A method for surface treatment, polishing and deburring of precision parts

Abstract

The present application relates to the technical field of polishing deburring, in particular to a precision part surface treatment polishing deburring method, the method comprises the following steps: in pre-washing, according to the surface gray mean value and the total temperature of incoming material, dynamically adjusting the spraying time and infrared preheating; in electrochemical-mechanical composite deburring, according to the voltage ripple coefficient, adjusting the pulse duty cycle or processing voltage, and according to the electrolyte temperature, adjusting the reaction temperature; in final cleaning, based on the change value of scattered light polarization degree and the average value of particle bright spot size, grading control of ultrasonic cleaning and high-pressure water jet; finally, through the qualified output efficiency, judging the batch eligibility, when unqualified, according to the roughness standard rate difference value, adjusting the magnetic abrasive grain addition amount of the next batch. Through the dynamic monitoring and coupling adjustment of multiple parameters in the operation process, the product quality is effectively improved, the deburring efficiency is ensured, and the waste of materials is avoided.

Description

Technical Field

[0001] This invention relates to the field of polishing and deburring technology, and in particular to a method for polishing and deburring the surface of precision parts. Background Technology

[0002] After precision parts are machined, stamped, or additively manufactured, burrs and microscopic unevenness often remain on their edges and surfaces, requiring polishing to remove burrs. The quality of this process directly affects the assembly accuracy, motion reliability, and fatigue life of the parts, especially for complex curved surfaces, micro-holes, and the consistent rounded corners and scratch-free surface condition at intersections.

[0003] Chinese Patent Application Publication No. CN106826411A discloses a cam-driven magnetorheological hydrodynamic polishing device and method. The device includes a polishing disc rotation mechanism, a cam drive mechanism, a workpiece clamping mechanism, and a magnetorheological polishing fluid. The polishing disc rotation mechanism includes a first spindle, a shaft cover, a polishing disc tray, and a polishing disc. The upper surface of the polishing disc has multiple wedge-shaped structures along its circumference. The cam drive mechanism includes a first bearing, a cam disc, a magnet assembly, a spring, and a second spindle, a second bearing, and a bushing, all housed within the polishing disc tray. The workpiece clamping mechanism includes a workpiece disc and a workpiece fixed to the bottom of the workpiece disc. The cam drives the magnet to move radially along the polishing disc, achieving real-time repair of the flexible polishing pad. Combined with the hydrodynamic pressure generated by the wedge-shaped structures on the polishing disc surface, it achieves highly efficient, ultra-smooth, and uniform polishing of the workpiece, resulting in uniform polishing, high efficiency, and good effect. However, this device relies solely on fixed process parameters and does not monitor the operation process data, making it impossible to adjust the operation flow in real time, thus limiting further improvement in product quality.

[0004] Therefore, there is an urgent need for a method that can monitor multi-source process data in real time throughout the entire process of pre-cleaning, deburring and final cleaning, and adjust various processing parameters and material ratios between batches accordingly, so as to further improve surface treatment quality and batch stability. Summary of the Invention

[0005] To address this, the present invention provides a method for polishing and deburring the surface of precision components, which overcomes the problems in the prior art that make it difficult to achieve real-time monitoring and adjustment of multiple process parameters throughout the entire process of pre-cleaning, deburring, and final cleaning, and also makes it impossible to adaptively optimize the material ratio based on production efficiency, thus making it difficult to further improve the surface treatment quality and batch stability.

[0006] To achieve the above objectives, the present invention provides a method for surface treatment, polishing, and deburring of precision components, comprising: Several parts to be processed were pre-cleaned, and the total temperature of the incoming materials and the average surface grayness were obtained. The cleaning fluid spraying time is extended based on the comparison between the average surface gray value and the preset average surface gray value. The spraying extension time of the cleaning fluid and the start time of infrared preheating are determined based on the total incoming material temperature and the target total incoming material temperature. After the pre-cleaning process is completed, the electrochemical-mechanical composite deburring process is monitored in real time to obtain the voltage ripple coefficient and electrolyte temperature of several parts to be treated. Whether to adjust the pulse duty cycle or processing voltage is determined based on the voltage ripple coefficient and the preset voltage ripple coefficient range, and whether to adjust the electrolysis reaction temperature is determined based on the electrolyte temperature and the preset electrolyte temperature range. After processing, several parts are transferred to the cleaning station for final cleaning and testing to determine the surface roughness of the parts and the processing time for this batch. The comparison between the qualified output efficiency determined by the batch processing time and the surface roughness compliance rate and the preset output efficiency determines whether the surface treatment process of the batch of parts is qualified. The surface roughness compliance rate is the ratio of the number of parts with qualified surface roughness to the total number of parts in the batch, and the qualified output efficiency is the ratio of the surface roughness compliance rate to the batch processing time. If the surface treatment process of this batch of components is deemed unqualified, the amount of magnetic abrasive particles added to the electrolyte will be adjusted based on the comparison between the surface roughness compliance rate and the preset roughness compliance rate.

[0007] Furthermore, the process of determining whether to extend the cleaning fluid spraying time includes: Based on the comparison results of the average surface gray value being greater than the preset average surface gray value, it is determined to extend the spraying time of the cleaning liquid.

[0008] Furthermore, the process of determining the extended spraying time of the cleaning fluid and the start-up time of infrared preheating includes: The temperature difference of the incoming material is obtained by calculating the difference between the target total temperature of the incoming material and the total temperature of the incoming material. The spray extension time coefficient corresponding to the cleaning liquid is obtained by calculating the ratio of the incoming material temperature difference to the target total temperature of the incoming material. The spray extension time is determined based on the spray extension time coefficient and the initial spray time; Based on the fact that the total temperature of the incoming material is less than or equal to the preset total temperature of the incoming material, it is determined that spraying will continue based on the extended spraying time and infrared preheating will be started.

[0009] Furthermore, the process of adjusting the pulse duty cycle or processing voltage includes: Based on the fact that the voltage ripple coefficient is less than the lower limit of the preset voltage ripple coefficient range, it is determined to increase the processing voltage, and the increase in processing voltage is positively correlated with the voltage ripple coefficient deviation value. Based on the fact that the voltage ripple coefficient is greater than the upper limit of the preset voltage ripple coefficient range, it is determined to reduce the pulse duty cycle, and the reduction in pulse duty cycle is positively correlated with the difference in voltage ripple coefficient.

[0010] Furthermore, the process of determining whether to adjust the electrolysis reaction temperature includes: Based on the fact that the electrolyte temperature is less than the lower limit of the preset electrolyte temperature range, it is determined to increase the electrolysis reaction temperature, and the increase in the electrolysis reaction temperature is positively correlated with the electrolyte temperature deviation value. Based on the fact that the electrolyte temperature is greater than the upper limit of the preset electrolyte temperature range, it is determined to reduce the electrolysis reaction temperature, and the reduction in the electrolysis reaction temperature is positively correlated with the difference in electrolyte temperature.

[0011] Furthermore, the process of transferring the processed components to the cleaning station for final cleaning includes: Obtain the change value of scattered light polarization degree and the average size of particle bright spots corresponding to several components; The ultrasonic cleaning time is extended based on the comparison between the change value of the polarization degree of the scattered light and the preset change value of the polarization degree of the scattered light. The extension time of ultrasonic cleaning and the start time of high-pressure water jet are determined based on the average size of the particle bright spots and the average size of the target particle bright spots.

[0012] Furthermore, the process of determining whether to extend the ultrasonic cleaning time includes: Based on the fact that the change in the polarization degree of the scattered light is greater than the preset change in the polarization degree of the scattered light, it is determined that the ultrasonic cleaning time should be extended.

[0013] Furthermore, the process of determining the extension time of ultrasonic cleaning and the start-up time of high-pressure water jet includes: The difference between the average size of the particle bright spots and the average size of the target particle bright spots is calculated to obtain the average size difference of the particle bright spots. The cleaning extension time coefficient corresponding to the ultrasonic wave is obtained by calculating the ratio between the mean difference in particle bright spot size and the target particle bright spot size. The cleaning extension time is determined based on the cleaning extension time coefficient and the initial cleaning time. Based on the fact that the average size of the particle bright spots is greater than the preset average size of the particle bright spots, it is determined that cleaning should continue based on the extended cleaning time and high-pressure water jet should be started.

[0014] Furthermore, the process for determining whether the surface treatment process of this batch of components is qualified includes: Based on the fact that the output efficiency is less than the preset output efficiency, it is determined that the surface treatment process of this batch of parts is unqualified.

[0015] Furthermore, the process of determining whether to adjust the amount of magnetic abrasive particles added to the electrolyte includes: The amount of magnetic abrasive particles added to the next batch of electrolyte is adjusted based on the fact that the surface roughness compliance rate is less than the preset roughness compliance rate. The increase in the amount of magnetic abrasive particles added in the electrolyte is determined based on the comparison between the difference in the roughness compliance rate and the preset difference in the roughness compliance rate, and the increase in the amount of magnetic abrasive particles added is positively correlated with the difference in the roughness compliance rate.

[0016] Compared with existing technologies, the advantages of this invention are as follows: By acquiring the average surface grayscale value and total incoming material temperature of the part to be treated in real time during pre-cleaning, the system determines whether to extend the cleaning solution spraying time based on the comparison between the average surface grayscale value and a preset value. Furthermore, the system determines the extended spraying time and the infrared preheating start time based on the graded total incoming material temperature, thus avoiding subsequent processing quality fluctuations caused by inconsistent initial cleanliness and improving the stability of pre-cleaning. After pre-cleaning, the system monitors the voltage ripple coefficient and electrolyte temperature during the electrochemical-mechanical composite deburring process in real time. Based on the degree to which the voltage ripple coefficient deviates from the preset range, the system selects to adjust the pulse duty cycle or processing voltage, effectively suppressing surface over-etching or burr residue caused by unstable discharge. Simultaneously, the system adjusts the voltage ripple coefficient based on the deviation from the preset range. The comparison results were used to adjust the electrolytic reaction temperature, ensuring the uniformity of the electrochemical action and significantly improving the deburring precision and surface quality. In the final cleaning process, the ultrasonic cleaning time and high-pressure water jet start-up time were controlled in stages by the change value of the scattered light polarization degree and the average size of the particle bright spots, avoiding resource waste caused by over-cleaning while ensuring surface cleanliness. The target output efficiency was achieved by calculating the ratio of the processing time of this batch to the surface roughness compliance rate, and comparing it with the preset output efficiency to determine whether this batch is qualified. At the same time, two indicators, quality and efficiency, were introduced to improve the comprehensiveness of the judgment. If the judgment is unqualified, the amount of magnetic abrasive particles added to the electrolyte in the next batch is increased according to the difference between the surface roughness compliance rate and the preset compliance rate, thus avoiding resource waste. This invention overcomes the surface quality fluctuation problems caused by initial state differences, process fluctuations, subsequent residues and parameter solidification by implementing progressive control of the pre-cleaning process, electrochemical deburring process, final cleaning process and the amount of magnetic abrasive particles added between batches. This significantly improves the quality consistency and batch stability of the surface treatment of precision parts.

[0017] Furthermore, by comparing the average surface grayscale value with the preset average surface grayscale value, the cleaning fluid spraying time is extended only when the average surface grayscale value exceeds the standard, avoiding efficiency loss and waste of cleaning fluid caused by blindly extending the spraying time, and achieving precise control of the pre-cleaning intensity. The difference between the target total temperature of the incoming material and the measured total temperature of the incoming material is calculated as the incoming material temperature difference, and the ratio of the incoming material temperature difference to the target total temperature of the incoming material is used as the spraying extension time coefficient. This coefficient is then multiplied by the initial spraying time to determine the spraying extension time, quantitatively linking the extension time with the degree of deviation of the incoming material temperature. The greater the temperature deviation, the longer the extension time, solving the problem that a fixed extension time cannot adapt to different incoming material conditions and achieving dynamic adjustment of the spraying time. At the same time, when the total temperature of the incoming material is lower than or equal to the preset total temperature of the incoming material, infrared preheating is initiated on the basis of continuing spraying according to the extended spraying time. The heat field assists in accelerating the softening and removal of surface stains, making up for the limited improvement of the cleaning effect of simply extending the spraying time on low-temperature components. This shortens the single-batch processing cycle while ensuring cleanliness, thereby improving the pre-cleaning efficiency and stability.

[0018] Furthermore, by real-time monitoring of the voltage ripple coefficient during the electrochemical-mechanical composite deburring process and comparing it with a preset voltage ripple coefficient range, when the voltage ripple coefficient is lower than the lower limit of the range, it is determined that the current processing voltage is too low, resulting in insufficient electrochemical action. At this time, the processing voltage is increased, and the increase is positively correlated with the voltage ripple coefficient deviation value. The larger the deviation, the greater the voltage increase, thereby quickly restoring the electrochemical removal capability and avoiding burr residue. When the voltage ripple coefficient is higher than the upper limit of the range, it is determined that the pulse discharge is unstable. At this time, the pulse duty cycle is reduced, and the reduction is positively correlated with the voltage ripple coefficient difference value. The more violent the fluctuation, the greater the duty cycle reduction, effectively suppressing the risk of surface over-etching and local burns.

[0019] Furthermore, regarding the electrolyte temperature, it is compared with a preset electrolyte temperature range. When the temperature is below the lower limit of the range, the electrolysis reaction temperature is increased, with the increase being positively correlated with the electrolyte temperature deviation. When the temperature is above the upper limit of the range, the electrolysis reaction temperature is decreased, with the decrease being positively correlated with the electrolyte temperature difference. By precisely driving the adjustment of heating or cooling power through the degree of temperature deviation, the problems of insufficient reaction activity due to excessively low temperature or aggravated side reactions due to excessively high temperature are avoided. This ensures that the electrolyte is always within the optimal reaction activity window, significantly improving the consistency and surface quality of deburring.

[0020] Furthermore, by comparing the change value of the scattered light polarization degree with the preset change value, the ultrasonic cleaning time is extended only when the change value exceeds the standard, avoiding efficiency loss and energy waste caused by blindly extending the cleaning time, and achieving precise triggering of the final cleaning intensity. The difference between the average particle bright spot size and the target average particle bright spot size is calculated to obtain the average particle bright spot size difference. The ratio of this difference to its target value is used as the cleaning extension time coefficient, which is then multiplied by the initial cleaning time to determine the cleaning extension time. The extension time is quantitatively correlated with the degree of particle residue. The larger the residual particles, the longer the extension time, solving the problem that a fixed extension time cannot be adapted to components with different levels of contamination, and realizing dynamic adjustment of the ultrasonic cleaning time. At the same time, when the average particle bright spot size is less than or equal to the preset average particle bright spot size, a high-pressure water jet is started on the basis of continuing ultrasonic cleaning according to the cleaning extension time. The impact force of the high-pressure water jet is used to assist in the peeling off of small and firmly attached particles, making up for the limited ability of simply extending the ultrasonic cleaning to remove attached particles. While ensuring surface cleanliness, the final cleaning cycle of a single batch is shortened, thereby improving cleaning efficiency and detection reliability.

[0021] Furthermore, by calculating the ratio of the processing time to the surface roughness compliance rate of this batch to the target output efficiency, and comparing this output efficiency with the preset output efficiency, the batch processing is deemed unqualified only when the output efficiency is lower than the preset value. This integrates quality and efficiency into a unified evaluation system, solving the problem of traditional methods focusing only on a single indicator while ignoring comprehensive benefits, and achieving a quantitative assessment of the overall effectiveness of the surface treatment process. When deemed unqualified, the comparison between the surface roughness compliance rate and the preset roughness compliance rate is used to determine the adjustment of the magnetic abrasive particle addition amount in the next batch of electrolyte only when the compliance rate is lower than the preset value. This avoids material waste and processing abnormalities caused by blind addition and achieves on-demand adjustment of additives. By calculating the difference between the preset roughness compliance rate and the measured roughness compliance rate, the roughness compliance rate difference is obtained. Based on the graded comparison results of this difference and the preset roughness compliance rate difference, the increase in the magnetic abrasive particle addition amount is determined. The greater the deviation of the compliance rate, the greater the increase in the addition amount, thereby reducing material consumption while continuously improving the surface treatment quality. Attached Figure Description

[0022] Figure 1 This is a schematic flowchart of a precision component surface treatment polishing and deburring method according to an embodiment of the present invention; Figure 2 This is a process control logic decision diagram based on the average surface gray value and the total incoming material temperature in an embodiment of the present invention. Figure 3 This is a flow control logic decision diagram based on voltage ripple coefficient and electrolyte temperature in an embodiment of the present invention; Figure 4This is a flowchart illustrating the control logic for determining the relationship between the change in the polarization degree of scattered light and the average size of the bright spot in the particle, as described in an embodiment of the present invention. Figure 5 This is a process control logic decision diagram based on the target output efficiency and surface roughness target rate in an embodiment of the present invention. Detailed Implementation

[0023] To make the objectives and advantages of the present invention clearer, the present invention will be further described below with reference to embodiments; it should be understood that the specific embodiments described herein are merely for explaining the present invention and are not intended to limit the present invention.

[0024] Preferred embodiments of the present invention will now be described with reference to the accompanying drawings. Those skilled in the art should understand that these embodiments are merely illustrative of the technical principles of the present invention and are not intended to limit the scope of protection of the present invention.

[0025] It should be noted that in the description of this invention, the terms "upper", "lower", "left", "right", "inner", "outer", etc., which indicate directions or positional relationships, are based on the directions or positional relationships shown in the accompanying drawings. This is only for the convenience of description and is not intended to indicate or imply that the device or element must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, it should not be construed as a limitation of this invention.

[0026] Furthermore, it should be noted that, in the description of this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0027] Please see Figure 1 The diagram shown is a schematic flow chart of a precision component surface treatment polishing and deburring method according to an embodiment of the present invention. The process in the embodiment includes at least the following steps.

[0028] S1: Perform pre-cleaning treatment on several parts to be processed, and obtain the total temperature of the incoming materials and the average surface gray value; Specifically, after several components have completed pre-cleaning, the vision sensors located above and to the side of the workstation start continuous image acquisition. The image recognition algorithm extracts the grayscale distribution features of each component's surface and calculates the average grayscale value. At the same time, the infrared thermal imager performs non-contact temperature field scanning on the surface of each component to obtain the overall and local temperature distribution of each component. After data processing, the total incoming temperature is formed to characterize the initial thermal state of the component.

[0029] If the sensor signal is lost or the value exceeds the physical limit (such as grayscale average > 100% or temperature > 100℃), an alarm will be triggered and the system will switch to a safe operating mode.

[0030] S2: Determine whether to extend the cleaning fluid spraying time based on the average surface gray value and the preset average surface gray value, and determine the extended spraying time of the cleaning fluid and the start time of infrared preheating based on the total incoming material temperature and the target total incoming material temperature. Specifically, please refer to Figure 2 As shown, it is a process control logic determination diagram based on the average surface gray value and the total temperature of incoming materials in an embodiment of the present invention.

[0031] In a specific embodiment, to accurately determine the control process, a preset surface grayscale mean A0 is set, corresponding to the surface grayscale mean A. The preset surface grayscale mean A0 is determined based on the surface cleanliness benchmark of the process system under ideal stable conditions during standard operating conditions. Specifically, under the premise that the composition of the incoming material of the component to be treated, the pre-cleaning process parameters, and the environmental temperature and humidity remain stable, standard batch samples, which have been rigorously inspected and confirmed to be free from any process disturbances or equipment malfunctions, are collected. Component surface images are continuously acquired at a fixed sampling frequency using a visual monitoring system, and surface grayscale feature values ​​are extracted using image processing algorithms to form a standard surface grayscale sample set. By calculating the mean and standard deviation of this sample set, or selecting a specific high quantile according to process tolerance requirements, the obtained statistical value is used as a basic threshold to finally establish the preset surface grayscale mean A0. For example, A0 is set to 75%. The process of comparing A and A0 is as follows: If A is less than or equal to A0, it indicates that the surface cleanliness of the component has reached the baseline level under ideal and stable conditions, and no additional intervention is required in the pre-cleaning process. Therefore, it is determined that the cleaning fluid spraying time should not be extended.

[0032] If A is greater than A0, it indicates that the average gray value of the component surface exceeds the cleanliness benchmark. The current pre-cleaning effect is insufficient to meet the requirements of subsequent processing, and the cleaning intensity needs to be increased. It is determined to extend the cleaning fluid spraying time. It should be noted that extending the cleaning fluid spraying can not only further remove residual stains on the surface, but also preheat the component through the heat exchange between the cleaning fluid and the component surface, so that the incoming material temperature is closer to the target temperature, thereby improving the consistency and stability of subsequent electrochemical-mechanical processing.

[0033] In this embodiment, the total incoming material temperature B is monitored in real time, and a target total incoming material temperature B1 and a preset total incoming material temperature B2 are set. For example, B1 can be set to 30°C as the target incoming material temperature, at which the cleaning fluid activity and heat exchange efficiency are optimal, ensuring consistency in subsequent processing. B2 is set to 25°C as the infrared preheating start threshold. When the incoming material temperature is below this value, simple spray preheating is insufficient, and infrared auxiliary heating needs to be activated to avoid excessively extending the spraying time. For example, the initial spraying time is set to 60 seconds. Specifically, an infrared preheating device using PID closed-loop control performs non-contact uniform radiative heating on the component surface during the extended spraying time, allowing the low-temperature component to quickly rise to the target temperature range, effectively improving the heat exchange efficiency between the cleaning fluid and the component interface.

[0034] The incoming material temperature difference is obtained by calculating the absolute value of the difference between the target total incoming material temperature B1 and the total incoming material temperature B. The ratio of the incoming material temperature difference to the target total incoming material temperature B1 is calculated to obtain the spray extension time coefficient corresponding to the cleaning liquid. The spray extension time is determined by calculating the spray extension time coefficient and the initial spray time. The process of comparing B and B2 is as follows: If B is less than or equal to B2, spraying will continue based on the extended spraying time and infrared preheating will be started. Infrared radiation will be used to assist in heating the low-temperature components, so that the surface temperature of the components can be quickly raised to the target range. At the same time, the activity of the cleaning fluid will be increased to ensure that the pre-cleaning effect and thermal state meet the requirements of subsequent processing. If B is greater than B2, it is determined that spraying will continue without starting infrared preheating based on the extended spraying time. At this time, the incoming material temperature is close to the target value, and sufficient preheating can be achieved solely by the heat exchange effect of the cleaning liquid spraying, thus avoiding additional energy consumption while ensuring cleanliness. In one specific embodiment, if the total incoming material temperature B is set to 22℃, then the spray extension time coefficient = |30-22| / 30 = 0.27, the spray extension time = 60*0.27 = 16.2s, and the final adjusted spray duration is determined to be 76.2s, and infrared preheating is started; if the total incoming material temperature B is set to 28℃, then the spray extension time coefficient |30-28| / 30 = 0.07, the spray extension time = 60*0.07 = 4.2s, and the final adjusted spray duration is determined to be 64.2s, and infrared preheating is not started; while ensuring the pre-cleaning cleanliness and component preheating requirements, the spray time is extended to meet the subsequent processing requirements.

[0035] It should be noted that adjusting the spray extension time and starting the infrared auxiliary heating will not have a negative impact on certain components, nor will it interfere with the polishing and deburring process.

[0036] S3: After completing the pre-cleaning process, monitor the electrochemical-mechanical composite deburring process in real time to obtain the voltage ripple coefficient and electrolyte temperature of several parts to be treated. Specifically, when several parts to be processed enter the electrochemical-mechanical composite deburring station, the parts are immersed in the electrolyte and connected to the anode of the power supply, while the tool electrode is connected to the cathode. Under the action of pulsed voltage, electrochemical dissolution occurs on the surface of the parts, while rotating magnetic abrasives or brushes mechanically remove burrs. The two work together to achieve precision deburring. During this process, a voltage monitoring unit located at the output of the processing power supply collects processing voltage waveform data in real time at a set sampling frequency. After signal processing, the voltage ripple coefficient, which characterizes the stability of the electrochemical processing process and the degree of fluctuation in the discharge state, is extracted. At the same time, a temperature sensing unit located in the electrolyte tank and circulation pipeline continuously monitors the real-time thermal state data of the electrolyte during the processing to obtain the electrolyte temperature.

[0037] S4: Determine whether to adjust the pulse duty cycle or processing voltage based on the comparison result between the voltage ripple coefficient and the preset voltage ripple coefficient range, and determine whether to adjust the electrolysis reaction temperature based on the comparison result between the electrolyte temperature and the preset electrolyte temperature range. Specifically, please refer to Figure 3 As shown, it is a process control logic determination diagram based on voltage ripple coefficient and electrolyte temperature in an embodiment of the present invention.

[0038] In a specific embodiment, to accurately determine the control process, a preset voltage ripple coefficient interval [C1, C2] corresponding to the voltage ripple coefficient C is set. The preset voltage ripple coefficient interval is determined based on the electrochemical processing stability benchmark of the process system under ideal stable conditions. Specifically, under the premise that process conditions such as electrolyte composition, processing voltage, pulse duty cycle, and electrolyte temperature remain stable, standard batch samples that have been rigorously inspected and confirmed to be free from any process disturbances or equipment abnormalities are collected. Processing voltage waveform data is continuously collected at a fixed sampling frequency through a voltage monitoring unit. The voltage ripple coefficient is extracted using a signal processing algorithm to form a standard voltage ripple coefficient sample set. By calculating the mean and standard deviation of this sample set, or selecting a specific quantile interval according to process tolerance requirements, the obtained statistical range is used as the basic threshold interval, ultimately establishing the preset voltage ripple coefficient interval [C1, C2]. For example, C1 = 2%, C2 = 5%. The process of comparing C with [C1, C2] is as follows: If C is less than C1, it indicates that the current processing voltage is too low, resulting in insufficient electrochemical effect. The processing process tends to be dominated by mechanical removal, which easily produces burr residue or poor surface uniformity. Therefore, it is necessary to increase the processing voltage to enhance the electrochemical dissolution capacity, promote uniform burr removal, and improve surface smoothness. If C∈[C1, C2], it indicates that the stability of the current electrochemical machining process meets the process requirements and the machining state is within the ideal fluctuation range, so it is determined not to adjust the pulse duty cycle or machining voltage. If C is greater than C2, it indicates that the current processing voltage is too high, which can easily cause instability in the pulse discharge process and excessive processing fluctuations, thereby causing over-etching or localized burns on the surface of the component. Therefore, it is necessary to reduce the pulse duty cycle to suppress discharge impact, stabilize the processing process, and protect the surface of the component from thermal damage.

[0039] In this embodiment, the voltage ripple coefficient deviation value F is obtained by calculating the difference between the lower limit value C1 of the voltage ripple coefficient range and the voltage ripple coefficient C. A preset voltage ripple coefficient deviation value F0 is set and compared with the voltage ripple coefficient deviation value F to determine the increase in processing voltage.

[0040] A larger voltage ripple coefficient deviation value F corresponds to a smaller voltage ripple coefficient C, indicating a more severe deviation of the current processing voltage from the ideal state and a serious deficiency in electrochemical interaction intensity. This necessitates a significant increase in the processing voltage to restore processing stability. Therefore, the increase in processing voltage is positively correlated with the voltage ripple coefficient deviation value F.

[0041] In one specific embodiment, to more accurately determine the increase in processing voltage, the preset voltage ripple coefficient deviation value F0 is divided into a first preset voltage ripple coefficient deviation value F1 and a second preset voltage ripple coefficient deviation value F2, exemplarily set as F1=0.5% and F2=1.5%. The comparison process between F and F1 and F2 is as follows: If F is less than or equal to F1, the processing voltage is increased by 10% based on the generated first processing voltage increase adjustment command; where the initial processing voltage is 20V, the increased processing voltage is 22V. If F is greater than F1 and less than or equal to F2, the processing voltage is increased by 20% based on the generated second processing voltage increase adjustment command. If F is greater than F2, the processing voltage is increased by 25% based on the generated third processing voltage increase adjustment command.

[0042] In this embodiment, the voltage ripple coefficient difference G is obtained by calculating the difference between the voltage ripple coefficient C and the upper limit value C2 of the preset voltage ripple coefficient range. A preset voltage ripple coefficient difference G0 is set and compared with the voltage ripple coefficient difference G to determine the reduction of the pulse duty cycle.

[0043] A larger voltage ripple coefficient difference G corresponds to a larger voltage ripple coefficient C, indicating a more severe fluctuation in the current discharge process and a higher risk of processing instability. This necessitates a greater reduction in the pulse duty cycle to suppress discharge fluctuations. Therefore, the reduction in pulse duty cycle is positively correlated with the voltage ripple coefficient difference G.

[0044] In one specific embodiment, to more accurately determine the reduction in pulse duty cycle, the preset voltage ripple coefficient difference G0 is divided into a first preset voltage ripple coefficient difference G1 and a second preset voltage ripple coefficient difference G2, exemplarily set as G1=1% and G2=2%. The comparison process between G and G1 and G2 is as follows: If G is less than or equal to G1, the pulse duty cycle is reduced by 10% based on the generated first pulse duty cycle reduction adjustment command; whereby, if the initial pulse duty cycle is 60%, the reduced pulse duty cycle is 54%. If G is greater than G1 and less than or equal to G2, the pulse duty cycle is reduced by 20% based on the generated second pulse duty cycle reduction adjustment command. If G is greater than G2, the pulse duty cycle is reduced by 35% based on the generated third pulse duty cycle reduction adjustment command.

[0045] In this embodiment, to accurately determine the control process, a preset electrolyte temperature range [T1, T2] corresponding to the electrolyte temperature T is set. The preset electrolyte temperature range is determined based on the electrochemical reactivity benchmark of the process system under ideal stable conditions under standard operating conditions. Specifically, under the premise that process conditions such as electrolyte composition, processing voltage, and pulse duty cycle remain stable, standard batch samples that have been rigorously inspected and confirmed to be free from any process disturbances or equipment malfunctions are collected. Electrolyte temperature data is continuously collected at a fixed sampling frequency through a temperature sensing unit, forming a standard electrolyte temperature sample set. By calculating the mean and standard deviation of this sample set, or selecting a specific quantile interval according to process tolerance requirements, the resulting statistical range is used as the basic threshold interval, ultimately establishing the preset electrolyte temperature range [T1, T2]. For example, T1 = 20℃ and T2 = 30℃ are set. The process of comparing T with [T1, T2] is as follows: If T is less than T1, it indicates that the current electrolyte temperature is too low, the electrochemical reaction activity is insufficient, the ion migration rate decreases, resulting in a decrease in burr removal efficiency and uneven dissolution on the surface. Therefore, it is determined to increase the electrolysis reaction temperature to enhance the reaction kinetics and promote uniform burr removal. If T∈[T1, T2], it indicates that the current electrolyte temperature is within the ideal activity window, the electrochemical reaction rate is stable, and it is determined that the electrolysis reaction temperature should not be adjusted. If T is greater than T2, it indicates that the current electrolyte temperature is too high, and side reactions are aggravated, such as hydrogen evolution and excessive oxide film, which can easily cause over-etching or localized burns on the component surface. It is necessary to reduce the electrolysis reaction temperature, for example, by starting the cooling cycle or reducing the heating power, so as to suppress side reactions and protect the surface quality.

[0046] In this embodiment, the electrolyte temperature deviation value U is obtained by calculating the difference between the lower limit value T1 of the preset electrolyte temperature range and the electrolyte temperature T. A preset electrolyte temperature deviation value U0 is set and compared with the electrolyte temperature deviation value U to determine the increase in the electrolysis reaction temperature.

[0047] A larger electrolyte temperature deviation value U corresponds to a smaller electrolyte temperature T, indicating a more severe deviation of the current temperature from the ideal lower limit and a serious lack of reaction activity. This necessitates a significant increase in the electrolysis reaction temperature to restore electrochemical efficiency. Therefore, the increase in electrolysis reaction temperature is positively correlated with the electrolyte temperature deviation value U.

[0048] In one specific embodiment, to more accurately determine the increase in electrolysis reaction temperature, the preset electrolyte temperature deviation value U0 is divided into a first preset electrolyte temperature deviation value U1 and a second preset electrolyte temperature deviation value U2, exemplarily set as U1 = 2℃ and U2 = 5℃. The comparison process between U and U1 and U2 is as follows: If U is less than or equal to U1, the electrolysis reaction temperature is increased by 5°C based on the generated first electrolysis reaction temperature increase adjustment command; whereby, if the initial electrolysis reaction temperature is 20°C, the increased electrolysis reaction temperature is 25°C. If U is greater than U1 and less than or equal to U2, the electrolysis reaction temperature is increased by 10°C based on the generated second electrolysis reaction temperature increase adjustment command. If U is greater than U2, the electrolysis reaction temperature is increased by 15°C based on the generated third electrolysis reaction temperature increase adjustment command.

[0049] In this embodiment, the electrolyte temperature difference value V is obtained by calculating the difference between the electrolyte temperature T and the upper limit value T2 of the preset electrolyte temperature range. A preset electrolyte temperature difference value V0 is set and compared with the electrolyte temperature difference value V to determine the reduction range of the electrolysis reaction temperature.

[0050] A larger electrolyte temperature difference V corresponds to a larger electrolyte temperature T, indicating a more severe deviation of the current temperature from the ideal upper limit and a higher risk of side reactions. This necessitates a greater reduction in the electrolysis reaction temperature to suppress thermally induced side reactions. Therefore, the magnitude of the reduction in the electrolysis reaction temperature is positively correlated with the electrolyte temperature difference V.

[0051] In one specific embodiment, to more accurately determine the reduction in electrolysis reaction temperature, the preset electrolyte temperature difference V0 is divided into a first preset electrolyte temperature difference V1 and a second preset electrolyte temperature difference V2, exemplarily set as V1 = 3℃ and V2 = 6℃. The comparison process between V and V1 and V2 is as follows: If V is less than or equal to V1, the electrolysis reaction temperature is reduced by 3°C based on the first electrolysis reaction temperature reduction adjustment command generated. If V is greater than V1 and less than or equal to V2, the electrolysis reaction temperature is reduced by 6°C based on the second electrolysis reaction temperature reduction adjustment command generated. If V is greater than V2, the electrolysis reaction temperature is reduced by 10°C based on the third electrolysis reaction temperature reduction adjustment command generated.

[0052] It should be noted that adjusting the processing voltage, pulse duty cycle, and electrolytic reaction temperature will not negatively affect any components or interfere with the polishing and deburring process. During the adjustment of the processing voltage, pulse duty cycle, or electrolytic reaction temperature, the rotational speed of the magnetic abrasive / brush remains constant. Furthermore, the control application scenarios in this embodiment do not include extreme low temperatures or severe over-etching.

[0053] S5: Transfer the processed components to the final cleaning station for final cleaning. Specifically, after several components have undergone electrochemical-mechanical deburring, they are transferred to the final cleaning station by a transport mechanism. Visual sensors and optical detection units positioned above and to the side of the final cleaning station work together to collect real-time surface condition data of the components using scattered light polarization detection technology. The polarization degree data of all components in this batch are summarized, and their standard deviation is calculated as the value of the change in scattered light polarization degree characterizing the overall uniformity of the cleanliness of the component surfaces in this batch. The particle bright spot size data detected on the surfaces of all components in this batch are extracted, and their arithmetic mean is calculated as the average particle bright spot size characterizing the overall particle size level of residual particles.

[0054] Specifically, please refer to Figure 4 As shown, it is a flow control logic determination diagram based on the change value of scattered light polarization degree and the average size of particle bright spots in an embodiment of the present invention.

[0055] In a specific embodiment, to accurately determine the control process, a preset scattered light polarization degree change value H0 is set, corresponding to the scattered light polarization degree change value H. The preset scattered light polarization degree change value H0 is determined based on the surface cleanliness benchmark of the process system under ideal stable conditions. Specifically, under the premise that the final cleaning process parameters, cleaning fluid concentration, ultrasonic power, and water temperature remain stable, standard batch samples, which have been rigorously inspected and confirmed to be free from any process disturbances or equipment malfunctions, are collected. Scattered light polarization degree data of the component surface are continuously collected at a fixed sampling frequency using a scattered light polarization detection unit. The scattered light polarization degree change value is extracted using a signal processing algorithm, forming a standard scattered light polarization degree change value sample set. By calculating the mean and standard deviation of this sample set, or selecting a specific high quantile according to process tolerance requirements, the obtained statistical value is used as the basic threshold to finally establish the preset scattered light polarization degree change value H0. For example, H0 is set to 5%. The process of comparing H and H0 is as follows: If H is less than or equal to H0, it indicates that the surface cleanliness of the component has reached an ideal state, with very few residual particles. No additional intervention is needed in the final cleaning process, and the ultrasonic cleaning time should not be extended.

[0056] If H is greater than H0, it indicates that there are too many residual particles on the surface of the component or the cleaning effect is insufficient. The current final cleaning intensity is not enough to meet the cleanliness standard required by the process. It is determined to extend the ultrasonic cleaning time to enhance the cavitation effect and mechanical abrasion, improve the ability to remove attached particles, and ensure that the surface cleanliness meets the requirements of subsequent testing.

[0057] In this embodiment, the average size I of the particle bright spots is monitored in real time, and a target average size I1 and a preset average size I2 of the particle bright spots are set. For example, I1 = 10 μm, I2 = 20 μm, and the initial cleaning time is 60 s.

[0058] The difference between the average particle bright spot size I and the average target particle bright spot size I1 is calculated to obtain the average particle bright spot size difference. The ratio of the average particle bright spot size difference to the average target particle bright spot size I1 is calculated to obtain the ultrasonic cleaning extension time coefficient. The cleaning extension time is determined based on the cleaning extension time coefficient and the initial cleaning time. The process of comparing I and I2 is as follows: If I is less than or equal to I2, it indicates that the residual particle size is within an acceptable range, and the impact of high-pressure water jet is not necessary. It is determined that cleaning should continue based on the extended cleaning time, without starting the high-pressure water jet. The surface particles can be effectively removed simply by extending the ultrasonic cleaning time, thus avoiding potential damage to precision components caused by high-pressure impact. If I is greater than I2, it indicates that the residual particles are too large or firmly attached. Simply extending the ultrasonic cleaning time is not enough to completely remove them within a reasonable time. Therefore, we determine to continue cleaning based on the extended cleaning time and start high-pressure water jet. The shear force of the high-pressure water jet is used to help peel off the large particles, ensuring that the surface cleanliness after the final cleaning meets the test requirements. In one specific embodiment, if the average particle bright spot size I is set to 15μm, then the cleaning extension time coefficient = |15-10| / 10 = 0.5, the cleaning extension time = 60*0.5 = 30s, and the final adjusted spray duration is determined to be 90s, without starting the high-pressure water jet; if the average particle bright spot size I is set to 25μm, then the cleaning extension time coefficient = |25-10| / 10 = 1.5, the cleaning extension time = 60*1.5 = 90s, and the final adjusted spray duration is determined to be 150s, with the high-pressure water jet started; while ensuring the final cleaning cleanliness, the ultrasonic cleaning time is extended to meet the cleanliness requirements of subsequent surface roughness testing.

[0059] It should be noted that adjusting the ultrasonic cleaning time and starting the high-pressure water jet will not have a negative impact on certain components, nor will it interfere with the polishing and deburring process.

[0060] S6: Conduct testing to determine the surface roughness of several components and the processing time for this batch; Specifically, after the final cleaning process, drying and rust prevention treatments are performed. These treatments include using a hot air knife to remove the macroscopic water film on the surface, combined with a vacuum drying chamber to remove moisture from microscopic crevices, thus eliminating the influence of thermal expansion on roughness measurements. After drying, the surface temperature of the components must return to room temperature before testing. An automated transfer mechanism then moves several components to the testing station. The testing station is equipped with an optical profilometer or a laser confocal microscope, which performs non-contact three-dimensional topographic scanning of the component surface at a set sampling interval, acquiring the surface roughness value at each point and comparing it with a preset roughness value. The number of components in this batch that meet the surface roughness standard is then counted. Simultaneously, the control system automatically times and records the total time from the start of pre-cleaning to the completion of the current test, generating the batch processing time.

[0061] S7: Based on the comparison between the qualified output efficiency determined by the processing time and surface roughness compliance rate of this batch and the preset output efficiency, determine whether the surface treatment process of this batch of parts is qualified. Specifically, please refer to Figure 5 As shown, it is a process control logic judgment diagram based on the standard output efficiency and surface roughness compliance rate in an embodiment of the present invention.

[0062] In a specific embodiment, to accurately determine the control process, a preset output efficiency J0 corresponding to the output efficiency J is set. The preset output efficiency J0 is determined based on the comprehensive output efficiency benchmark of the process system under ideal stable conditions under standard operating conditions. Specifically, under the premise that all process links, such as incoming material status, pre-cleaning parameters, electrochemical-mechanical processing parameters, final cleaning parameters, and environmental conditions, remain stable, standard batch samples that have been rigorously inspected and confirmed to have no process disturbances or equipment abnormalities and have a surface roughness compliance rate of 100% are collected. The surface roughness compliance rate and processing time of each batch are recorded, and the output efficiency of each batch is calculated to form a standard output efficiency sample set. By calculating the mean and standard deviation of the sample set, or selecting a specific quantile based on a comprehensive balance between production capacity targets and quality requirements, the obtained statistical value is used as a basic threshold to ultimately establish the preset output efficiency J0. For example, J0 is set to 3% / min, meaning 3% of the output meets the standard per minute. For instance, when the total number of parts requiring surface polishing and deburring is 100, an output efficiency of 3% / min means that 3 parts meet the standard per minute. The actual number of parts meeting the standard is calculated by rounding down, meaning that approximately 34 minutes of processing time is needed to achieve a 100% compliance rate. This processing time is consistent with the expected processing efficiency for this batch. The process of comparing J and J0 is as follows: If J is less than J0, it indicates that the overall efficiency of the surface treatment process of this batch of parts is low and fails to reach the ideal output level, thus determining that the surface treatment process of this batch of parts is unqualified. If J is greater than or equal to J0, it indicates that the overall efficiency of the surface treatment process of this batch of parts meets the process requirements, and the surface treatment process of this batch of parts is deemed qualified.

[0063] S8: If the surface treatment process of this batch of parts is deemed unqualified, the amount of magnetic abrasive particles added to the electrolyte in the next batch will be adjusted based on the comparison between the surface roughness compliance rate and the preset roughness compliance rate.

[0064] Specifically, please refer to Figure 5As shown, to accurately determine the control process, a preset surface roughness compliance rate K0 is set, corresponding to the surface roughness compliance rate K. The preset surface roughness compliance rate K0 is determined based on the quality qualification benchmark of the process system under ideal stable conditions. Specifically, under the premise that all process links, including incoming material conditions, pre-cleaning parameters, electrochemical-machining parameters, and final cleaning parameters, remain stable, standard batch samples that have undergone rigorous inspection and confirmation of no process disturbances or equipment malfunctions, and whose surface roughness meets the standards, are collected to form a standard surface roughness compliance rate sample set. By calculating the mean and standard deviation of this sample set, or selecting specific quantiles according to product quality requirements, the obtained statistical values ​​are used as the basic threshold to finally establish the preset surface roughness compliance rate K0. For example, K0 = 95%. The process of comparing K and K0 is as follows: If K is less than K0, it indicates that the number of parts with surface quality that meet the standards in this batch does not meet the process requirements. Therefore, it is determined that by adjusting the amount of magnetic abrasive particles added to the electrolyte, the grinding ability of the electrolyte can be enhanced, and the efficiency of removing burrs and surface micro-protrusions can be improved, thereby achieving a better polishing and deburring effect for the next batch of parts. If K is greater than or equal to K0, it indicates that there are enough parts in this batch that meet the surface quality standards and process requirements. Therefore, it is determined that the processing method for parts under the same conditions in subsequent batches will be consistent with the processing method of this batch.

[0065] In this embodiment, the roughness compliance rate difference L is obtained by calculating the difference between the preset surface roughness compliance rate K0 and the surface roughness compliance rate K. A preset roughness compliance rate difference L0 is set and compared with the roughness compliance rate difference L to determine the increase in the amount of magnetic abrasive particles added.

[0066] The larger the difference in surface roughness compliance rate L, the smaller the corresponding surface roughness compliance rate K, indicating a greater deviation between the surface quality of the current batch and the process requirements. This necessitates a significant increase in the amount of magnetic abrasive particles added to enhance the polishing and deburring effect. Therefore, the increase in the amount of magnetic abrasive particles added is positively correlated with the difference in surface roughness compliance rate L.

[0067] In one specific embodiment, to more accurately determine the increase in the amount of magnetic abrasive particles added, the preset roughness compliance rate difference L0 is divided into a first preset roughness compliance rate difference L1 and a second preset roughness compliance rate difference L2, exemplarily set as L1=2% and L2=3%. The comparison process between F and F1 and F2 is as follows: If L is less than or equal to L1, the amount of magnetic abrasive particles added is increased by 10% based on the generated first magnetic abrasive particle addition increase adjustment command; whereby, if the initial addition amount is 20 g / L, the increased addition amount is 22 g / L. If L is greater than L1 and less than or equal to L2, the amount of magnetic abrasive particles added is increased by 15% based on the generated second magnetic abrasive particle addition increase adjustment command. If L is greater than L2, the amount of magnetic abrasive particles added is increased by 25% based on the generated third magnetic abrasive particle addition increase adjustment command.

[0068] It should be noted that adjusting the amount of magnetic abrasive added will not have a negative impact on certain components, nor will it interfere with the polishing and deburring process.

[0069] To better illustrate the method for polishing and deburring the surface of precision parts, the present invention will be further described below with reference to specific embodiments.

[0070] Example 1 Adjustment range: Pre-cleaning process only.

[0071] Initial conditions: 3 consecutive production batches, 100 precision parts per batch. Pre-cleaning: Preset surface grayscale average 75%, target incoming material total temperature 30℃, preset incoming material total temperature threshold 25℃, initial spray 60s. Electrochemical fixed parameters: Processing voltage 20V, pulse duty cycle 60%, electrolyte temperature 25℃. Final cleaning fixed parameters: Ultrasonic cleaning 60s, no high-pressure water jet. Fixed magnetic abrasive addition: 20g / L magnetic abrasive.

[0072] In the processing procedure, (1) the average gray value of the surface was detected to be 82%, and the spraying time of the cleaning liquid was extended. The total temperature of the incoming material was detected to be 22℃, the spraying extension time coefficient was calculated to be 0.267, the spraying extension time was 16s, the total spraying time was 76s, and the infrared preheating was started.

[0073] Example 2 Adjustment range: pre-cleaning process + electrochemical process.

[0074] The pre-cleaning process is the same as in Example 1.

[0075] Electrochemical process: preset voltage ripple coefficient range [2%, 5%], preset electrolyte temperature range [20℃, 30℃].

[0076] The processing procedure is as follows: (1) The pre-cleaning process is the same as in Example 1. (2) The voltage ripple coefficient is detected as 1.5%, and the processing voltage is increased. The voltage ripple coefficient deviation is calculated as 0.5%, and the processing voltage is increased by 10% from 20V to 22V. The electrolyte temperature is detected as 18℃, and the electrolyte temperature deviation is calculated as 2℃, and the electrolysis reaction temperature is increased from 20℃ to 25℃.

[0077] Example 3 Adjustment range: pre-cleaning process + electrochemical process + final cleaning process.

[0078] The pre-cleaning process and electrochemical process are the same as in Example 2.

[0079] Final cleaning process: preset scattered light polarization degree change value 5%, target particle bright spot size average 10μm, preset particle bright spot size average 20μm, initial cleaning time 60s.

[0080] The processing procedure is as follows: (1) Pre-cleaning process is the same as in Example 1. (2) Electrochemical process is the same as in Example 2. (3) Final cleaning: The change in polarization of the scattered light is detected as 6%, and the ultrasonic cleaning time is extended. The average size of the particle bright spots is detected as 15 μm, the cleaning extension time coefficient is calculated as 0.5, the cleaning extension time is 30 s, the total ultrasonic time is 90 s, and the high-pressure water jet is not started.

[0081] Example 4 Adjustment range: pre-cleaning process + electrochemical process + final cleaning process + adjustment of magnetic abrasive particle addition amount.

[0082] The pre-cleaning process, electrochemical process, and final cleaning process are the same as in Example 3.

[0083] Magnetic abrasive addition adjustment rules: Based on the surface roughness compliance rate of the previous batch, adjust the magnetic abrasive addition amount of the next batch in stages.

[0084] The processing procedure is as follows: (1) Pre-cleaning process is the same as in Example 1. (2) Electrochemical process is the same as in Example 2. (3) Final cleaning process is the same as in Example 3. (4) Production efficiency = 2.75% / min, the surface treatment process of this batch of parts is deemed unqualified, the surface roughness compliance rate is 94%, the pre-set roughness compliance rate difference is calculated to be 1%, and the amount of magnetic abrasive added is increased from 20g / L to 22g / L.

[0085] Comparative Example Pre-cleaning process: Place the parts to be treated into the cleaning basket, start the spray device, and automatically stop after 60 seconds of spraying. Surface grayscale imaging analysis is not performed, the incoming material temperature is not recorded, and infrared heating is not activated. After cleaning, the parts are directly transferred to the electrochemical station.

[0086] Electrochemical process: The component is immersed in the electrolyte, the power is turned on, and electrochemical machining is performed with a pulse waveform of 20V voltage and 60% duty cycle, while the magnetic abrasive / brush rotates at a constant speed of 300rpm. During the machining process, the voltage waveform is not collected, the ripple coefficient is not calculated, the electrolyte temperature is not measured, and no electrical parameters are adjusted. The machining time is fixed at 5 minutes.

[0087] Final cleaning process: After processing, the parts are transferred to the final cleaning tank and ultrasonically cleaned for 60 seconds. No scattered light polarization detection is performed, particle bright spot size is not counted, and high-pressure water jets are not activated. After cleaning, the parts proceed directly to the drying stage.

[0088] Inter-batch adjustment: All three batches use the same 20g / L magnetic abrasive addition amount, which is not changed due to the surface roughness compliance rate of the previous batch.

[0089] Testing and evaluation methods: To comprehensively evaluate the surface treatment, polishing, and deburring methods for precision components, the following indicators were used: 1. Pre-cleaning effect: Five components are randomly selected from each batch, and the number of residual particles per unit area is counted using a scattered light polarization detector. For example, the unit area is set to 1 cm². 2 Take the average value.

[0090] 2. Electrochemical effect: The height of burrs at the same position before and after deburring was measured using a laser confocal microscope. The average of the five highest points was taken to calculate the removal rate.

[0091] 3. Final cleaning effect: The number of bright spots on the surface of the parts was counted before and after the final cleaning, and the removal rate was calculated.

[0092] 4. Consistency effect: Three batches are produced continuously. After each batch is completed, the surface roughness of all parts in that batch is counted and the mean of that batch is calculated. Finally, the sample standard deviation between the means of the three batches is calculated as the consistency index between batches.

[0093] Please see Table 1 below for specific data.

[0094] Table 1. Performance comparison results between the examples and comparative examples.

[0095] Conclusion Analysis: Example 1 improved surface cleanliness through pre-cleaning monitoring, but batch-to-batch consistency was poor due to the lack of feedback adjustment during electrochemical cleaning, final cleaning, and batch-to-batch processes. Example 2, with the addition of electrochemical monitoring, significantly improved burr removal rate and batch-to-batch consistency to 0.028 μm. Example 3 further incorporated final cleaning monitoring, resulting in a substantial increase in particle bright spot removal rate and optimized batch-to-batch consistency to 0.022 μm. Example 4, based on full-process monitoring of pre-cleaning, electrochemical cleaning, and final cleaning, added feedback adjustment of magnetic abrasive particle addition based on the previous batch's compliance rate, reducing the average standard deviation of surface roughness between batches to 0.015 μm. Simultaneously, the residual particle density was only 3 particles / cm², the burr removal rate was 93%, and the particle bright spot removal rate was 92%, all indicators being superior to other examples.

[0096] The above data shows that only by simultaneously implementing dynamic monitoring throughout the entire process and batch-to-batch feedback adjustment can the highest surface cleanliness, the most thorough burr removal, the optimal final cleaning efficiency, and the best batch-to-batch consistency be achieved simultaneously. For the mass production of precision components, Example 4 is the optimal implementation scheme.

[0097] All technologies not mentioned in the above embodiments are existing technologies. It is understood that no specific limitation is made to any preset parameter or critical parameter in the embodiments of the present invention, and the above values ​​are not limited thereto. Those skilled in the art can adjust the preset parameters or critical parameters accordingly based on actual needs, analysis of historical data, or equipment usage.

[0098] The technical solution of the present invention has been described above with reference to the preferred embodiments shown in the accompanying drawings. However, it will be readily understood by those skilled in the art that the scope of protection of the present invention is obviously not limited to these specific embodiments. Without departing from the principles of the present invention, those skilled in the art can make equivalent changes or substitutions to the relevant technical features, and the technical solutions after these changes or substitutions will all fall within the scope of protection of the present invention.

Claims

1. A method for polishing and deburring the surface of precision parts, characterized in that, include: Several parts to be processed were pre-cleaned, and the total temperature of the incoming materials and the average surface grayness were obtained. The determination of whether to extend the cleaning fluid spraying time is based on the average surface gray value and the preset average surface gray value, and the determination of the extended spraying time of the cleaning fluid and the start time of infrared preheating are based on the total incoming material temperature and the target total incoming material temperature. Real-time monitoring of the electrochemical-mechanical composite deburring process after pre-cleaning to obtain the voltage ripple coefficient and electrolyte temperature of several parts to be treated; Whether to adjust the pulse duty cycle or processing voltage is determined based on the voltage ripple coefficient and the preset voltage ripple coefficient range, and whether to adjust the electrolysis reaction temperature is determined based on the electrolyte temperature and the preset electrolyte temperature range. After the processing is completed, several parts are subjected to final cleaning, and the surface roughness of several parts and the processing time of this batch are detected and determined. The comparison between the qualified output efficiency determined by the batch processing time and the surface roughness compliance rate and the preset output efficiency determines whether the surface treatment process of the batch of parts is qualified. The surface roughness compliance rate is the ratio of the number of parts with qualified surface roughness to the total number of parts in the batch, and the qualified output efficiency is the ratio of the surface roughness compliance rate to the batch processing time. If the surface treatment process of this batch of components is deemed unqualified, the amount of magnetic abrasive particles added to the electrolyte will be adjusted based on the comparison between the surface roughness compliance rate and the preset roughness compliance rate.

2. The method for surface treatment, polishing, and deburring of precision components according to claim 1, characterized in that, The process of determining whether to extend the cleaning fluid spraying time includes: Based on the comparison results of the average surface gray value being greater than the preset average surface gray value, it is determined to extend the spraying time of the cleaning liquid.

3. The method for surface treatment, polishing, and deburring of precision components according to claim 2, characterized in that, The process of determining the extended spraying time of the cleaning fluid and the start time of infrared preheating includes: The temperature difference of the incoming material is obtained by calculating the absolute value of the difference between the target total temperature of the incoming material and the total temperature of the incoming material. The spray extension time coefficient corresponding to the cleaning liquid is obtained by calculating the ratio of the incoming material temperature difference to the target total temperature of the incoming material. The spray extension time is determined based on the spray extension time coefficient and the initial spray time; Based on the fact that the total temperature of the incoming material is less than or equal to the preset total temperature of the incoming material, it is determined that spraying will continue based on the extended spraying time and infrared preheating will be started.

4. The method for surface treatment, polishing, and deburring of precision components according to claim 1, characterized in that, The process of adjusting the pulse duty cycle or processing voltage includes: Based on the fact that the voltage ripple coefficient is less than the lower limit of the preset voltage ripple coefficient range, it is determined to increase the processing voltage, and the increase in processing voltage is positively correlated with the voltage ripple coefficient deviation value. Based on the fact that the voltage ripple coefficient is greater than the upper limit of the preset voltage ripple coefficient range, it is determined to reduce the pulse duty cycle, and the reduction in pulse duty cycle is positively correlated with the difference in voltage ripple coefficient.

5. The method for surface treatment, polishing, and deburring of precision components according to claim 1, characterized in that, The process of determining whether to adjust the electrolysis reaction temperature includes: Based on the fact that the electrolyte temperature is less than the lower limit of the preset electrolyte temperature range, it is determined to increase the electrolysis reaction temperature, and the increase in the electrolysis reaction temperature is positively correlated with the electrolyte temperature deviation value. Based on the fact that the electrolyte temperature is greater than the upper limit of the preset electrolyte temperature range, it is determined to reduce the electrolysis reaction temperature, and the reduction in the electrolysis reaction temperature is positively correlated with the difference in electrolyte temperature.

6. The method for surface treatment, polishing, and deburring of precision components according to claim 1, characterized in that, The process of performing a final cleaning on several components after processing includes: Obtain the change value of scattered light polarization degree and the average size of particle bright spots corresponding to several components; The ultrasonic cleaning time is extended based on the comparison between the change value of the polarization degree of the scattered light and the preset change value of the polarization degree of the scattered light. The extension time of ultrasonic cleaning and the start time of high-pressure water jet are determined based on the average size of the particle bright spots and the average size of the target particle bright spots.

7. The method for surface treatment, polishing, and deburring of precision components according to claim 6, characterized in that, The process of determining whether to extend the ultrasonic cleaning time includes: Based on the fact that the change in the polarization degree of the scattered light is greater than the preset change in the polarization degree of the scattered light, it is determined that the ultrasonic cleaning time should be extended.

8. The method for surface treatment, polishing, and deburring of precision components according to claim 6, characterized in that, The process of determining the extended time of ultrasonic cleaning and the start-up time of high-pressure water jet includes: The difference between the average size of the particle bright spots and the average size of the target particle bright spots is calculated by the absolute value of the difference. The cleaning extension time coefficient corresponding to the ultrasonic wave is obtained by calculating the ratio between the mean difference in particle bright spot size and the target particle bright spot size. The cleaning extension time is determined based on the cleaning extension time coefficient and the initial cleaning time. Based on the fact that the average size of the particle bright spots is greater than the preset average size of the particle bright spots, it is determined that cleaning should continue based on the extended cleaning time and high-pressure water jet should be started.

9. The method for surface treatment, polishing, and deburring of precision components according to claim 1, characterized in that, The process for determining whether the surface treatment process of this batch of components is qualified includes: Based on the fact that the output efficiency is less than the preset output efficiency, it is determined that the surface treatment process of this batch of parts is unqualified.

10. The method for surface treatment, polishing, and deburring of precision components according to claim 9, characterized in that, The process of determining whether to adjust the amount of magnetic abrasive particles added to the electrolyte includes: The amount of magnetic abrasive particles added to the next batch of electrolyte is adjusted based on the fact that the surface roughness compliance rate is less than the preset roughness compliance rate. The increase in the amount of magnetic abrasive particles added in the electrolyte is determined based on the comparison between the difference in the roughness compliance rate and the preset difference in the roughness compliance rate, and the increase in the amount of magnetic abrasive particles added is positively correlated with the difference in the roughness compliance rate.

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