Bulk mass flow in a vibratory finisher: mechanisms and effect of process parameters

Vibratory finishing is a widely-used manufacturing process in which a vibrating container filled with granular media becomes fluidized. The resulting bulk flow entrains workpieces and exposes their surfaces to the impacts resulting from the small-scale media vibrations. The bulk flow is responsible for entrainment and mixing, while the media vibration does work on the surfaces. The selection of machine vibration parameters is commonly based on experience due to the difficulty in predicting the fluidized bed behavior. In this work, a discrete element method was used to investigate how the bulk flow in an actual tub finisher filled with steel balls depends on the tub motion parameters through a parametric study. The underlying mechanisms that create and drive the bulk flow were identified by examining the relationships between the bulk flow rates and the wall forces. Finally, the connection between the wall motion and the wall forces was investigated. The tub frequency was the most effective control parameter and there was an optimal phase difference between the horizontal and vertical vibrations to maximize bulk flow. The relationship between the media packing at the walls and the tangential forces between the walls and the media explained the formation and speed of the bulk flow. Lastly, it was shown that the tangential wall forces, unlike the normal forces, cannot be obtained from the known wall motion alone since they also depend on the media velocities relative to the walls.