Considering the poor accessibility of the current finishing process for parts with complicated geometries, a novel bidirectional composite vibratory finishing (BCVF) approach was proposed, which combined the power actions on abrasive particles and processed workpieces. To examine the feasibility and effectiveness of the BCVF approach, comparative simulations based on discrete element method (DEM) and experimental validation were performed on a cylindrical workpiece simplified by a gear. Moreover, the effects of container size (or wall effects), media amount, workpiece position, and vibration parameters (including vibration amplitude and frequency) on the media-component interaction were systematically studied by DEM. The results show that the BCVF had the highest polishing efficiency, resulting in a workpiece surface roughness reduction rate up to 57% within 15 min. The distance between the container wall and the workpiece surface along the container width direction can be reduced to 4d (d is the abrasive particle diameter) with little effect on the finishing effect. Meanwhile, with the enhancing one-dimensional horizontal vibration, particle impact and shear effects are subsequently strengthened. In contrast, the media amount above the workpiece and the vibration along the workpiece axial direction are mainly effective for the shear effect. This BCVF approach provides reference for the finishing of various complex-shaped components including gears.

考虑到当前对复杂几何形状零件的精加工工艺的可及性差，提出了一种新型的双向复合振动精加工（BCVF）方法，该方法将磨粒和加工工件的动力作用结合起来。为检验 BCVF 方法的可行性和有效性，对由齿轮简化的圆柱形工件进行了基于离散元法 (DEM) 的比较模拟和实验验证。此外，通过 DEM 系统研究了容器尺寸（或壁效应）、介质量、工件位置和振动参数（包括振幅和频率）对介质-组件相互作用的影响。结果表明BCVF的抛光效率最高，15分钟内工件表面粗糙度降低率高达57%。沿容器宽度方向容器壁与工件表面的距离可减小至4d（d为磨料粒径）对光洁度影响不大。同时，随着一维水平振动的增强，粒子撞击和剪切效应随之增强。相比之下，工件上方的介质量和沿工件轴向的振动主要对剪切作用有效。这种BCVF方法为包括齿轮在内的各种复杂形状零件的精加工提供了参考。