0026] It should be noted that during processing, the positive terminal of the power supply is connected to the upper plate 4, and the negative terminal of the power supply is connected to the electrode head 2. According to the electrochemical characteristics, the tiny peaks on the steel ball 1 are first removed by corrosion.

[0027] In the above embodiments of this application, the upper plate 4 drives the steel ball 1 to perform precise pure rolling, and the transmission device controls the double-layer electrochemical electrode device to follow the trajectory of the center of mass of the steel ball 1 in real time. This achieves dynamic constancy of the processing gap between the electrode and the spherical surface, ensuring that the electrochemical corrosion occurs uniformly on the entire surface of the steel ball 1. Combined with the characteristics of electrochemical processing without mechanical stress and surface damage, and the continuous flushing of the flushing head 3 to the processing area and the continuous flushing away of electro-corrosion products, the ultra-precision polishing of the surface of the steel ball 1 can be achieved efficiently and stably, improving the geometric accuracy consistency, surface roughness uniformity and overall process reliability of the processed steel ball 1.

[0028] In some specific embodiments of this application, when the upper plate 4 drives the steel ball 1 to perform a pure rolling motion without slippage, a set pressure is applied to the top of the upper plate 4 to press down the steel ball 1 and restrict the upper plate 4 and the steel ball 1 to only perform pure rolling motion.

[0029] The set pressure includes the weight of the upper plate 4.

[0030] It should be noted that the set pressure should not cause plastic deformation between the upper plate 4, the lower plate 5 and the steel ball 1.

[0031] In the above embodiments of this application, by applying a set pressure (including the weight of the upper plate 4) to the top of the upper plate 4, the steel ball 1 is stably pressed between the upper plate 4 and the lower plate 5. This ensures sufficient frictional traction to drive the steel ball 1 to achieve pure rolling, while remaining below the yield strength of the materials of the upper plate 4 and the steel ball 1, avoiding any plastic deformation in the contact area and ensuring that the moving interface is in an elastic contact state. By using pressure to enhance the contact friction between the upper plate 4 and the steel ball 1, relative sliding between the upper plate 4 and the steel ball 1 is avoided, ensuring pure rolling motion and preventing problems such as plastic deformation and surface damage to the contact surface caused by excessive pressure. At the same time, the set pressure includes the weight of the upper plate 4, eliminating the need for additional complex pressurization structures and simplifying the complexity of the device.

[0032] In some specific embodiments of this application, the double-layer electrochemical electrode device is a double-layer ring structure. Multiple flushing heads 3 and multiple electrode heads 2 can be combined to form a double-layer ring structure or uniformly spaced on the double-layer ring structure. The flushing heads 3 are located on the upper layer of the double-layer ring structure, and the electrode heads 2 are located on the lower layer of the double-layer ring structure.

[0033] During processing, multiple electrode heads 2 are kept at equal intervals with steel balls 1.

[0034] The ring containing electrode head 2 is located halfway between the upper plate 4 and the lower plate 5, and is parallel to both plates. The positions of electrode head 2 and flushing head 3 can be adjusted along the circumference of the double-layer electrochemical electrode device, and the gap between electrode head 2 and steel ball 1 can also be adjusted.

[0035] It should be noted that the double-layer electrochemical electrode device is formed by stacking and connecting the flushing head 3 with the electrochemical processing electrode to form a double-layer structure. The electrode head 2 is a ring-shaped structure with the steel ball 1 placed in the middle to achieve an equal distance between the electrode head 2 and the steel ball 1.

[0036] In the embodiments described above, the lower layer of the double-layer electrochemical electrode device is connected to the negative terminal of the power supply via multiple electrochemical machining electrode heads 2 (the electrodes cannot be connected in series or in parallel), ensuring that each electrode head 2 maintains an equidistant machining gap with the surface of the steel ball 1. The multiple electrode heads can form a complete ring or a part of a ring. The upper layer consists of multiple flushing heads 3 corresponding to the multiple electrode heads 2 (the electrodes and the flushing liquid are insulated from each other). The electrochemical machining liquid is flushed into the machining gap area between the steel ball 1 and the electrode head 2 through the flushing heads 3, quickly removing the electro-corrosion layer in the corresponding area of ​​the electrode head.

[0037] In some specific embodiments of this application, a driving device is also included, which is connected to the upper plate 4 and is used to drive the upper plate 4 to move; the driving device includes a servo motor and a transmission component; the speed of the servo motor can be adjusted within a preset range; the transmission component is connected to the servo motor and the upper plate 4 and is used to transmit the motion of the servo motor to the upper plate 4 and control the movement trajectory and displacement of the upper plate 4.

[0038] Specifically, when it is necessary for the upper plate 4 to move parallel to the lower plate 5 in a horizontal plane according to a preset trajectory, the drive device is activated. The servo motor serves as the power source, and the rotational speed is fed back and adjusted to a preset range. Its output shaft is connected to the transmission component. The transmission component converts the rotational motion of the motor into the horizontal motion of the upper plate 4, ensuring that the upper plate 4 moves along a spiral or planetary trajectory, and ensuring the synchronization of the rolling of the steel ball 1 with the movement of the double-layer electrochemical electrode device.

[0039] In the above embodiments of this application, a drive device including a servo motor and a transmission component is used to drive the upper plate 4 to move. The speed of the servo motor can be adjusted within a preset range, so that the movement displacement of the upper plate 4 can be flexibly changed according to actual needs to meet the requirements of diverse working scenarios. At the same time, the transmission component can transmit the motion of the servo motor to the upper plate 4, control the movement trajectory and speed of the upper plate 4, ensure the accuracy and stability of the movement of the upper plate 4, and improve the operating accuracy and reliability of the entire system.

[0040] In some specific embodiments of this application, the upper plate 4 is a metal plate and the lower plate 5 is a non-metal plate; the upper plate 4 moves relative to the lower plate 5 through a driving device and is connected to the positive terminal of a power supply, while the lower plate 5 is fixedly installed.

[0041] The lower plate 5 is fixed and not connected to a power source.

[0042] Specifically, the lower layer of the double-layer structure consists of multiple electrochemical electrode heads 5 (connected to the negative terminal of the power supply) arranged around the steel ball 4, maintaining an equidistant processing gap with the steel ball 4 at all times. During operation, the lower plate 5 remains stationary (connected to the foundation), while the upper plate 4 (metal, connected to the positive terminal of the power supply) moves parallel to the lower plate 5 in a horizontal plane along a certain trajectory. The steel ball 1 then rolls purely on the surface of the lower plate 5 under the drive of the upper plate 4. At this time, the trajectory of the center of mass of the double-layer electrochemical electrode device is exactly the same as that of the steel ball 1, thus realizing the electrolytic polishing of the surface of the steel ball 1.

[0043] Reference Figure 5 As shown, in some specific embodiments of this application, the preset trajectory is a spiral trajectory or a planetary motion trajectory.

[0044] Reference Figure 1 As shown in one embodiment of this application, an electrochemical ultra-precision machining method for controllable steel ball surface trajectory includes: Set up the processing device, fix the lower plate, connect both the lower and upper plates to the positive terminal of the power supply, connect the electrode head to the negative terminal of the power supply, connect the flushing head to the flushing pump, and connect the double-layer annular electrochemical electrode device to the transmission device. Place a steel ball between the upper and lower plates, and position the steel ball in the middle of the double-layer electrochemical electrode device; The surface of the steel ball can be electrochemically polished in the following sequence: The movement of the double-layer electrochemical electrode device is linked to the upper plate that drives the steel ball, then the flushing liquid is started, and then an electrical load is applied between the electrode head and the upper plate (steel ball).

[0045] Specifically, the process begins with the construction of a processing device consisting of an upper plate and a lower plate arranged parallel to each other. Between these two plates, a double-layer electrochemical electrode assembly surrounds a steel ball. The lower layer contains multiple electrochemical electrode heads, and the upper layer contains multiple flushing heads. The circular ring containing the electrode heads is positioned precisely in the center of the upper and lower plates. Next, a steel ball is placed between the upper and lower plates within the double-layer electrochemical electrode assembly, maintaining an equidistant processing gap between the electrode heads and the steel ball. The lower plate is then fixed, and the upper plate is electrically connected to the positive terminal of a power supply, while the electrode heads are connected to the negative terminal. The upper plate is driven to move parallel to the lower plate along a predetermined trajectory in a horizontal plane, causing the steel ball to roll on the surface of the lower plate. Simultaneously, the double-layer electrochemical electrode assembly is driven in sync, ensuring their movements are synchronized. After this initial setup, the flushing heads inject liquid into the processing gap between the steel ball and the electrode heads. Finally, the power is switched on, causing electrochemical corrosion to occur on the surface of the steel ball opposite the electrode heads. Due to the flushing and the movement of the steel ball, ultra-precision polishing of the steel ball surface is achieved.

[0046] The embodiments described above in this application establish a processing device comprising upper and lower parallel plates and a double-layer electrochemical electrode device arranged around a steel ball. The upper plate drives the steel ball to roll purely, while controlling the double-layer electrochemical electrode device to be consistent with the trajectory of the steel ball's center of mass and maintain an equidistant processing gap. This achieves efficient and uniform electrochemical polishing of the steel ball surface, which helps improve the surface quality of the steel ball and meets the requirements of ultra-precision processing.

[0047] It should be noted that during processing, the positive terminal of the power supply is connected to the upper plate, and the negative terminal is connected to the electrode head. Based on the electrochemical characteristics, the tiny peaks on the steel ball are removed.

[0048] In some specific embodiments of this application, the electrode head and the flushing head are activated, and the movement trajectory of the double-layer electrochemical electrode device is controlled to be exactly the same as the trajectory of the steel ball's center of mass, and electrochemical electrode polishing is performed on the surface of the steel ball, including: Turn on the flushing pump and align the flushing nozzle of the flushing head with the machining gap between the steel ball and the electrode head. Then, flush the surface with a special electrochemical machining fluid. The trajectory of the double-layer electrochemical electrode device is exactly the same as the trajectory of the center of mass of the steel ball. Turn on the processing power supply and connect the electrode head to the negative electrode. Apply a certain voltage between the electrode and the steel ball. Through the conductivity of the electrochemical special processing fluid, anodic dissolution electro-corrosion is generated on the surface of the steel ball opposite the electrode. Under the action of the flushing fluid, the dissolved electro-corrosion material is blown away, thus achieving the polishing process of the steel ball surface. According to the preset motion trajectory, the continuous rotation of the steel ball surface washes away the anodic dissolution electro-corrosion products, and performs continuous electrochemical electrode polishing on the steel ball surface.

[0049] Specifically, the process begins by starting the flushing pump, precisely injecting the electrochemical machining fluid through the flushing head into the machining gap between the electrode head and the steel ball surface. The control system drives the double-layer electrochemical electrode device, ensuring its movement trajectory is synchronized with the trajectory of the steel ball's center of mass, thus maintaining a constant electrochemical machining gap. The machining power supply is then turned on, applying a working voltage between the electrode head (negative electrode) and the steel ball (positive electrode). The conductivity of the electrochemical fluid induces controlled anodic dissolution corrosion on the steel ball surface. Simultaneously, a continuous and powerful flushing process blows away the dissolved substances generated by electro-corrosion from the machining area, preventing secondary deposition. As the steel ball continues to rotate along the preset trajectory, the entire surface is sequentially exposed to the electrochemical action area, thereby achieving continuous and uniform electrochemical polishing of the entire steel ball surface.

[0050] The embodiments described above in this application, through the synergistic effect of synchronous motion control, dynamic flushing, and continuous electrochemistry, ensure that all points on the surface of the steel ball are always in a stable and consistent electrochemical environment during the processing, achieving extremely high processing uniformity and surface accuracy. The dynamic flushing, which combines multi-point processing with multi-point high-intensity flushing, not only removes electrochemical products in a timely manner and maintains the stability of the electrochemical liquid performance in the processing area, but also realizes uninterrupted polishing of the steel ball surface, improving the surface finish and uniformity of the steel ball, ensuring the quality stability of ultra-precision machining, and improving processing efficiency.

[0051] In some specific embodiments of this application, the motion trajectory of the double-layer electrochemical electrode device is made exactly the same as the trajectory of the center of mass of the steel ball, including: The lower plate is fixed, and the upper plate is driven to make parallel motion parallel to the lower plate according to a preset motion trajectory. The steel ball, driven by the upper plate, makes pure rolling motion without slippage between the upper and lower plates. The double-layered annular electrochemical electrode device is controlled by a transmission device to move along the trajectory of the center of mass of the steel ball.

[0052] Specifically, when controlling the motion trajectory of the double-layer electrochemical electrode device to be the same as that of the steel ball, the lower plate is first fixed, and then the upper plate is driven to make a translational motion parallel to the lower plate according to the preset motion trajectory. This allows the steel ball placed between the upper and lower plates to make a pure rolling motion without slippage under the driving force of the upper plate. At the same time, the motion information of the center of mass of the steel ball is received in real time through an independent transmission device, and the double-layer annular electrochemical electrode device is driven to follow the trajectory of the center of mass of the steel ball. Thus, the processing gap between the electrode head and the surface of the steel ball remains constant throughout the rolling process of the steel ball.

[0053] In the embodiments described above, by fixing the lower plate and driving the upper plate to make the steel ball roll without slippage, additional scratches on the surface of the steel ball are avoided due to slippage. At the same time, the motion trajectory of the electrochemical electrode device is controlled by the transmission device to be exactly the same as the trajectory of the center of mass of the steel ball, so as to always keep the processing gap between the electrode head and the surface of the steel ball uniform and ensure that the electrochemical effects on all parts of the steel ball are balanced during the electrochemical polishing process. The complex two-dimensional trajectory synchronization problem is decomposed into the predetermined trajectory control of the upper plate and the following control of the electrode device, which significantly reduces the coupling difficulty of system control and realizes the coordinated control of the upper plate actively driving the steel ball to roll and the double-layer electrochemical electrode device following the movement, thereby improving the processing accuracy of the steel ball surface and the quality stability of ultra-precision machining.

[0054] In some specific embodiments of this application, the double-layer annular electrochemical electrode device is controlled by a transmission device to move according to the trajectory of the center of mass of a steel ball, and the transmission device is controlled by a steel ball center of mass trajectory tracking drive system.

[0055] The trajectory tracking drive system controls the real-time acquisition of the position signal of the steel ball's center of mass, and drives the transmission device to operate according to the position signal. The transmission device drives the double-layer electrochemical electrode device to move synchronously, so that the motion trajectory of the double-layer electrochemical electrode device is consistent with the motion trajectory of the steel ball.

[0056] In the embodiments described above, during the process of the steel ball rolling without slippage between the upper and lower plates, the trajectory tracking drive system continuously collects the position signal of the steel ball's center of mass through sensors (such as displacement sensors and encoders) and transmits the signal to the controller in real time. The controller compares and calculates the target trajectory (the trajectory of the steel ball's center of mass) with the actual position and generates control commands to drive the transmission device. The transmission device drives the double-layer electrochemical electrode device to move synchronously, forming a dynamic follow-up system. This ensures that the movement trajectory of the electrode device is always consistent with the real-time movement trajectory of the steel ball, thus achieving active, precise, and dynamic maintenance of the processing gap.

[0057] When performing electrochemical polishing on the surface of a steel ball, if there are multiple steel balls, each steel ball corresponds to a set of independent double-layer electrochemical electrode devices.

[0058] Each set of double-layer electrochemical electrode devices can also be controlled by an independent steel ball centroid trajectory tracking drive system, so that the centroid trajectory of each set of electrochemical processing electrode devices is consistent with that of the corresponding steel ball.

[0059] The preferred features in the above embodiments can be used individually in any embodiment, or in any combination thereof, provided they do not conflict with each other. Furthermore, parts not described in detail in the embodiments can be implemented using existing technologies.

[0060] The following examples and comparative examples will be used to further illustrate this application in order to better understand the above-mentioned technical solutions. It should be understood that the following are only some examples and are not intended to limit this application.

[0061] See attached document Figure 2 As shown, the parts preparation includes: one stainless steel plate and one non-metallic plate, one annular electrochemical machining electrode group composed of multi-point copper electrodes, one hollow annular flushing tube (with multiple flushing holes below the corresponding parts of the electrodes), a quantity of electrochemical machining fluid, one steel ball to be processed, one metal plate servo drive system, and one steel ball centroid trajectory tracking drive system.

[0062] Installation: Step 1, fix the non-metallic plate horizontally; Step 2, stack and connect the hollow annular flushing tube and the electrochemical copper electrode together to form a double-layer structure. The hollow annular flushing tube has a flushing outlet at the corresponding electrode head; Step 3, place the steel ball in the middle of the electrochemical flushing double-layer structure, ensuring an equal distance between the electrochemical electrode and the steel ball being processed, and then place them together on the surface of the non-metallic plate; Step 4, place the metal plate horizontally on top of the steel ball (forming a structure like...). Figure 1 (As shown in the installation effect) Apply a certain pressure to hold the steel ball down; Step 5: Connect the metal plate to the positive terminal of the power supply and connect it to the metal plate servo drive system; connect the electrochemical electrode to the negative terminal of the power supply; connect the hollow annular flushing pipe to the electrochemical liquid supply pump; connect the double-layer electrochemical electrode device to the steel ball centroid trajectory tracking drive system.

[0063] Operation and processing: First, start the electrochemical liquid supply pump to flush the steel ball between the electrochemical electrode and the electrochemical plate; start the metal plate servo drive system and the steel ball centroid trajectory tracking drive system to make the metal plate drive the steel ball to move along the set trajectory. At the same time, the steel ball centroid trajectory tracking drive system drives the flushed electrochemical double-layer structure to maintain an equal gap with the steel ball and follow it; connect the power supply to the electrochemical electrode and the metal plate respectively, and the small peaks on the steel ball are removed according to the electrochemical characteristics.

[0064] The method for controlling the trajectory involves clamping a steel ball between two parallel plates, with the lower plate fixed in place. The upper plate is driven (under certain conditions) to move the steel ball, achieving pure rolling. Electrochemical ultra-precision removal is then performed on the steel ball's surface according to a set trajectory. The key to achieving pure rolling is that the velocity at the contact point between the upper plate and the steel ball is equal to the entrainment velocity (relative velocity without sliding) at that point, as derived below: Assumptions: 1. The steel ball is a rigid body with no deformation; there is no sliding friction between the upper and lower plates and the steel ball (only static friction is provided for rolling).

[0065] 2. The plate is placed at a constant speed. Horizontal drive, lower plate fixed (speed) =0). 3. The contact points between the steel ball and the upper and lower plates are A (upper) and B (lower), respectively. The center velocity of the steel ball is... ω is the angular velocity of rotation, and r is the radius of the steel ball.

[0066] The core condition for pure scrolling: The essence of pure rolling is "no relative slippage at the contact point", which requires that the relative velocity of the two contact points be 0 at the same time; (1) The lower plate is fixed, and the contact point B does not slide relative to the lower plate: -ωr=0 (the velocity at the center of the steel ball and its rotational linear velocity are in opposite directions and equal in magnitude) =ωr.

[0067] (2) The upper plate moves, and the contact point A does not slide relative to the upper plate: -( +ωr) = 0 (the speed of the upper plate is equal to the speed of the attraction at the contact point A of the steel ball).

[0068] Final result: Substituting =ωr into the second condition, we get = +ωr=2ωr=2 In summary, the condition for a steel ball to roll purely is that the speed of the upper plate is equal to twice the speed of the center of the steel ball (or the speed of the upper plate is equal to twice the linear speed of the steel ball's rotation).

[0069] Reference Figure 8 As shown, based on Adams simulation, a force analysis was performed on the processing equipment to verify whether it could achieve pure rolling drive of the steel ball. The results are as follows: When a normal force of 5N is applied to the steel plate, the results show that during the processing, the net force on the steel ball is 5N, and the normal force of the steel plate on the steel ball is 5N and remains constant. At the same time, the tangential force of the steel plate on the steel ball is a tiny order of magnitude, indicating that there is only normal force and static friction between the steel plate and the steel ball, without any additional sliding friction, and the force remains constant.

[0070] The electrochemical ultra-precision machining method in this application is as follows: A double-layer annular electrochemical electrode device is horizontally arranged between the upper plate and the lower plate. The lower layer of the double-layer annular electrochemical electrode device consists of multiple electrodes for electrochemical ultra-precision machining, which can form a complete ring or a part of a ring. The upper layer consists of multiple flushing heads (insulated from each other) corresponding to the number of electrode heads. A steel ball is located in the center of the double-layer annular electrochemical electrode device, maintaining an equal distance between the annular electrochemical electrodes and the steel ball. The electrodes are connected to the negative terminal of the power supply, and the upper (lower) plate is connected to the positive terminal. The movement trajectory of the double-layer annular electrochemical electrode device is controlled to be exactly the same as the trajectory of the center of mass of the steel ball.

[0071] During processing, the flushing pump is first activated to create a powerful flushing fluid (special solution) between the electrode and the steel ball. Then, the drive device is activated, causing the upper plate to move along a preset trajectory while simultaneously driving the steel ball. At the same time, the steel ball centroid tracking system is activated, aligning the center of the double-layered annular electrochemical electrode device with the steel ball's centroid. Finally, the power is turned on, generating an electric field between the steel ball and the electrode, inducing anodic corrosion. The corrosion layer on the steel ball's surface is washed away by the flushing fluid, exposing a fresh surface. As the steel ball rotates continuously, the surface of the steel ball along the trajectory of the electrode head is processed, achieving electrochemical machining of the steel ball surface. To achieve ultra-precision electrochemical machining, the special processing fluid medium, concentration and temperature, electrical parameters, steel ball movement speed, and processing gap need to be appropriately adjusted. This can achieve removal capabilities at the micron and sub-micron levels, thus realizing electrochemical ultra-precision polishing.

[0072] One specific embodiment of an electrochemical ultra-precision machining method for a steel ball surface includes: A. Construct a processing device, which includes: A double-layered annular electrochemical electrode device is constructed by an upper and lower plate arranged in parallel, surrounding a steel ball, and positioned between the upper and lower plates. The device includes three electrochemical electrode heads (1x1mm cross-sectional size, spaced 120° apart) in the lower layer and three flushing heads in the upper layer. Each flushing head has a 1x1mm liquid outlet at its end face (located above the electrode heads), and the flushing device is insulated from the electrode heads. A drive unit is used to drive the upper plate and track the movement of the steel ball's center of mass. Therefore, the drive unit includes a servo motor and a transmission device. The servo motor's speed is adjustable within a preset range. The transmission device is connected to the servo motor and transmits the servo motor's motion to the upper plate, controlling the upper plate's trajectory and speed.

[0073] Prepare the power supply and liquid supply pump for electrochemical ultra-precision machining.

[0074] B. Constructing a processing system device, including: Connect the upper plate to the positive terminal of the power supply, fix the lower plate, and connect the three electrode heads to the negative terminal of the power supply respectively (do not connect them). Then, use three flushing pipes to connect the flushing heads to the output terminal of the liquid supply pump, and insert the input terminal of the liquid supply pump into the liquid supply tank.

[0075] By connecting the double-layer annular electrochemical electrode device to the helical trajectory motion transmission mechanism, the double-layer annular electrochemical electrode device can move along the trajectory of the center of mass of the steel ball.

[0076] C. Install steel balls, including: Lift the upper plate and adjust the positions of the three electrode heads within the annular electrochemical electrode assembly, ensuring a 120-degree interval between them. Then, place a 9mm diameter steel ball at the center of the lower plate, positioning it within the double-layer annular electrochemical electrode assembly. Maintain a 0.05mm gap between the electrode heads and the steel ball. Set the processing power and process parameters. Finally, adjust the flushing port position to align with the processing gap between the steel ball and the electrode head, placing it 3mm above the gap. After completing these steps, align the center of the upper plate with the steel ball and connect it to the transmission mechanism in the planar spiral drive device. At this point, the entire assembly is positioned such that the steel ball is located between the upper and lower plates and within the double-layer annular electrochemical electrode assembly, subjected to a 5N positive pressure from the upper plate (assuming the upper plate weighs 5N). To further illustrate the positional relationship between the double-layer annular electrochemical electrode assembly and the steel ball, consider the contact points between the steel ball and the upper and lower plates as the Earth's North and South Poles; the three electrodes would then be located at the Earth's equator.

[0077] D. Process according to the following steps: Turn on the liquid supply pump, then start the power supply of the upper plate actuator and the steel ball centroid tracking mechanism, so that the upper plate moves along a planar spiral trajectory (i.e., drives the steel ball to make a planar spiral motion) and the double-layer annular electrochemical electrode device moves in a planar spiral trajectory synchronously. Then immediately turn on the processing power supply so that the three electrode heads process the steel ball at the same time.

[0078] The top plate drives the steel ball via a spiral motion, while the bottom plate remains stationary. (See reference) Figures 5 to 6 As shown, the spiral motion of the top plate can be achieved by using the following trajectory equation and velocity equation, and thus reach the desired state. Figure 3 and Figure 4 The surface finish of the steel ball shown is achieved in 240 seconds. Top plate trajectory: (polar coordinates) (Cartesian coordinates) Top plate speed: The steel ball radius is 4.5mm (consistent with the ball grinding machine parameters), and t is the processing time. Reference Figure 7 As shown, the uniformity of the machining trajectory on the surface of the steel ball is analyzed based on MatLab simulation: The steel ball radius was set to 4.5 mm (consistent with the ball grinding machine in the reference paper). The surface of the steel ball was divided into 256 cells, each with an area of ​​approximately 1 mm². The percentage density of trajectory points and the standard deviation were calculated. The percentage density of trajectory points is the percentage of the number of trajectory points in a cell out of the total number of trajectory points. The standard deviation reflects the uniformity of the processing. (For ease of comparison, the ideas and methods are consistent with the ball grinding machine, so they will not be elaborated further. Please refer to the reference paper for details.) Figure 7 The graph shows the uniformity of the distribution. The vertical bar on the right represents the percentage of trajectory point density (in %). The percentage of trajectory point density in all cells is greater than 0 (the lowest is around 0.2%), which means that the surface of the steel ball is fully covered, thus achieving full processing. The calculated standard deviation is 0.11%, which means that uniform processing can be achieved.

[0079] like Figure 9 As shown, only a very small number of cells have a density percentage greater than 0.4%, because the statistical step size is larger when the speed is slower. The density percentage of most cells is between 0.2% and 0.3%, with small fluctuations, reflecting uniformity. The difference between the maximum and minimum density percentages is 2 times. Based on the above points, it can be concluded that the processing effect is better than that of the ball grinding machine. The minimum density percentage of the ball grinding machine is close to 0.05%, and the maximum is close to 0.6%.

[0080] Referring to the table below, this application compares its data with existing methods: The data comparison in the table above shows that the experimental time of this application is shorter, the density is more uniform, and the variance of the reaction uniformity is significantly better than that of the grinding method.

[0081] The foregoing has described some specific embodiments of this application. It should be understood that this application is not limited to the specific embodiments described above, and those skilled in the art can make various modifications or variations within the scope of the claims, which do not affect the substantive content of this application. The above-described preferred features can be used in any combination without conflict.

Claims

1. An electrochemical ultra-precision machining device for controllable steel ball surface trajectory, characterized in that, include: Upper plate, lower plate, double-layer electrochemical electrode device and transmission device; The upper plate and the lower plate are arranged parallel to each other, and the steel ball is placed between the upper plate and the lower plate; The double-layer electrochemical electrode device is located between the upper plate and the lower plate, and is arranged around the steel ball; The transmission device is connected to the double-layer electrochemical electrode device and is used to drive the double-layer electrochemical electrode device to move; During processing, the upper plate acts as a driving component, moving parallel to the lower plate according to a preset trajectory, driving the steel ball to perform pure rolling motion between the upper plate and the lower plate; The trajectory of the double-layer electrochemical electrode device is exactly the same as the trajectory of the center of mass of the steel ball. The double-layer electrochemical electrode device includes multiple electrode heads and flushing heads, arranged around the steel ball, for electrochemical processing and flushing of the steel ball.

2. The electrochemical precision machining method for controllable surface trajectory of a steel ball according to claim 1, characterized in that, When the upper plate drives the steel ball to perform a pure rolling motion without slippage, a set pressure is applied to the top of the upper plate to press down the steel ball, so that the steel ball can only perform pure rolling motion between the upper plate and the lower plate. The set pressure includes the weight of the upper plate.

3. The electrochemical precision machining device for controllable steel ball surface trajectory according to claim 1, characterized in that, The double-layer electrochemical electrode device has a double-layer ring structure. Multiple flushing heads and multiple electrode heads can be combined to form a double-layer ring structure or uniformly spaced on the double-layer ring structure. The flushing head is disposed on the upper layer of the double-ring structure, and the electrode head is disposed below the double-ring structure; During processing, the multiple electrode heads are kept at equal intervals with the steel ball.

4. The electrochemical precision machining device for controllable steel ball surface trajectory according to claim 1, characterized in that, It also includes a drive device connected to the upper plate, used to drive the upper plate to move; The drive device includes a servo motor and a transmission component; The speed of the servo motor can be adjusted within a preset range; The transmission component is connected to the servo motor and the upper plate, and is used to transmit the motion of the servo motor to the upper plate, thereby controlling the movement trajectory and speed of the upper plate.

5. The electrochemical precision machining device for controllable steel ball surface trajectory according to claim 4, characterized in that, At least one of the upper plate and the lower plate is a metal plate; The upper plate moves relative to the lower plate via the driving device. The upper or lower plate is made of metal and is connected to the positive terminal of a power supply. The lower plate is fixedly installed.

6. The electrochemical precision machining device for controllable steel ball surface trajectory according to claim 1, characterized in that, The preset trajectory is a spiral trajectory or a planetary motion trajectory.

7. A processing method for an electrochemical ultra-precision machining apparatus with controllable surface trajectory of a steel ball as described in any one of claims 1-6, characterized in that, include: Set up the processing device, fix the lower plate, connect both the lower plate and the upper plate to the positive terminal of the power supply, connect the electrode head to the negative terminal of the power supply, connect the flushing head to the flushing pump, and connect the double-layer annular electrochemical electrode device to the transmission device. One steel ball corresponds to one double-layered annular electrochemical electrode device; when one or more steel balls are placed between the upper plate and the lower plate, all the steel balls are located in the middle of the corresponding double-layered electrochemical electrode devices, and these double-layered annular electrochemical electrode devices are connected together and can move along the same trajectory. The electrode head and the flushing head are activated, and the movement trajectory of the double-layer electrochemical electrode device is controlled to be exactly the same as the trajectory of the center of mass of the steel ball, so as to perform electrochemical electrode polishing on the surface of the steel ball.

8. The electrochemical ultra-precision machining method for controllable surface trajectory of a steel ball according to claim 7, characterized in that, The step of activating the electrode head and the flushing head, and controlling the movement trajectory of the double-layer electrochemical electrode device to be exactly the same as the trajectory of the steel ball's center of mass, and performing electrochemical electrode polishing on the surface of the steel ball includes: Turn on the flushing pump and align the flushing port of the flushing head with the processing gap between the steel ball and the electrode head, and perform a powerful flushing with electrochemical special processing fluid; The motion trajectory of the double-layer electrochemical electrode device is controlled to be exactly the same as the trajectory of the center of mass of the steel ball; Turn on the processing power supply to connect the electrode head to the negative electrode. Apply a certain voltage between the electrode and the steel ball. Through the conductivity of the electrochemical special processing fluid, anodic dissolution electro-corrosion is generated on the surface of the steel ball opposite the electrode. Under the action of strong flushing fluid, the dissolved electro-corrosion material is blown away, and the surface of the steel ball is polished. According to the preset trajectory, the continuous rotation of the steel ball surface washes away the anodic dissolution and electro-corrosion substances, and performs continuous electrochemical electrode polishing on the steel ball surface.

9. The electrochemical ultra-precision machining method for controllable surface trajectory of a steel ball according to claim 8, characterized in that, The control of the motion trajectory of the double-layer electrochemical electrode device to be exactly the same as the trajectory of the center of mass of the steel ball includes: The lower plate is fixed, and the upper plate is driven to move parallel to the lower plate according to a preset motion trajectory. The steel ball, driven by the upper plate, performs a pure rolling motion without slippage between the upper plate and the lower plate. The transmission device controls the movement of the double-layered annular electrochemical electrode device according to the trajectory of the center of mass of the steel ball.

10. The electrochemical ultra-precision machining method for controllable surface trajectory of a steel ball according to claim 9, characterized in that, The transmission device controls the double-layer annular electrochemical electrode device to move according to the trajectory of the steel ball's center of mass, and the transmission device is controlled by the steel ball's center of mass trajectory tracking drive system. The trajectory tracking drive system controls the real-time acquisition of the position signal of the center of mass of the steel ball, and drives the transmission device to operate according to the position signal. The transmission device drives the double-layer electrochemical electrode device to move synchronously, so that the motion trajectory of the double-layer electrochemical electrode device is consistent with the motion trajectory of the steel ball.

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