In the rounding sampling operation for large-angle chamfering of 20mm carbon steel material using the LANUSS LSP-L1350 equipment, the ceramic roller brush serves as the core execution component. It directly determines chamfering precision, surface quality and processing efficiency, and its performance advantages are particularly prominent in high-strength carbon steel processing scenarios.
I. Material Characteristics of Ceramic Roller Brushes: Tailored for High-Strength Carbon Steel Processing Requirements
Ultra-Hard and Wear-Resistant Ceramic Matrix
The core working layer of the roller brush is made of 99% high-purity alumina ceramic, with a Vickers hardness reaching HV1600-1800—far exceeding the hardness range of carbon steel (HV200-300). When contacting and chamfering 20mm-thick carbon steel, the ceramic bristles are resistant to wear, deformation or curling. The bristle wear loss after a single sampling operation is less than 0.02mm, enabling continuous completion of over 500 chamfering operations for carbon steel of the same specification. Its service life is 3-5 times longer than that of traditional silicon carbide roller brushes.
High Temperature Resistance and Chemical Stability
Ceramic materials exhibit excellent high temperature resistance. They can maintain structural stability even under frictional heat generated during high-speed processing (local temperature up to 150-200℃), without causing chamfer radius deviation due to high-temperature softening. Meanwhile, the dense and non-porous ceramic surface prevents adhesion of iron filings and cutting fluid produced in carbon steel processing, effectively avoiding roller brush corrosion or impurity accumulation, and ensuring surface consistency for each sampling operation.
II. Structural Design of Ceramic Roller Brushes: Precisely Matched for Large-Angle Processing Requirements
Gradient Bristle Arrangement Structure
To meet the arc transition requirements of R3 large-angle chamfering, the ceramic roller brush adopts a spiral gradient bristle arrangement. The bristle length decreases stepwise from the center to the edge, forming a processing surface that perfectly fits the R3 arc. When contacting the carbon steel edge, it achieves gradual grinding from acute angle to arc, avoiding the problem of over-grinding at both ends or under-grinding in the middle of the arc caused by uniform bristle length in traditional roller brushes. The chamfering precision can be controlled within ±0.05mm.
Elastic Buffer Substrate Design
The bottom of the ceramic bristles is compounded with a polyurethane elastic substrate, with a compression rebound rate of 30%-50%. When processing 20mm carbon steel, it can adapt to minor flatness deviations on the material surface, ensuring uniform contact pressure between the roller brush and the workpiece. This prevents surface depression or chamfer dimension deviation of carbon steel caused by excessive local pressure, while reducing vibration noise during equipment operation and lowering mechanical wear.
III. Processing Compatibility with LSP-L1350 Equipment: Ensuring Sampling Efficiency and Quality
High Rotational Speed Compatibility
The spindle speed of the LSP-L1350 equipment can reach 1500-3000r/min. The high-strength ceramic matrix of the roller brush can withstand centrifugal force under high rotational speed without risk of fracture or deformation. Compared with traditional resin-bonded abrasives, the cutting efficiency of the ceramic roller brush is improved by more than 40% at high rotational speed. The R3 chamfering process for 20mm carbon steel can be completed within 15-20 seconds, significantly shortening the sampling cycle.
Chip Removal and Cooling Optimization
The bristles of the ceramic roller brush feature a rhombic cross-section design, forming V-shaped chip removal channels between adjacent bristles. These channels can quickly discharge carbon steel debris during processing, avoiding chamfer surface scratches or roller brush clogging caused by iron filings accumulation. Meanwhile, the roller brush matrix integrates a spiral cooling water channel inside, which can be linked with the equipment cooling system to control the temperature of the processing area below 80℃. This prevents carbon steel from oxidation discoloration due to high temperature and ensures the surface finish of sampling parts (Ra≤0.8μm).
