Effects of Pressure Rollers with Variable Compliance in the Microfinishing Process Utilizing Abrasive Films

This article presents a comprehensive investigation into pressure rollers utilized in the microfinishing process, covering aspects such as design, experimental properties, compliance, and finite element simulation. Prototype pressure rollers with unconventional elastomer configurations were designed and analyzed to explore their effectiveness in achieving superior surface finishes. Experimental analysis and finite element simulations were conducted to gain insights into the performance and behavior of these pressure rollers under various loading conditions. This study addresses the validation of constitutive material models used in finite element simulations to ensure accuracy and reliability. The results indicate that the applied material model, validated through experimental analysis, accurately predicts pressure roller behavior. Finite element simulations reveal distinct contact zone patterns and stress distributions across the contact surfaces, highlighting the importance of considering deflection-induced variations in contact behavior. Additionally, the investigation evaluates the effectiveness of different pressure rollers in removing surface irregularities during the microfinishing process. Roller R3 demonstrates the highest efficacy in removing surface peaks, suggesting its potential for achieving superior surface finishes. Overall, this research contributes to the advancement of microfinishing techniques by providing insights into pressure roller design, performance, and behavior, thereby optimizing microfinishing processes to produce high-quality components. The urgency of this study arises from the growing need for exceptional surface finishes in various industrial sectors. With manufacturing industries increasingly pursuing high-precision components boasting flawless surface quality, the significance of microfinishing processes is highlighted.