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<p>In mass finishing processes, the large number of granular media leads to low efficiency in discrete element method (DEM) simulations. Currently, common approaches such as GPU-accelerated computing, adjustment of simulation parameters, and coarse-grained methods exhibit respective advantages and limitations in terms of simulation cost and accuracy. Similarity theory has been employed to establish equivalent models for mass finishing processes. However, its primary objective lies in reducing experimental costs and simplifying process operations, rather than addressing the issue of simulation efficiency. To solve this problem, a construction method of gravity-size distortion equivalent model was proposed. Two specific distortion schemes were determined: enlarging the diameter of granular media and reducing the sizes of container and workpiece. The validity of the equivalent model was verified by DEM simulations and experimental tests, and the improvement degree in simulation efficiency was further analyzed. The results show that the equivalent model has favorable consistency with the real model under various vibration parameters. The scheme of enlarging granular media has higher prediction accuracy in velocity (96.66%) compared to the scheme of reducing the container and workpiece sizes (92.42%), whereas the latter yielded superior accuracy in predicting normal force. The average prediction accuracies of two distortion schemes are 83.62% and 90.13%, respectively. Furthermore, the gravity-size distortion equivalent model significantly enhances the computational efficiency of DEM simulations. The fundamental reason is that the equivalent model significantly reduces the number of granular media. When the number of granular media is identical, the two distortion schemes resulted in simulation efficiency improvements of 60.27% and 78.15%, respectively, with the scheme of reducing container and workpiece sizes demonstrating superior performance. This research provides a methodology for efficient DEM simulation and low-cost experimental research in mass finishing, thereby promoting process development. Additionally, it can also be extended to other discrete element fields.</p> Graphical abstract <p></p>

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A gravity-size distortion equivalent model of horizontal vibratory finishing process: analysis of similarity and simulation efficiency

  • 期刊论文

  • 发表日期：

    2025年12月2日

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  • Xuejie Wen,
  • Wenhui Li,
  • Xiuhong Li,
  • Jiaming Wang,
  • Lijun Cheng

摘要

In mass finishing processes, the large number of granular media leads to low efficiency in discrete element method (DEM) simulations. Currently, common approaches such as GPU-accelerated computing, adjustment of simulation parameters, and coarse-grained methods exhibit respective advantages and limitations in terms of simulation cost and accuracy. Similarity theory has been employed to establish equivalent models for mass finishing processes. However, its primary objective lies in reducing experimental costs and simplifying process operations, rather than addressing the issue of simulation efficiency. To solve this problem, a construction method of gravity-size distortion equivalent model was proposed. Two specific distortion schemes were determined: enlarging the diameter of granular media and reducing the sizes of container and workpiece. The validity of the equivalent model was verified by DEM simulations and experimental tests, and the improvement degree in simulation efficiency was further analyzed. The results show that the equivalent model has favorable consistency with the real model under various vibration parameters. The scheme of enlarging granular media has higher prediction accuracy in velocity (96.66%) compared to the scheme of reducing the container and workpiece sizes (92.42%), whereas the latter yielded superior accuracy in predicting normal force. The average prediction accuracies of two distortion schemes are 83.62% and 90.13%, respectively. Furthermore, the gravity-size distortion equivalent model significantly enhances the computational efficiency of DEM simulations. The fundamental reason is that the equivalent model significantly reduces the number of granular media. When the number of granular media is identical, the two distortion schemes resulted in simulation efficiency improvements of 60.27% and 78.15%, respectively, with the scheme of reducing container and workpiece sizes demonstrating superior performance. This research provides a methodology for efficient DEM simulation and low-cost experimental research in mass finishing, thereby promoting process development. Additionally, it can also be extended to other discrete element fields.

Graphical abstract