Experimental Study of Both-Sides Cylindrical Roller Machining Based on Ceramic Plate

Abstract

In order to improve the accuracy and batch consistency of cylindrical roller machining, in this paper, a both-sides cylindrical roller machining method based on hard ceramic plate is proposed. Traditional cast iron and stainless-steel polishing plate were replaced by ceramic materials with high hardness and good wear resistance. After processing by centerless grinding, the cylindrical roller is processed by both-sides lapping and polishing using Al2O3 ceramic plates. The roundness, diameter and surface quality of the roller and the wear of the ceramic plate before and after machining were compared and analyzed in order to evaluate the feasibility and effectiveness of this method. After grinding for 1 h and polishing for 8 h, the average roundness of the cylindrical rollers decreased from the initial 2.3 μm to 0.32 μm, while the roundness of each roller tended to be the same. At the same time, the batch diameter deviation of cylindrical rollers was reduced from 3 μm to 1 μm, and the batch consistency was satisfactory. The machining marks produced by centerless grinding on the roller surface were completely removed, and the surface quality was significantly improved. The surface roughness after polishing reached Ra 16 nm. The upper and lower ceramic plate had certain wear, but the amount was small, having little impact on the machining results. The shape accuracy and batch consistency of the rollers after machining were satisfactory. The ceramic plate had high hardness, good wear resistance and small wear in the machining process. Additionally, it could maintain extremely high flatness for a long time. Using hard ceramic plates to process cylindrical rollers, high precision and high consistency cylindrical rollers can be obtained after machining.