High precision and consistent machining of cylindrical rollers using ceramic lapping plates with both-sides machining method

To address the issue of rapid wear and loss of shape accuracy in traditional both-sides lapping plates, which limits the further application of both-sides machining for high-precision cylindrical rollers, an extremely high precision and consistent machining method for both-sides cylindrical rollers using ceramic lapping plate is proposed. The principles of shape accuracy and consistency correction for rollers were analyzed, and the motion dynamics of the rollers during machining were simulated. Additionally, the impact of machining trajectory distribution uniformity was clarified. Machining experiments were also carried out, with deformation, wear, and machining accuracy used as evaluation criteria. Results demonstrated that silicon carbide (SiC) ceramics exhibited superior wear resistance and machining performance. Optimal process parameters and their influence weights for SiC plate were identified through orthogonal experiments, revealing that the shape of the lapping plate significantly affects the rollers' shape accuracy. The optimal processing parameters were found to be: an upper plate load of 8 kg, a lower plate speed of 90 rpm, and a lapping plate flatness of 0.3 μm. Under these conditions, the average roundness of the rollers was 0.125 μm, cylindricity was 0.347 μm, generatrix straightness was 0.372 μm, and surface roughness was 6.2 nm. This method achieves extremely high precision and consistency in cylindrical rollers machining, offering a new technical approach for ultra-precision machining of cylindrical rollers.