Modeling and test verification of variable cross-section contact behavior for spherical rollers during lapping process

Curved surface contact is widely used in the industry of bearing roller machining and shaft-hole connection, but there is no universal model to describe it. In order to study the contact problem between the spherical roller and the lapping sleeve, the existing cylindrical contact models were firstly compared and applied to the contact problem using slicing method, and a hybrid contact model was established. Based on Winkler's elastic foundation theory, a variable cross-section contact model was established and its analytical expression was obtained. Since the new model has no elastic half-space assumption, it can be used to solve conformal contact and non-conformal contact problems. Finally, the finite-element simulation results and the lapping test results show that compared with the hybrid contact model, the variable cross-section contact model can more accurately describe the static contact characteristics between the spherical roller and the lapping sleeve, and can provide a theoretical reference for roller machining and coordinated deformation of shaft-hole.