1. Material Preparation: Use seamless steel pipe for the roller body, 45mm round steel for the shaft, and Q235 steel plate for the end plates. Cut the material according to the dimensions shown in the drawing, leaving an 8mm machining allowance.
2. Machining: Machin the mating surfaces of the roller body, end plates, and shafts to H9/f9 fit precision.
3. Welding: Assemble the reinforcing ribs and end shafts within the roller body. Pay attention to correcting the coaxiality of the end shafts and the inner sleeve. Weld only the inner end plates on the shafts.
4. Insert the fully welded inner sleeve into the roller body. Weld the mating interface between the inner end plates and the roller body.
5. Mount the outer end plates onto the end shafts. Weld the mating interfaces between the outer end plates, the shafts, and the roller body.
6. Anneal the welded roller blank to eliminate internal stress.
7. Machine one end of the steel roller shaft flat and drill a standard center hole.
8. Turning: Rough and finish turn all parts of the steel roller body to the dimensions required by the drawing. The surface roughness of the roller body should not exceed 1.6μm; the radial runout tolerance of the roller's working surface to the two end shaft support surfaces (rolling bearing mounting locations) is 0.025mm; the roundness of the roller body's working surface is 0.036mm; the bearing mating circle is machined to k6 precision. Then, set up a center rest, turn the end faces, and drill holes to the required dimensions.
9. Machine the pattern according to the pattern requirements of the patterned steel roller. Then, plate a hard chrome layer with a thickness of 0.03~0.05mm.
10. Adjust the static balance of the steel roller.
