Abstract: Flexible cable impact contact rust removal is a good method for surface rust removal and strengthening of steel plates. A reasonable combination of process and structural parameters has a significant impact on the quality of rust removal. Finding the optimal parameter combination is of great significance for improving the quality of rust removal. A method for optimizing process parameters that directly affect the rust removal quality of the device is proposed based on the surface rust removal machine for flexible cable impact contact steel plates developed by the project team in the early stage. The contact mechanics model of the rust remover is established. According to the influence factors of the mechanical model, the diameter of the flexible cable, the height of the drum and the rotation speed of the drum are determined as the parameters to be optimized. Using the Taguchi method and response surface optimization method, the signal-to-noise ratio of parameter combinations is calculated to evaluate stability, and an predictive optimization model for impact contact stress is constructed. Further global prediction optimization is carried out to obtain the best combination of stability and contact stress parameters, achieving the improvement of the rust removal effect and improving the mechanical properties of the steel plate surface. Finally, taking the flexible cable impact rust removal machine manufactured with the optimal parameter combination as an example, the proposed optimization method was verified to achieve the goal of improving the rust removal performance of the flexible cable impact rust removal machine.