Buhrov D. Substantiation of parameters of equipment with an active processing element for combined vibratory finishing of complex-shaped parts

Taking into account current trends in the development of energy-efficient manufacturing, improving the energy efficiency of processing equipment has become an important scientific and engineering challenge. Vibratory abrasive finishing is a versatile method for the mass finishing of complex-shaped parts for which the use of machine tools with rigid kinematic links is impractical, particularly for deburring, flash removal, edge radiusing, and polishing. It has been established that only 1–5% of the total energy consumed during vibratory finishing is utilized for useful work, whereas in other machining processes this value typically ranges from 20% to 70%, indicating the high energy intensity of vibratory finishing. This is primarily caused by significant non-productive energy losses due to dissipative processes, including interactions between abrasive particles and between the particles and the walls of the working chamber. Therefore, reducing the energy intensity of the process by minimizing non-productive energy losses through the determination of rational equipment parameters is of considerable practical importance. Current studies of vibratory finishing do not comprehensively address all influencing factors; therefore, determining rational operating parameters of the equipment remains a relevant scientific and engineering problem that requires comprehensive investigations to establish the governing relationships of the process, improve existing equipment, and develop new design and technological solutions. The aim of this research is to improve the productivity and energy efficiency of the finishing process for complex-shaped parts by applying a combined vibratory abrasive finishing method using equipment with an active working body and by substantiating its rational operating conditions. The object of the research is the technological process of combined vibratory abrasive finishing of complex-shaped parts. The subject of the research is the relationships governing the influence of the operating parameters of equipment for combined vibratory abrasive finishing of complex-shaped parts on the productivity and energy efficiency of the technological process. The scientific novelty of the obtained results is as follows. For the first time: the application of a combined vibratory abrasive finishing method for complex-shaped parts has been substantiated as a means of improving the energy efficiency of the technological process; the relationships describing the influence of vibration amplitude, rotational speed of the active working body, and the mass of the processing media components on the productivity of the combined vibratory finishing process have been established; a quantitative indicator for evaluating the energy efficiency of combined vibratory equipment has been proposed, together with a methodology for its determination that accounts for both process productivity and energy consumption. The relationships between the energy efficiency, vibration amplitude, and rotational speed of the active working body have been established; the application of the energy efficiency indicator as a criterion for determining the rational operating parameters of equipment for combined vibratory abrasive finishing has been substantiated. Improved: the methodology for modelling the contact interaction between abrasive media and workpieces under the simultaneous action of vibration and rotational motion during combined vibratory finishing. The practical significance of the obtained results consists in: the development of a new engineering design of equipment with an active working body for implementing the combined vibratory finishing process of complex-shaped parts. The technical novelty of the proposed design has been confirmed by a Ukrainian utility model patent; the manufacture of an experimental installation for scientific investigations of equipment and processes of vibratory abrasive finishing of complex-shaped parts in the educational laboratory of the Department of Industrial Mechanical Engineering and Mechatronics at Yuri Kondratyuk National University "Poltava Polytechnic"; the further development of scientific and engineering principles for the design of combined-action vibratory abrasive machines, which can be applied in the design of new equipment and the modernization of existing machines. The results of the dissertation can be applied at mechanical engineering enterprises for the design, modernization, and operation of vibratory equipment intended for the finishing of parts, in research and design organizations engaged in the development of new vibratory technological machines and the improvement of vibratory abrasive finishing processes, as well as in higher education institutions for the education and training of students in mechanical engineering disciplines.