Theroretic Analysis And Simulation Of Centrifugal Barrel Finishing Based On Three-Dimensional Discrete Element Method

As final machining process, surface finishing technology has important influence on part or product quality, performance, service life etc. With machining equipment development, there is more request for surface finishing technology improving surface quality. At present, there is not enough research for dynamic finishing course of new surface finishing process, which affects its application.Based on research results of centrifugal barrel finishing, three-dimensional discrete element method and artificial intelligence is used to surface finishing for the first time, macroscopic motion characteristic of mixed medium, microscopic finishing mechanism, finishing efficiency, etc. are thoroughly studied by theoretic analysis, simulation and experiments, which is done through the combination with macroscopic and microscopic, dynamics simulation and black-box simulation, experiment and simulation. Main research contents are as follows:1. Based on particle theory, force, velocity and mechanism of particles is analyzed theoretically, and the condition of particles separated from barrel wall is defined. Theoretical calculation formula of critical transmission ratio and finishing efficiency is induced.2. With three-dimensional discrete element method, dynamics model is established, and visualization simulation is done for finishing process of the single particle and particles. By analyzing particle position, particle velocity, barrel wall force, contact force and contact energy between particles and particle-barrel wall, etc., affecting rules of different parameters is studied for particle motion characteristic, finishing mechanism, finishing efficiency, finishing effect.3. The concept of critical transmission ratio is proposed for centrifugal barrel finishing, and critical transmission ratio for different type is obtained by simulation, which is basically consistent with theoretic computation.4. Black-box prediction model is established by BP neural network method, and BP neural network weight is optimized with genetic algorithm. Simulated with Matlab software programming, finishing results prediction of different parameters is realized, which can provide basis for further multi-objective optimization.5. Major effect factors, rotational speed, transmission ratio, loading capacity, mass ratio, particle diameter etc., are studied by experiments, which can confirm accuracy and the validity of simulation analysis.In this paper, affecting rules of particles motion, finishing mechanism, finishing efficiency, finishing effect, etc. are thoroughly studied through theory and simulation analysis. Research results can deepen the theory of barrel finishing technology, and can provide perfect theoretic basis for equipment design and industrial application. It can replace massive numerous and diverse experiments, save manpower, physical and financial resource, which should be of great significance for the further development and industrial applications of surface barrel finishing.