Development of a force model for the prediction of the contact forces and frequencies between chips and work piece in unguided vibratory finishing process

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The contact forces and frequencies between work piece and chips in vibration finishers are a major determinant of the unguided vibratory finishing process that affect the machining properties and thus the surface quality, the edge rounding or the removal rate significantly. The contact forces and frequencies in unguided vibratory finishing processes cannot be described or determined by measurements till this day. Therefore, a measurement system will be developed in this research project, which is able to determine the contact force and frequency of the workpiece edges and surfaces, which are caused by contact with the chips, depending on relevant factors in unguided vibratory finishing process for the first time. These variables are used as the basis for a force model describing the work piece and chip interaction. Despite the high economic importance of surface finishing technology in vibration finishers are no comprehensive process models for the prediction of the process result. As a basis for such a process model in this DFG research project, a force model will be developed, which describes the interactions between the chips and the work piece within the unguided vibratory finishing process and predicts the contact forces and frequencies. The knowledge of the force variables help to describe the tribological system which prevails in the unguided vibratory finishing process. Based on these results it will be possible to understand the cutting mechanisms in unguided vibratory finishing. This includes important insights that allow direct control of the removal rate, the surface quality and the edge rounding of the work piece.