The double-disk arc-contact lapping (DDACL) method is a novel for precision machining of the rolling surface of cylindrical roller. The contact characteristics of DDACL process can affect the lapping quality of the bearing roller. However, there is a limited amount of study on the contact theory of DDACL. Therefore, the objective of this research is to create a semi-analytical modeling approach that can effectively and accurately forecast the contact characteristics of DDACL. In the initial step, the spatial coordinate transformation was employed to establish accurate mathematical models that represents the surfaces of the cylindrical roller and arc groove. Subsequently, the potential contact area was determined and subdivided into discrete elements based on the differential geometry principles. The accurate flexibility of the potential contact area is achieved by utilizing the interpolation theory and considering both the global and local deformations of the roller and groove. By employing the influence coefficient method and the force-deformation coordination relation, the deformation and contact force can be calculated. Finally, the accuracy and efficiency of this calculation is confirmed through a comparison between the finite element method (FEM) and the proposed method.
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