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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 2470/1e
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Plastic Forming of Top Layer
...for a smooth operation ECOROLL Plastic Forming of Top Layer workpiece rolling force roller 2470/1e
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Plastic Forming of Top Layer
...for a smooth operation ECOROLL Plastic Forming of Top Layer roller rotation feed workpiece rotation 2470/1e
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Levelling of Surface Profile
...for a smooth operation ECOROLL Levelling of Surface Profile pre-operation surface roller burnished 2470/1e
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Advantages of Roller Burnished Surface
...for a smooth operation ECOROLL 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 2470/1e
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...for a smooth operation ECOROLL
Process Limits 2470/1e
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Compressive Stress in Top Layer
...for a smooth operation ECOROLL Compressive Stress in Top Layer Compressive stress characteristic HG6 / hardened steel 600 HV shot peened Compressive stress [Mpa] Depth [µm] 2470/1e
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...for a smooth operation ECOROLL
Process Comparison 2470/1e
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Deep Rolling versus Shot Peening
... for a smooth operation ECOROLL 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 2470/1e
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Economical Aspects of Deep Rolling
... for a smooth operation ECOROLL 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 2470/1e
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Multi Roller Tools G: Bores RA: O.D.‘s
...for a smooth operation ECOROLL Multi Roller Tools G: Bores RA: O.D.‘s 2470/1e
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Single Roller Tools EG14 EG5 EGi5-32 EGI-xxF
...for a smooth operation ECOROLL Single Roller Tools EG EG5 EGi EGI-xxF 2470/1e
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Hydrostatic tools „ballpoint“ HG
...for a smooth operation ECOROLL Hydrostatic tools „ballpoint“ HG 2470/1e
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Hydrostatic Tool HG6-5 with Integrated Pump
...for a smooth operation ECOROLL Hydrostatic Tool HG6-5 with Integrated Pump 2470/1e
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Production Costs over Roughness
...for a smooth operation ECOROLL Production Costs over Roughness super finish, lapping honing Manufacturing costs grinding turning roller burnishing Roughness 2470/1e
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Cost Reduction by Roller Burnishing
...for a smooth operation ECOROLL 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 2470/1e
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Roller Burnishing Rz < 10µm
...for a smooth operation ECOROLL 10-G Stratetgy Roller Burnishing Rz < 10µm 2470/1e
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Economical Aspects of Deep Rolling
... for a smooth operation ECOROLL 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 2470/1e
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Environmental Aspects of
...for a smooth operation ECOROLL Environmental Aspects of Roller Burnishing No material removal no dust or mud low energy consumption little coolant required low noise 2470/1e
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Bearing and Seal Surfaces
...for a smooth operation ECOROLL Roller Burnishing of Bearing and Seal Surfaces Tool type G for bores EG5 for bearing seats and seal surfaces 2470/1e
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Application Example Differential Gear
...for a smooth operation ECOROLL Application Example Differential Gear Process time 4 s Pressure bar 2470/1e
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Application Example Hydraulic Cylinders
...for a smooth operation ECOROLL Application Example Hydraulic Cylinders Skive Burnishing Tool RDZ for cylinder Tubes Roller Burnishing of Piston Rod with EG14 2470/1e
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Large Bore (Bearing Housing)
...for a smooth operation ECOROLL Application Example Large Bore (Bearing Housing) Speed RPM Feed rate 0,4 mm/rev. Process time min 2470/1e
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Application Example Flexible Shaft
...for a smooth operation ECOROLL Application Example Flexible Shaft Speed m/min Feed rate ,3 mm/rev. Pressure bar 2470/1e
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Wöhlerdiagram Flexible Shaft
...for a smooth operation ECOROLL Wöhlerdiagram Flexible Shaft deep rolled with HG6 hand polished turned 2470/1e
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