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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 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
...for a smooth operation ECOROLL Plastic Forming of Top Layer workpiece rolling force roller 2470/1e
...for a smooth operation ECOROLL Plastic Forming of Top Layer roller rotation feed workpiece rotation 2470/1e
...for a smooth operation ECOROLL Levelling of Surface Profile pre-operation surface roller burnished 2470/1e
...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
...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
...for a smooth operation ECOROLL Process Limits 2470/1e
...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
...for a smooth operation ECOROLL Process Comparison 2470/1e
... 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
... 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
...for a smooth operation ECOROLL Multi Roller Tools G: Bores RA: O.D.‘s 2470/1e
...for a smooth operation ECOROLL Single Roller Tools EG14 EG5 EGi5-32 EGI-xxF 2470/1e
...for a smooth operation ECOROLL Hydrostatic tools „ballpoint“ HG 2470/1e
...for a smooth operation ECOROLL Hydrostatic Tool HG6-5 with Integrated Pump 2470/1e
...for a smooth operation ECOROLL Production Costs over Roughness super finish, lapping honing Manufacturing costs grinding turning roller burnishing Roughness 2470/1e
...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
...for a smooth operation ECOROLL 10-G Stratetgy Roller Burnishing Rz < 10µm 2470/1e
... 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
...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
...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
...for a smooth operation ECOROLL Application Example Differential Gear Process time 4 s Pressure 150 bar 2470/1e
...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
...for a smooth operation ECOROLL Application Example Large Bore (Bearing Housing) Speed 18 RPM Feed rate 0,4 mm/rev. Process time 62 min 2470/1e
...for a smooth operation ECOROLL Application Example Flexible Shaft Speed 100 m/min Feed rate 0,3 mm/rev. Pressure 350 bar 2470/1e
...for a smooth operation ECOROLL Wöhlerdiagram Flexible Shaft deep rolled with HG6 hand polished turned 2470/1e
