Vibratory finishing is widely used in mass-finishing of components. However, it is difficult to guarantee shape accuracy and predict surface roughness evolution. Here, a material removal model is proposed that is based on Preston's law and statistical overlapping of particle trajectories computed by Discrete Element Method (DEM). After validating DEM motion by particle image velocimetry and rope experiment, the occupancy ratio is studied as function of media type and mixing. Predictions of removal volume and surface roughness agree with experimental results within 12% on average, making this simulation method a very practical tool that reduces the need for extensive trial runs and barrel reloading.
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