Experimental study on double disc straight groove lapping of cylindrical rollers

This paper presents a study on the double disc straight groove lapping (DDSGL) process for cylindrical rollers. The motion characteristics of cylindrical rollers during DDSGL were analyzed, and a theoretical model for predicting the surface roughness of the ground rollers was established. The revised surface roughness model demonstrated good agreement with experimental data, with a relative error of less than 15%. Experimental investigations were conducted to determine the influence of lapping parameters on the roundness error and surface roughness of cylindrical rollers. The findings indicate that increasing the lapping load and lapping disc speed significantly improves the reduction efficiency of roundness error, with higher loads yielding lower stabilized error values. In contrast, variations in lapping fluid abrasive concentration and abrasive grit size have minimal impact on the reduction efficiency of roundness error. For surface roughness, abrasive grit size exerts the strongest influence, followed by lapping load, abrasive concentration, and lapping disc speed. Notably, increasing the lapping disc speed markedly accelerates the reduction of surface roughness, thereby enhancing overall process efficiency. After processing via DDSGL, the roundness error of the cylindrical roller rolling surface can be reduced to 0.23 μm, and the surface roughness can reach 0.027 μm, achieving a mirror-like surface quality. These results demonstrate the significant potential of DDSGL for achieving ultra-precision machining of cylindrical rollers and provide crucial insights for optimizing the DDSGL process to enhance efficiency and surface quality.