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<p>Digital hydraulic technology is an emerging field in fluid power systems. It requires pilot valve spools with exceptional surface integrity to ensure high response speed and reliability. However, for valve spools with complex geometries, conventional electrochemical polishing struggles to achieve simultaneous burr elimination, superior surface finish, and dimensional accuracy due to non-uniform material removal caused by electric field edge effects and limited electrolyte solution access. To bridge this gap, a novel electrochemical approach that integrates polishing and deburring into a single process is presented. The fundamental mechanisms of burr removal and surface evolution were first elucidated through experiments and electric field simulations on flat samples, establishing an optimal parameter window. Subsequently, a specialized rotary electrochemical machining (RECM) device was developed for valve spools. Crucially, the process was optimized through coupled electric-flow field simulations, guiding the use of rotation to control hydrodynamic conditions, counteract edge effects, and ensure uniform dissolution. The RECM-processed valve spools exhibited remarkable improvement: the low-frequency surface roughness was reduced from Sa 1.258&#xa0;μm to 0.252&#xa0;μm, and the high-frequency surface roughness from Sa 0.702&#xa0;μm to 0.055&#xa0;μm, while maintaining dimensional uniformity and eliminating burrs. This work provides a practical and efficient solution for the high-performance surface finishing of complex hydraulic components, demonstrating a strategy of multi-physics field coupling for electrochemical manufacturing.</p>

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Simultaneous electrochemical deburring and polishing of digital hydraulic valve spools

  • 期刊论文

  • 发表日期：

    2026年2月20日

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  • Shenglong Zhang,
  • Hao Guo,
  • Wei Sun,
  • Xiaozhe Yang,
  • Xu Yang,
  • Zhuangde Jiang

摘要

Digital hydraulic technology is an emerging field in fluid power systems. It requires pilot valve spools with exceptional surface integrity to ensure high response speed and reliability. However, for valve spools with complex geometries, conventional electrochemical polishing struggles to achieve simultaneous burr elimination, superior surface finish, and dimensional accuracy due to non-uniform material removal caused by electric field edge effects and limited electrolyte solution access. To bridge this gap, a novel electrochemical approach that integrates polishing and deburring into a single process is presented. The fundamental mechanisms of burr removal and surface evolution were first elucidated through experiments and electric field simulations on flat samples, establishing an optimal parameter window. Subsequently, a specialized rotary electrochemical machining (RECM) device was developed for valve spools. Crucially, the process was optimized through coupled electric-flow field simulations, guiding the use of rotation to control hydrodynamic conditions, counteract edge effects, and ensure uniform dissolution. The RECM-processed valve spools exhibited remarkable improvement: the low-frequency surface roughness was reduced from Sa 1.258 μm to 0.252 μm, and the high-frequency surface roughness from Sa 0.702 μm to 0.055 μm, while maintaining dimensional uniformity and eliminating burrs. This work provides a practical and efficient solution for the high-performance surface finishing of complex hydraulic components, demonstrating a strategy of multi-physics field coupling for electrochemical manufacturing.