Numerical modeling of the edge rounding of brittle materials by vibratory finishing

The paper presents a numerical model of the edge rounding of brittle materials during vibratory finishing. The material removal in this process is dominated by small-scale edge chipping where the abrasive particles protruding from the impacting media indent the surface asperities of the wear zone producing chips of the order of 10 μm in length. The model predicts the evolution of the edge profile by applying random indentations to the edge, evaluating the possibility of chip formation, and modifying the edge profile accordingly. The model predictions of the change in edge shape with processing time agreed quite well with experimental results for borosilicate glass edges having initial chamfer angles of 105°, 120°, and 135°. The model was used to identify the effect of edge angle and the distribution of impact forces on edge wear and the resulting surface micro-topography.