COMSOL-based Simulation Analysis and Experiment of Micro-Hole Burr Removal

The burr generated by drilling micro-hole seriously affects the surface processing quality of the parts. For the micro-hole burr removal, a three-dimensional deburring simulation model is established by using the COMSOL Multiphysics simulation software, and a spiral drill bit is used as the tool cathode to study the effects of 4.5 V, 5.5 V, 6.5 V processing voltage, 13%, 15%, 17% NaNO₃ electrolyte concentration on the burr removal on the deburring effect. The simulation results show that increasing the processing voltage and electrolyte concentration will accelerate the burr removal rate, and also lead to the expansion of micro-hole pore size, with a maximum expansion of 126 μm; the burr tip of micro-hole gets a high current density, and the burr tip is removed preferentially; the current density size corresponds to the burr removal ability; the processing gap size is inversely proportional to the current density size. The simulation results are verified experimentally, and the trend changes between the test and simulation are basically the same.