Experiment and simulation analysis on the mechanism of the spindle barrel finishing

摘要

The spindle barrel finishing is commonly used to improve the surface integrity of the important parts of the high-end equipment while it is difficult to provide enough test artifacts for the traditional trial and error experiment to obtain the desirable processing technology. The EDEM simulation of the spindle barrel finishing can provide effective help for the process design. In this paper, simulations and experiments are conducted based on the identical apparatus and conditions to facilitate the comparison and validation between each other. The parameters required in the simulation are determined based on reliable experiments. In order to explain the interaction of ceramic media and metal workpieces in the finishing barrel, firstly, the depth of material wear on the surface of the workpiece is obtained, and the amount of material removal is calculated in conjunction with Archard wear theory based on the Hertz-Mindlin with Archard wear model in EDEM. The relationship between the amount of material removed and the time and position of workpiece clamping is quantified. It is in good agreement with the experimental results; the maximum deviation is 20.14%. The finishing mechanism is analyzed based on the motion trajectory of the barrel finishing media that are in contact with the workpiece observed in the simulation and the corresponding contact forces obtained from both the simulation and the experiment. Furthermore, the machining effect of the workpieces after the finishing process is discussed considering the analysis of the motion trajectory and the contact force. The achieved trajectories permit to calculate the active working time. This work provides an understanding of spindle barrel finishing process fundamentals and guidelines for optimal operating conditions.