The work aims to explore the effect of vertical vibratory finishing process parameters on the surface integrity indexes (including residual stress, surface roughness and stress concentration factor) of TC4 specimens. In this study, the effects of amplitude (2.5-4.5 mm), frequency (20-40 Hz), immersion depth (20-40 mm), installation angle (0°-90°), granular media diameter (2-10 mm) and processing time (0-180 min) on the surface integrity indexes are systematically analyzed by single-factor tests. Combined with discrete element simulations, the average contact force and the relative velocity (including both normal and tangential components) between the granular media and the specimen surface are extracted, and the effect of each process parameter on the dynamic behavior of the granular media is revealed accordingly. Considering the effect of various parameters on the roughness reduction rate, the compressive residual stress on the specimen surface, and the decrease in the stress concentration factor, the process parameters that achieve both low surface roughness and high compressive residual stress are optimized.
The experimental results showed that all surface integrity indexes change significantly during the initial stage of processing (within approximately 90 min), after which the changes slow down and eventually enter a stable stage. Among all the parameters examined, the diameter of the granular media has the greatest effect. Specifically, as the granular media diameter increased, the compressive residual stress, the roughness reduction rate, and the decrease in the stress concentration factor all increase first and then decrease, and the optimal diameter is determined to be 4 mm. As the installation angle increases, the compressive residual stress on the specimen surface decreases sharply, from -498.8 MPa at 0° to -256.1 MPa at 90°. The roughness reduction rate is poor at 0°, reaching only 20.9%. When the installation angle increases, the surface roughness processing effect becomes noticeably better. After the installation angle exceeds 45°, the roughness reduction rate tends to stabilize, and the maximum reduction rate observed is 78.5%. With increasing amplitude, each surface integrity index is significantly improved. However, once the amplitude exceeds 3.5 mm, the growth rate of the compressive residual stress slows down, and the roughness reduction rate tends to saturate at approximately 79.3%. With increasing frequency, the surface compressive residual stress increases markedly, and the maximum compressive residual stress reaches -421.6 MPa. The surface roughness tends to stabilize after 30 Hz, although some fluctuations are still observed. The decrease in the stress concentration factor is the largest at 30 Hz. As the immersion depth increases, the compressive residual stress increases only slightly, while the roughness and stress concentration factor show little change.
The optimized process parameters are determined as follows: amplitude of 3.5 mm, frequency of 40 Hz, immersion depth of 40 mm, installation angle of 45°, and granular media diameter of 4 mm. Under these optimized parameters, the compressive residual stress on the specimen surface increases from -82.75 MPa to -438.73 MPa, the average surface roughness Ra value decreases from 0.837 μm to 0.189 μm, and the stress concentration factor decreases from 1.036 to 1.005.
Key words
vertical vibratory finishing /
surface roughness /
residual stress /
stress concentration factor /
titanium alloy /
discrete element method
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Funding
The National Natural Science Foundation of China (52575523, 52575527, 51975399); the Key Program of Tianjin Natural Science Foundation (25JCZDJC00800)
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