Control of the Finishing Zone by Roller Geometry and Compliance in a Dual-Roller Superfinishing Attachment

This study describes the design and analysis of a dual-roller superfinishing attachment for the abrasive-film microfinishing process, where two independently mounted compliant conical rollers make contact with separate zones of the abrasive film in order to manage the geometry of the contact zone. In this regard, the geometry-related simulation based on a 3D SolidWorks 2022 model was carried out to analyze the effects of the vertical shift of the contact-zone center point, h = 1–4 mm, and horizontal deformation of the abrasive film, δx = 0.1–0.5 mm. Under each setting, the contact area, Ac, the geometric interference volume, Vint, and the characteristic contact-zone length, lc, were evaluated. Increasing the value of δx from 0.1 mm to 0.5 mm resulted in the growth of the average Ac by 2.27 times, increasing from 79.42 mm2 to 180.41 mm2, and Vint by 11.4 times, growing from 5.26 mm3 to 59.94 mm3. The effect of h on Ac is relatively small, which means that h mostly affects the positioning of the contact zone, and δx controls its size and geometric interactions.