Analysis and experimental study on the contact characteristics of spherical roller ring groove lapping based on finite line contact theory

Abstract

Analyzing the contact characteristics of spherical rollers during lapping is crucial for understanding the formation mechanism of their rolling surfaces in ring groove lapping processes. Based on the contact line characteristics between spherical rollers and lapping tools in ring-shaped straight groove machining, this paper uses finite-length contact theory based on the influence coefficient method to solve the contact stress distribution between spherical rollers and lapping surfaces. The accuracy of the solution is verified through finite element simulations. This paper analyzes the contact stress distribution under load between spherical rollers and lapping surfaces of various sizes, and discusses the influence of load and roller size on contact characteristics. Spherical roller ring-and-slot lapping experiments were conducted, and the rationality and accuracy of the contact model were verified by analyzing the experimental results of surface morphology and roundness changes. Research shows that the contact area between the roller rolling surface and the linear groove working surface forms a “saddle surface,” while the contact area with the circular groove forms a “cross-shaped” surface, with significant stress concentration at the roller ends. Increasing load results in proportional growth of contact area and deformation. Both the cross-sectional and axial cross-sectional radii of spherical rollers directly govern contact stress distribution. Regions with elevated contact stress during grinding exhibit accentuated wear, accompanied by intensified roundness variations and diameter deviations. This contact theory model can serve as a theoretical basis for analyzing the accuracy evolution of bearing rollers in ring-and-slot lapping processes and predicting wear on lapping tool surfaces.