Simulation and experimental study on the bidirectional composite vibratory finishing characteristics

Abstract

Abstract As a novel high efficiency collaborative surface finishing technology of structure shape and surface integrity, bidirectional composite vibratory finishing (BCVF) can be applied to finish various complex components. The movement behavior of abrasive particles is closely related to the machined part performance. The flow characteristics of particles were analyzed based on the discrete element method (DEM), which reveals that the granular temperature can explain the changes in the normal and tangential cumulative contact energy on the workpiece surface. In addition, the normal contact force on the container sidewall and the pressure distribution on the workpiece surface were tested under different process parameters and the results were compared with DEM simulations. The results show that DEM model accurately predicted the particle-wall normal contact force frequency content, and the dominant frequencies are the container driving frequency and its multiplication. Meanwhile, the pressure-sensitive film can clearly and intuitively demonstrate the integrated action behavior of the particles on the workpiece surface. The overall trends of the measured pressure were comparable to the simulation results, in that the pressure increased significantly with vibration frequency and amplitude. Dimensionless vibration velocity amplitude has been verified effective in analyzing the combined effect of vibration frequency and amplitude. Therefore, it is shown that spherical particle in simulation can predict some critical properties in non-spherical processing, which provides a reference for the extended application of the BCVF process.