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...for a smooth operation ECOROLL. Saving Manufacturing Costs by Roller Burnishing and Deep Rolling (Presentation 2470/1e). 1. Introduction. 2. Processes. 3. Tools. 4. Cost Reduction. 5. Environmental Aspects. 6. Application Examples. ...for a smooth operation ECOROLL.

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for a smooth operation ecoroll
...for a smooth operation ECOROLL

Saving Manufacturing Costs

by Roller Burnishing and Deep Rolling

(Presentation 2470/1e)

1. Introduction

2. Processes

3. Tools

4. Cost Reduction

5. Environmental Aspects

6. Application Examples

2470/1e

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Plastic Forming of Top Layer

workpiece

rolling force

roller

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Plastic Forming of Top Layer

roller

rotation

feed

workpiece

rotation

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Levelling of Surface Profile

pre-operation

surface

roller burnished

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Advantages of Roller Burnished Surface

  • Low rouhgness
  • High surface contact area
  • Soft profile transitions
  • No profile peaks, shallow pits only
  • Hardness increase
  • Better sliding properties
  • Less wear
  • Less galling and seizing

2470/1e

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...for a smooth operation ECOROLL

Advantages of the Burnishing Process

  • Short process time
  • Applicable on virtually all machine tools
  • Finishing in onre setting
  • No material removal
  • No wear of bearings ans slide ways
  • Easy process controll
  • Little lubrication required
  • Low noise
  • Long lasting tools
  • No dimensional change by tool wear

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Compressive Stress in Top Layer

Compressive stress characteristic

HG6 / hardened steel 600 HV

shot peened

Compressive stress [Mpa]

Depth [µm]

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Process Comparison

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Deep Rolling versus Shot Peening

Deep Rolling

+ Deeper penetration

+ Compressive stress depends on load F

+ F hydraulic or spring controlled

+ Easy operation and reproduction

+ Fast

+ In one setting after cutting

+ Access to bores and cavities

+ Applicable on all machine tools

- Predominantly for regular shapes

Shot peening

+ Good for irregular shapes

- Small grains

- Irregular in shape and size

- Rough surface

- Compressive stress depends on impact and coverage

- Influenced by 12 parameters

- Difficult to reproduce

- Special equipment required

- Only to handle by specialists

- Time consuming

- high transport costs

- Long lead time

- Difficult in cavities

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Economical Aspects of Deep Rolling

  • Weight reduction
  • saving material
  • elimination of heat treatment
  • elimination of transports
  • shorter lead time
  • faster cash flow
  • less investment
  • less energy consumption
  • less workshop space required

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Multi Roller Tools

G: Bores

RA: O.D.‘s

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Single Roller Tools

EG14 EG5

EGi5-32 EGI-xxF

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Hydrostatic tools „ballpoint“ HG

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Hydrostatic Tool HG6-5

with Integrated Pump

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Production Costs over Roughness

super finish,

lapping

honing

Manufacturing costs

grinding

turning

roller burnishing

Roughness

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Cost Reduction by Roller Burnishing

  • Process time
  • handling (by complete finishing)
  • short lead time
  • less capital bound in WIP
  • no waste disposal costs
  • no costs for personnal protection
  • (for noise, dust, fumes)
  • low energy costs

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10-G Stratetgy

Roller Burnishing Rz < 10µm

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Economical Aspects of Deep Rolling

  • Weight reduction
  • saving material
  • elimination of heat treatment
  • elimination of transports
  • shorter lead time
  • faster cash flow
  • less investment
  • less energy consumption
  • less workshop space required

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Environmental Aspects of

Roller Burnishing

  • No material removal
  • no dust or mud
  • low energy consumption
  • little coolant required
  • low noise

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Roller Burnishing of

Bearing and Seal Surfaces

Tool type G for bores

EG5 for bearing seats and seal surfaces

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Application Example

Differential Gear

Process time 4 s

Pressure 150 bar

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Application Example

Hydraulic Cylinders

Skive Burnishing Tool RDZ for cylinder Tubes

Roller Burnishing of Piston Rod with EG14

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Application Example

Large Bore (Bearing Housing)

Speed 18 RPM

Feed rate 0,4 mm/rev.

Process time 62 min

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Application Example

Flexible Shaft

Speed 100 m/min

Feed rate 0,3 mm/rev.

Pressure 350 bar

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Wöhlerdiagram

Flexible Shaft

deep rolled with HG6

hand polished

turned

2470/1e