Calculation of high-duty cold reduction rollers grinding cycles based on radial force cycle optimization

Abstract

Currently, the grinding operation of fabrication mill rollers through the use of fine-grained wheels is the most progressive method of finishing, because it saves from labor-intensive finishing processes in the technological cycle allowing to get a desired accuracy of the size, shape, surface roughness, physical and mechanical properties of the work material along with the reduction of manufacturing content. Considering that grinding rate of fine-grained wheels increases with an depth-of-cut increase in a single grain, the method of calculating grinding cycles by radial force for finishing of cold reduction rollers using fine-grained abrasive wheels is viewed. The calculation was carried out, and the optimal modes of a high-performance grinding cycle of parts made of steel 9X2, 55...60 HRC, wheels 1-400x50x203 63C M14 CM 8B with a change in the radial component of the cutting force at the cycle stages were determined. For experimental verification of the calculated cycle, grinding samples d×l = 65×250 mm at a constant radial force corresponding to a given surface roughness and with a change in radial force were tested. Radial grinding force was set by technological system tightness and maintained by a device for registering a radial force within each run. During the experiments, the following measurements: removal of metal to diameter with a lever bracket; surface roughness parameters on a profilometer-profilograph mod. 201 were carried out. The conducted tests proved the effectiveness of design cycles with a change in radial force. When using the proposed cycles, a given surface roughness is provided, while the productivity of the operation increases by 2,0 – 2,5 times.