Low pressure test of high pre machining finish of steerable diamond rolling cutter

The customer processes the outer circle of d35.4, the processing length is 15mm, the material is 35# steel, and the hardness is about 30 degrees. Required finish rz3.2 (Ra0.4)

Demand: finish turning can actually meet the requirements of finish, but due to the instability of finish turning, the tool often needs to be changed, so a rolling process needs to be added to make the finish of the workpiece more stable.

Diamond rolling cutter model: DIA-TU180-R1.0-25*25 blue spring (medium elastic force)

Parameters before commissioning: rotational speed 1300, feed 0.07, press in amount 2 wires on one side.

The processed cutter pattern is obvious, the brightness is slightly improved, and the cutter pattern is still obvious after debugging for many times. The finish turning of the previous process can reach rz2.3 (about ra0.3). At present, the finish can be improved to more than RZ1 after rolling, but the surface texture is rougher than that of finish turning, which looks obvious to the naked eye.

Initial solution: tighten the screw for half a turn, keep the pressing amount unchanged, and use oil if conditions permit. The effect is still not ideal.

At present, the customer has processed 2000 ball joints, which are worn. The rolling effect of these 2000 pieces is unstable and basically guaranteed by fine turning, so the cutter is often changed

Final solution:
The spring is replaced with yellow (light spring). The conventional elastic screw is screwed to the flat position and then loosened by one turn.

The speed feed remains unchanged, and the single side rolling amount is 1 wire.
Test results, customer satisfaction, stable service life! The renderings are as follows:

Scheme summary: there are usually two schemes to achieve extrusion effect: A. use heavy elastic force + small interference; B. Use light elastic force + slightly larger interference.

Through comparative analysis, it is found that scheme B is better, because the diamond head of diamond rolling cutter is usually r1.5 or R1.0, with small contact area and large pressure. The use of heavy elastic force is easy to accelerate the wear of drill stone. The use of light elastic force can process the finish required by customers, with less wear and longer service life.