Optimizing Size Consistency in Batch Roller Production: A Mixed Strategy Approach

Abstract

The Double-Disk Straight Groove Lapping (DDSGL) technique, a novel approach to batch processing of bearing rollers, achieves high dimensional consistency by removing material through size comparison between multiple rollers in the processing area. To avoid collision between the rollers, the prevalent practice in DDSGL involves circulating the rollers in fixed linear sequences, an approach that impedes comprehensive size comparison throughout the entire batch of rollers. To counter this, we introduce a Dual-Channel Mixing Scheduling (DCMS) strategy that disrupts the roller sequence without triggering collisions. This strategy promotes extensive size comparison and enhances batch size consistency. To elucidate the operational principles of DCMS, we have developed a computational model grounded in DDSGL, designed simulation test plans under different mixing parameters, and summarized the number of direct comparisons, total comparisons, and differences in roller cycle times to determine the optimal combination of mixing parameters. Finally, structural modifications were made in the DDSGL system for validation studies under different mixing parameters. The test results show that the use of DCHS can reduce processing time by up to 50%, and the batch diameter change of the rollers can converge from 1.15 μm to as low as 0.76 μm. The industrial relevance of this research is significant; these improvements can lead to higher efficiency in the manufacturing process and improved quality of bearing rollers.