Abstract
The surface quality and accuracy of the geometry of the cylindrical rollers are important factors for bearing life. This paper presents effects of machining parameters on the surface roughness, topography and roundness of cylindrical rollers through the lapping and polishing experiments. And then the surface roughness of the cylindrical rollers is optimized. The results found that the surface roughness of rollers is significantly changed in lapping process with different abrasive particle sizes, while the surface roughness has slightly reduced in polishing process. It also indicated that the smoother surfaces with better roughness can be obtained after lapping and polishing process. In addition, the surface roughness of cylindrical rollers is rapidly reduced from Ra of 0.5 µm to Ra of 0.063 µm after the 3-h lapping process and Ra of 0.013 µm after the 1-h polishing process. The surface topography of rollers can be achieved by the smoother surface when loads are from 25 to 35 N in lapping process, and the loads are from 35 to 40 N in polishing process. Finally, the Taguchi method is applied to optimize the surface roughness in polishing process. The result found that the optimal surface roughness achieves 0.015 µm with respect to the time of 35 min and type of 4000# Al2O3.
Highlights
Cylindrical rollers are popular parts in mechanical equipment and machinery, electric motors, motorcycles and gearboxes
The cylindrical rollers were lapped on the double-side lapping machine to reach the required surface quality before entering the polishing process
In order to explore the effect of abrasive sizes, different types of 800# SiC, 1200# SiC and 2000# SiC abrasive were chosen for the experimentations
Summary
Cylindrical rollers are popular parts in mechanical equipment and machinery, electric motors, motorcycles and gearboxes. The surface quality and profile accuracy of the workpiece were significantly improved by using those machining techniques.[4,5,6] In order to improve the surface quality of the cylindrical rollers, the influences of rotation of the roller, lapping plate, load, abrasive concentrate and abrasive size were studied.[7,8,9,10] Experimental results showed that the roundness is achieved in the range of 0.91 mm, and the surface roughness in the range of 0.1 mm.[11,12,13] Besides, electro-chemical mechanical polishing method (e-CMP) was applied to polish the crown cylindrical rollers. It revealed that the surface roughness and roundness of rollers are reduced less than 0.023 and 0.39 mm.[14,15] the surface quality of workpieces was extremely achieved the flat and smooth surface via using CMP technique.[16,17,18,19] By using CMP method, the influents of chemical and the mechanical properties on the material removal process were studied.[20,21] In addition, the contact process and machining trajectory of cylindrical rollers with lapping plate were simulated
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