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<p>Thermally sprayed WC-10Co-4Cr coatings are widely used to enhance the wear resistance of spherical plain bearing inner rings. However, their finishing is challenging owing to the material’s heterogeneous microstructure and the component’s complex convex spherical geometry. To address this issue, this paper proposes a novel ring-shaped bonnet polishing (RSBP) method. A theoretical roughness model based on micro-cutting mechanics and surface micro-topography assumption was established and validated, achieving an average relative error of 18.36%. Experimental results demonstrate that RSBP achieves superior surface quality (Ra 0.01&#xa0;μm) and form accuracy (roundness error 0.8443&#xa0;μm), alongside improved micro-homogeneity by reducing interphase height differences by approximately 71.5%. Furthermore, life testing under low-speed and heavy-load conditions reveals that RSBP-processed bearings exhibit a Polytetrafluoroethylene (PTFE) fiber wear thickness of merely 0.07&#xa0;mm after 50,000 cycles, substantially below the 0.11&#xa0;mm failure threshold. This represents a service life extension of over 170% compared to conventionally finished bearings. This work demonstrates RSBP as a deterministic finishing process to achieving ultra-precision coating quality and extended spherical plain bearing service life.</p>

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Achieving ultra-precision finishing of WC-10Co-4Cr coating and life extension of spherical plain bearings through ring-shaped bonnet polishing process

  • 期刊论文

  • 发表日期：

    2026年6月29日

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  • Zhenyu Jiang,
  • Chen Jiang,
  • Lingqi Wang,
  • Xiongrong Huang,
  • Ruonan Shao,
  • Hui Ye

摘要

Thermally sprayed WC-10Co-4Cr coatings are widely used to enhance the wear resistance of spherical plain bearing inner rings. However, their finishing is challenging owing to the material’s heterogeneous microstructure and the component’s complex convex spherical geometry. To address this issue, this paper proposes a novel ring-shaped bonnet polishing (RSBP) method. A theoretical roughness model based on micro-cutting mechanics and surface micro-topography assumption was established and validated, achieving an average relative error of 18.36%. Experimental results demonstrate that RSBP achieves superior surface quality (Ra 0.01 μm) and form accuracy (roundness error 0.8443 μm), alongside improved micro-homogeneity by reducing interphase height differences by approximately 71.5%. Furthermore, life testing under low-speed and heavy-load conditions reveals that RSBP-processed bearings exhibit a Polytetrafluoroethylene (PTFE) fiber wear thickness of merely 0.07 mm after 50,000 cycles, substantially below the 0.11 mm failure threshold. This represents a service life extension of over 170% compared to conventionally finished bearings. This work demonstrates RSBP as a deterministic finishing process to achieving ultra-precision coating quality and extended spherical plain bearing service life.