Effect of strong flexible polycrystalline diamond abrasive tools in magnetic abrasive finishing of V-grooved ceramic guide rollers

Abstract

The V-grooved ceramic guide roller, employed in textile cable machines, wire drawing machines, and copper wire guiding machines, is one of the most critical components used in the winding industry. The components used in this industry must have specific properties, such as an ultra-smooth surface and high-precision roundness, to reduce wear and friction. However, achieving both a high-precision roundness and a smooth surface with general machining processes is extremely difficult due to the high degree of hardness and inherent brittleness of ceramic rollers with a complex V-grooved shape. In this work, a novel device for magnetic abrasive finishing (MAF) process was designed to smooth the V-grooved surface of ceramic guide rollers. In addition, the strong flexible polycrystalline diamond (PCD) abrasive tools were used to achieve a high level of precision and accuracy during the MAF process. It was found that a newly developed experimental device of MAF process using strong flexible PCD abrasive tools could produce a V-grooved ceramic guide roller with a low surface roughness (Ra) of 0.03 µm and a high-precision roundness of 0.33 µm after 8 min of finishing.