Research on high efficiency lapping process of cylindrical roller based on consolidated diamond abrasive tool

To solve the problem of low efficiency in the high precision grinding process of cylindrical roller, on the basis of double plane eccentric disc polishing method, the lapping method of cylindrical roller based on diamond consolidated abrasive tool is proposed.In order to study the influences of different diamond powder size code, ratio of sand to binder and slurry viscosity on the surface roughness, the material removal rate, the average roundness error and the batch diameter variation of cylindrical roller, the ultra precision lapping of cylindrical roller was carried out by using self-made diamond pellets attached to the upper and lower plates. The results show that the material removal rate and the surface roughness of cylindrical roller increase with the increase of diamond powder size code. If the ratio of sand to binder of diamond pellet is too large or too small, the material removal rate of cylindrical roller will decreases, and then the surface roughness will be affected. The proper viscosity of the lapping fluid can improve the lubrication performance and prevent large particles from scratching the surface of the workpiece. When the size code of diamond powder is M2/4, the pellet ratio of sand to binder is 1.6, and the viscosity of the lapping liquid is 5.380 mPa·s, the material removal rate of cylindrical roller is 1.70 μm/min, the surface roughness R_a decreases from 0.081 μm to 0.025 μm, the average roundness error decreases from 1.085 μm to 0.553 μm, the batch diameter variation R_DWL decreases from 6 μm to 2 μm, and the lapping efficiency and precision of cylindrical roller are significantly improved.