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Kinematics and machinability using bidirectional composite vibratory finishing

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Abstract

Considering the poor accessibility of the current finishing process for parts with complicated geometries, a novel bidirectional composite vibratory finishing (BCVF) approach was proposed, which combined the power actions on abrasive particles and processed workpieces. To examine the feasibility and effectiveness of the BCVF approach, comparative simulations based on discrete element method (DEM) and experimental validation were performed on a cylindrical workpiece simplified by a gear. Moreover, the effects of container size (or wall effects), media amount, workpiece position, and vibration parameters (including vibration amplitude and frequency) on the media-component interaction were systematically studied by DEM. The results show that the BCVF had the highest polishing efficiency, resulting in a workpiece surface roughness reduction rate up to 57% within 15 min. The distance between the container wall and the workpiece surface along the container width direction can be reduced to 4d (d is the abrasive particle diameter) with little effect on the finishing effect. Meanwhile, with the enhancing one-dimensional horizontal vibration, particle impact and shear effects are subsequently strengthened. In contrast, the media amount above the workpiece and the vibration along the workpiece axial direction are mainly effective for the shear effect. This BCVF approach provides reference for the finishing of various complex-shaped components including gears.

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Data availability

The datasets supporting the results of this article are included within the article.

Abbreviations

a :

Data bin position along the circumference of the workpiece

A x, A z :

Amplitude of horizontal and vertical vibration (mm)

b :

Data bin group along the axial of the workpiece

BCVF:

Bidirectional composite vibratory finishing

\(\delta\) :

Overlap distance of two particles (m)

δt :

Contact time (s)

d :

Diameter of the abrasive particle (mm)

DEM:

Discrete element method

e :

Recovery coefficient

E :

Young’s modulus

E n , E t :

Normal and tangential cumulative contact energy (J)

f x, f z :

Frequency of horizontal and vertical vibration (Hz)

\(F^{d}\) :

Damping force (N)

F n , F t :

Normal and tangential contact force (N)

G :

Shear modulus (Pa)

h :

Workpiece vertical position (mm)

H :

Loading height of abrasive particles (mm)

i, j :

Indicate the particles in contact

L x, L y, L z :

Length, width, and height of the container (mm)

Lc :

Sampling length (mm)

Lm :

Measuring length (mm)

Lt :

Traverse length (mm)

n :

Rotational speed of the workpiece (rpm)

\(\rho\) :

Density (kg/m3)

r :

Radius of the workpiece (mm)

R :

Radius of each particle in contact (mm)

S :

Stiffness (N/m)

t :

Process duration (s)

\(\mu_{s}\) :

Static friction coefficient

\(\mu_{r}\) :

Rolling friction coefficient

v :

Poisson’s ratio

\(v_{{}}^{{\overrightarrow {rel} }}\) :

Relative velocity of contact particles (m/s)

V x , V y , V z :

Components of the abrasive particle velocity along x, y, z directions (m/s)

V :

Total cutting speed of the abrasive particle (m/s)

V n , V t :

Normal and tangential relative velocity (m/s)

x, y, z :

Coordinate axis

z 0 :

Initial height of the abrasive particle (mm)

X, Y, Z :

Components of the abrasive particle displacement along x, y, z directions (mm)

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Funding

The work was co-supported by the National Natural Science Foundation of China (Grant Nos. 51875389 and 52075362) and Fundamental Research Program of Shanxi Province (20210302124209).

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Authors and Affiliations

  1. College of Mechanical and Vehicle Engineering, Taiyuan University of Technology, Taiyuan, 030024, China

    Yingbo Yang, Xiuzhi Wang, Yupeng Hao, Shengqiang Yang & Xiuhong Li

  2. Shanxi Province Key Laboratory of Precise Machining, Taiyuan, 030024, China

    Yingbo Yang, Wenhui Li, Xiuzhi Wang, Yupeng Hao, Shengqiang Yang & Xiuhong Li

  3. College of Aeronautics and Astronautics, Taiyuan University of Technology, Taiyuan, 030024, China

    Wenhui Li

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Contributions

Yingbo Yang designed and performed the manuscript, analyzed the data, and drafted the manuscript. Wenhui Li conceived and supervised the study and edited the manuscript. Yupeng Hao and Shengqiang Yang performed the experiments. Xiuzhi Wang and Xiuhong Li analyzed the data. All authors read and approved the manuscript.

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Correspondence to Wenhui Li.

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Yang, Y., Li, W., Wang, X. et al. Kinematics and machinability using bidirectional composite vibratory finishing. Int J Adv Manuf Technol 131, 2191–2206 (2024). https://doi.org/10.1007/s00170-023-10853-z

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