2470/1e1...for a smooth operation ECOROLL Saving Manufacturing Costs by Roller Burnishing and Deep...

2470/1e 1

...for a smooth operation ECOROLL

Saving Manufacturing CostsSaving Manufacturing Costsby Roller Burnishing and Deep Rollingby 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 2

...damit alles glatt geht ECOROLL

RandschichtumformungPlastic Forming of Top LayerPlastic Forming of Top Layer

workpiece

rolling force

roller


2470/1e 3


Plastic Forming of Top LayerPlastic Forming of Top Layer

rollerrotation

feed

rotationworkpiece


2470/1e 4


Levelling of Surface ProfileLevelling of Surface Profile

pre-operation surface

roller burnished


2470/1e 5


Advantages of Roller Burnished SurfaceAdvantages 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 6

•Short process time

•Applicable on virtually all machine tools

•Finishing in onre setting

Advantages of the Burnishing ProcessAdvantages of the Burnishing Process

•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 7

Process LimitsProcess Limits

Criteria Parameter Description Approx.FormingRatio

Hardness <42 bis 45 HRC Mechanical single and multi roller tools 20 : 1

>42 > 65 HRC Hydrostatic tools „ballpoint“ 10 : 1 bis 2 :1(ac. to hardness)

A4 8 % Suitable without restrictions 20 :1

Elongation tilrupture

A4 5 < 8% Test recommended 10 : 1

A4 < 5 % Rz 2 µm achievable 5 :1

Exception:Cast Iron

Rz 3 bis 4 µm achievable. Typical structure:Top plateaus and shallow pits.

5 :1


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Compressive Stress in Top LayerCompressive Stress in Top Layer

Compressive stress characteristicHG6 / hardened steel 600 HV

shot peened

Co

mp

ress

ive

str

ess

[Mp

a]

Depth [µm]


2470/1e 9

Process ComparisonProcess Comparison

Roller Burnishing Deep Rolling

Task Achieving the specified surface

roughness

Increase of faitigue strength

Proof of quality Non destructive surface test With destructive methods on test spe-cimen only Faitigue test Measuring of compressive stresses

Corrective action Second pass possible Not possible on serial production com-ponents

Requirements Diameter adjustment or indication or adjustment of rolling

force

In process control of parameters: Rolling force Feed rate Speed Geometry


2470/1e 10

... for a smooth operation ECOROLL

Deep Rolling versus Shot PeeningDeep Rolling versus Shot PeeningDeep 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 11


Economical Aspects of Deep RollingEconomical 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 ToolsMulti Roller Tools

G: Bores

RA: O.D.‘s


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Single Roller ToolsSingle Roller Tools

EG14 EG5EGi5-32 EGI-xxF


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Hydrostatic tools „ballpoint“ HGHydrostatic tools „ballpoint“ HG


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Hydrostatic Tool HG6-5 Hydrostatic Tool HG6-5 with Integrated Pump with Integrated Pump


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Production Costs over Roughness Production Costs over Roughness

super finish,lapping

honing

grinding

turning

roller burnishing

Roughness

Man

ufac

turin

g co

sts


2470/1e 17

Cost Reduction by Roller BurnishingCost 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 18

10-G Stratetgy10-G StratetgyRoller Burnishing RRoller Burnishing Rzz < 10µm < 10µm

Vergleich Feindrehen / 10-X ; Comparison Fine Turning / 10 - X

0

50

100

150

200

15x3

0

25x5

0

35x7

0

45x9

0

55x1

10

65x1

30

75x1

50

85x1

70

95x1

90D x L [mm]

Tim

e [

s]

Fine Turning

10-X

Einsparung / Savimg (%)

-20-10

01020304050

15x3

0

25x5

0

35x7

0

45x9

0

55x1

10

65x1

30

75x1

50

85x1

70

95x1

90

D x L [mm]

[%]


2470/1e 19


Economical Aspects of Deep RollingEconomical 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 20

Environmental Aspects of Environmental Aspects of Roller BurnishingRoller Burnishing

•No material removal

•no dust or mud

•low energy consumption

•little coolant required

•low noise


2470/1e 21

Roller Burnishing of Roller Burnishing of

Bearing and Seal SurfacesBearing and Seal Surfaces

Tool type G for bores

EG5 for bearing seats and seal surfaces


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Application ExampleApplication ExampleDifferential GearDifferential Gear

Process time 4 sPressure 150 bar


2470/1e 23

Application ExampleApplication ExampleHydraulic CylindersHydraulic Cylinders

Skive Burnishing Tool RDZ for cylinder Tubes

Roller Burnishing of Piston Rod with EG14


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Speed 18 RPMFeed rate 0,4 mm/rev.

Process time 62 min

Application ExampleApplication ExampleLarge Bore (Bearing Housing)Large Bore (Bearing Housing)


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Speed 100 m/minFeed rate 0,3 mm/rev.Pressure 350 bar

Application ExampleApplication ExampleFlexible ShaftFlexible Shaft


2470/1e 26

Wöhlerdiagram Wöhlerdiagram Flexible ShaftFlexible Shaft


turned

hand polished

deep rolled with HG6

2470/1e1...for a smooth operation ECOROLL Saving Manufacturing Costs by Roller Burnishing and Deep...

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Transcript of 2470/1e1...for a smooth operation ECOROLL Saving Manufacturing Costs by Roller Burnishing and Deep...