Beruflich Dokumente
Kultur Dokumente
for
Metal Surface
Improvement
Roller burnishing,
Deep rolling,
Combined skive-burnishing
ECOROLL AG
ECOROLL Corporation
Mailing address:
Address:
Postfach 3142
D-29231 Celle Germany
WERK ZEUGTECHNIK
Street address:
Hans-Heinrich-Warnke Str. 8
D-29227 Celle Germany
Phone:
FAX:
E-Mail:
Web:
++49(0) 5141-9865-0
++49(0) 5141-881440
mail@ecoroll.de
www.ecoroll.de
TOOL TECHNOLOGY
Phone:
FAX:
E-Mail:
Web:
(00)1-513-248-4700
(00)1-513-248-4265
tjacobs@ecoroll.com
www.ecoroll.com
ECOROLL AG Werkzeugtechnik
& ECOROLL Corporation
We design, manufacture and sell high quality tools
and machines for improving metal surfaces and
components.
ECOROLL tools and solutions can be applied across
a wide range of industries:
Roller burnishing
Deep rolling
Combined skive-burnishing
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Table of Contents
4
6
Section 1
Product Overview
Section 2
Mechanical
Multiple Roller Tools
Product Overview
G Tool Application: Cylindrical bores up to 200 mm
R Tool Application: Cylindrical bores larger than 200 mm
RD and RAD Tool Applications: Stepped bores and stepped shafts
RA Tool Application: External cylindrical surfaces
RP, RDP, RK, RKA Tool Applications: Non-cylindrical surfaces (cones, faces)
8
10
12
13
14
16
Section 3
Mechanical
Single Roller Tools
Product Overview
EG5 Tool Applications: Cylinders, faces, tapers and bores
EG5 Tool Applications: Contours, llets, groove anks, short bores
EG14 Tool Applications: External surfaces and bores, cylindrical and tapered
EG45 Tool Applications: Fillets and contours
18
20
22
24
26
Section 4
Hydrostatic Tools
Product Overview
Hydrostatic Tool Design and Specications
HGx-1, HGx-2, HGx-4, HGx-11 Application: Internal diameters
HGx-5, HGx-6, HGx-9, HGx-10, HGx-19 Applications:
Rotationally symmetrical surfaces and complex contours
HGx-7, HGx-20, HGx-23, HGx-29 Applications:
Faces, free-form surfaces and outer diameters
HG with HFR Roller Application: Deep rolling llets
Accessories for Type HG Tools: Type HGP High Pressure Pumps
Accessories for Type HG Tools: Type DS/DE Rotating Unions
28
31
32
33
Section 5
Deep Rolling Tools
38
40
41
42
43
Section 6
Tools for
Processing Cylinders
44
45
46
47
48
51
Section 7
Customized Tools and
New Developments
52
53
54
55
Section 8
Application Examples
56
87
Section 9
Appendix
88
88
91
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34
35
36
37
Diameter
(mm)
0
HG3
100
HG6
HG3
RH
U3
EG5
EG45
RK
HG6
HG3
HG3
EG5
50
RDP
HG6
HG6
HG6
HG6
HG13
HG13
HG13
HG13
EGI5
150
EG5
200
HG13
HG13
250
300
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D
0
GZ, SK
EF45
RHA
HG6
FAK
120
EG90
EG45
HG3
HG3
EG5
EG5
RP
HG6
EG14
RD
RAD
EG45
EG5
RKA
HG6
RA
HG6
EG14
HG6
EG14
HG6
50
RDO
RDS
Section 1
Product Overview
100
EGI5
150
EG5
200
HG13
HG13
HG13
HG13
HG13
HG13
EG14
EG45
250
300
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The curved arrows pictured at the materials surface demonstrate how the material is displaced into
the valleys between the peaks. Plastic deformation increases the rollers contact with the surface in
that the applied rolling pressure (or burnishing force) aects the peaks that lie ahead of the rollers
current position while causing the peaks at the point of contact to ow. The region found between
the arrows labelled rotation direction in the gure above demonstrates how the materials surface
is shaped during the roller burnishing or deep rolling process. The roller suppresses the plasticized
material, preventing it from owing backwards against the feed direction, while clearance angle
ensures that the surface is not over-burnished.
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Section 1
Both roller burnishing and deep rolling can take place right in the same setting after an initial cutting process
such as turning, boring, reaming, milling or broaching. ECOROLL tools are compatible with conventional
and CNC-controlled lathes, drills, milling machines and other machining centers. Moreover, these tools
can process both regular (turned and bored) and irregular (milled or pressed) components and surfaces.
ECOROLL tools can also be set up to work with special machines in mass production settings .
Product Overview
Combined skive-burnishing
The tools in ECOROLLs innovative OMEGA line combine skiving and roller burnishing to eliminate
irregularities in circular form, such as rippling, that occur in the manufacture of hydraulic cylinders and
other tubes. In comparison with already established processes for machining cylinders, the combination
of skiving and roller burnishing oers an especially economical alternative. The OMEGA tools have proven
eective for machining cylinders with diameters from 60 mm to 455 mm in lengths up to 10 m.
While the skiving head cuts the tubes inner surface to the exact size and form required, the roller head
burnishes it. Several rollers positioned on the tools circumference are pressed into the cylinders inner wall.
This process smoothes and forms the surface prole generated by skiving. The forming process increases
hardness and enhances the wear and fatigue resistance of surfaces subject to dynamic load.
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The RP, RDP, RK and RKA tools process similar non-cylindrical surfaces.
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Section 2
The tools can be applied with CNC-controlled lathes, drills, milling machines and
machining centers as well as with manually controlled machines.
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10
Parameters
Diameter
range D
(all measurements in mm)
Tool shank:
Morse taper or
cylindrical shank
exf
4 < 17
MK2
20h6 x 50
G1.1
G1.2
17 < 21
21 < 33
33 < 36
G1.3
36 < 50
MK2
20h6 x 50
25h6 x 56
G2
50 < 100
MK3
25h6 x 56
G3
MK4
32h6 x 60
c1)
d
max.
Rolling length
80
Rolling
length
+ 8 mm
Standard rolling
length: 50 mm
1.5
35
52
70
80
74
89
3
49
68
71
84
93
99
79
110
124
100
Unlimited
rolling length
NOTE: 1) All measurements in mm. Measurement c does not apply for blind hole tools.
2) For workpieces with diameters larger than 201 mm, please see ECOROLL Type R tools.
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1. Tool
body
G1.225.00150MK
Diameter 2. Design
4. Shank
3. Rolling
length
How to order:
Specify the tool body type and machining diameter (see following table).
Special diameter sizes (also in inches) are available upon request.
NOTE: Depending on the application, blind hole tools may allow a larger range of
settings than shown in the table.
2. Specify the design version:
Tool body
Diameter
D
Setting range
through hole blind
hole3)
mm
- / + mm
4<5
5<6
G1.1
4 < 21
6<8
8 < 10
10 < 11
11 < 17
17 < 21
G1.2
21 < 33
G1.3
33 < 50
21 < 25
25 < 33
- 0.05 / + 0.2
no blind hole
- 0.05 / + 0.3
- 0.05 / + 0.1
- 0.05 / + 0.4
- 0.05 / + 0.1
- 0.05 / + 0.6
- 0.05 / + 0.1
33 < 36
Number of
rollers4)
Roller diameter
gxh
Roller radius
r
Section 2
Advantages
Rolling length
mm
1x4
3
0.5
1.5 x 6
2x6
2 x 103)
1
50
3x9
5
1.5
5 x 16
6
75
36 < 38
38 < 50
G2
50 < 100
50 < 86
G3
100 < 201
86 < 100
170 < 201
- 0.05 / + 0.8
- 0.05 / + 0.1
8 x 25
2.5
14 x 35
unlimited
12
16
NOTE: 3) Depending on the application, blind hole tools may allow a larger range of settings than shown in the table.
4) Please exchange only complete sets of rollers. When ordering rollers, specify through or blind hole.
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11
12
Advantages
Parameters
Tool
body
R5
Diameter
range
D
Setting
range
through
blind hole1)
mm
- / + mm
- 0.05 / + 0.8
- 0.05 / + 0.1
Roller
radius
r
mm
MK5
50 h6 x 80
mm
16
20
14 x 35
90 100
28
NOTE: 1) Depending on the application, blind hole tools may allow a larger range of settings than shown in
the table.
2) Please exchange only complete sets of rollers. When ordering rollers, specify through or blind hole.
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Features
Advantages
Type RD and RAD tools consist of a tool body and roller head.
Tool body includes shank and two diameter adjustment assemblies for independent
adjustment.
Roller head consists of two external or internal cones, one double cage, and two sets
of rollers.
Standard for Type RD tools are Morse taper shanks; Type RAD has cylindrical shanks.
Roller head is designed for specic workpiece dimensions.
Section 2
Parameters
Tool
body
Diameter
range
D
mm
RD1
16 < 50
RD2
50 < 100
RD3
RAD1
12 < 25
Setting range
through
blind hole
- / + mm
mm
- 0.05 / + 0.6
- 0.05 / + 0.1
- 0.05 / + 0.8
- 0.05 / + 0.1
MK3
25 h6 x 60
c3)
d min.
25 < 51
53
110
125
99
168
124
g
min.
h
min.
3
MK4
32 h6 x 60
75
150
30
Setting range
(through hole)
Tool shank
exf
a1
a2
b
c
d min.
min. min.
- 0.1 / + 0.4
25 h6 x 56
96
65
130
- 0.1 / + 0.6
mm
12 and/or
0.6 x D
0.8 x D
30
RAD2
32 h6 x 60
140 105
160
depends on
the workpiece
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13
14
Type RA roller burnishing tools consist of a tool body and roller head.
Tool body includes shank and diameter adjustment assembly.
Cylindrical shanks standard (Morse taper shanks also available).
Roller head consists of the external cone, cage, and rollers.
Roller heads interchangeable within the diameter range for the tool body size.
Parameters
Tool
body
Diameter
range D
Tool shank:
Morse taper or cylindrical shank
exf
mm
RA1
RA2
RA3
3 < 12
12 < 25
25 < 55
RA4
55 < 85
RA5
85 < 110
RA6
20 h6 x 50 (MK2)
25 h6 x 56 (MK3)
40 h6 x 70 (MK4)
50 h6 x 80 (MK5)
mm
25 h6 x 60 x 15
55
45
40 h6 x 70 x 28
73
65
80 h6 x 90 x 57
114
105
110 h6 x 110 x 88
152
140
190
180
238
225
c1)
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80
21
81
28
108
35
130
99
124
156
RA325.003MK
Diameter
3. Shank
2. Design
How to order:
1. Specify the tool body type and machining diameter (see following table).
NOTE: Non-standard diameters are available by request.
2. Specify the design version:
3: with non-feeding cage
Tool body
Diameter
D
Setting range
mm
- / + mm
3<6
RA1
3 < 12
Number of
Rollers
RA3
25 < 55
Rolling
length
mm
3
6<8
12 < 17
- 0.4 / + 0.1
17 < 25
5 x 16 S
1.5
85
8 x 25 S
2.5
110
14 x 35 S
135
25 < 40
40 < 55
RA4
55 < 85
55 < 85
11
RA5
85 < 110
85 < 110
RA6
110 160
Roller radius
r
- 0.2 / + 0.05
8 < 12
RA2
12 < 25
Roller diameter
gxh
Section 2
Advantages
- 0.6 / + 0.1
9
11
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15
16
Advantages
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Morse taper
DIN 228
MK
Available
shanks:
Section 2
Available
roller heads:
Tool
application:
RP
Plane faces
RDP
Plane faces and
cylindrical bores
How to order:
RK
Tapered bore
holes
RK60.645.030S3MK
Tool
type
Diameter Diameter
D
d
RKA
External tapered
surfaces
Tool body
b
mm
Angle
(only for
RK, RKA)
Maximum
force
Shank
Tool
body
Standard
shank
kN
S1
26
66
3.9
MK1
S2
35
92
13.5
MK2
S3
45
107
21.6
MK3
S4
65
135
40.5
MK4
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17
EG5
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EG45
Machining a housing
Machining a train axle with an EG45-40M tool.
Section 3
EG14
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19
20
Advantages
Parameters
Bore Application
with Design Version 1 (see illustrations, following page)
Bore depth (mm)
Smallest bore diameter (mm)
16
> 66
55
140
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How to order:
EG53VDI30
Tool
type
EG5, Design 2
Faces on the chuck side
EG5, Design 3
Cylindrical surfaces
Feed direction: toward tailstock
VDI shank
d1)
(mm)
Height
(mm)
h1
20
EG5
30
Section 3
EG5, Design 1
Cylindrical surfaces
Tool
type
Shank:
VDI = DIN 69880
SL = square shank
45
40
Square
shank
(mm)
h2
p1)
67
16
77
20
82
25
EG5, Design 4
Faces on the tailstock side
2
c
e
64
78
82
120
69
3
f
111
78
84
10
84
44
120
112
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21
Features
22
Parameters
Tool
Advantages
EG5-08F
EGI5-32
EGI5
EG5-40M
EG5-40M-45
Circumferential
speed
Feed rate
80-100 m/min.
80-150 m/min.
0.1-0.6 mm/rev.
100-200 m/min.
0.1-0.8 mm/rev.
EG5-08F
Roller burnishes groove anks on the face or circumference and bores
EGI5-32
Roller burnishes bores with diameters of 32 mm and larger
surface
Roller head attached to the tool bodys exible, spring-loaded
section
Roller head consists of a cage that guides the burnishing roller
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EGI5
Roller burnishes bores with diameters of 55 mm and larger
surface
Roller head attached to the tool bodys exible, spring-loaded section
Roller head consists of a cage that guides the burnishing roller and a
EG5-40M
Roller burnishes contoured external surfaces
Section 3
EG5-40M-45
Roller burnishes cylindrical surfaces with connecting llet radii
workpiece surface
Roller head attached to the tool bodys exible, spring-loaded
section
Extremely narrow roller with an integrated four-point bearing
Tool type
EG5-08F
EGI5-32
EGI5
EG5-40M
EG5-40M-45
VDI
shank
D
(mm)
Height
(mm)
h1
h2
Square
shank
(mm)
20,30,40
50
20,30,40
50
a
106
40
117
67-91
150
50
30, 40
161
63
81-90
20
25
32
252
20,30,40
50
20,30,40
67-91
50
77
136
147
53
95
8.5 / 11.5
8 / 11
58
99
32
24
41
122
55
44
l
20/30
80
100
f
66
50
92
134
65
115
10
30
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23
24
Advantages
Parameters
Bore Application
with Design Version 1 (see illustrations, following page)
Bore depth (mm)
25
50
> 50
120
150
180
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Tool
type
EG14, Design 2
Faces on the chuck side
EG14, Design 1
Cylindrical surfaces
EG14, Design 3
Cylindrical surfaces
Feed direction: toward tailstock
Tool
type
VDI shank
d1)
(mm)
Height
(mm)
h1
40
EG14
50
Shank:
VDI = DIN 69880, double toothed
SL = square shank
Specially designed shanks by
request
Section 3
How to order:
h2
Square
shank
(mm)
p1)
81
63
60
90
110
EG14, Design 4
Faces on the tailstock side
25 or 32
71
b
131
150
2
c
e
40
152
43
45
50
3
f
159
166
g
113
i
127
124
4
k
50
106
m
20
50
147
13
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25
EG45-40M
26
EG45-40M
EG45-45T
Roller burnishes cylinders and faces in addition to
Advantages
EG45-45T
Parameters
Radius Application
Tool type
1.2
1.6
2.5
EG45-40M
0.8 - 3
1.2 - 5
2.5 - 8
4 - 12
6 - 40
EG45-45T
0.8 - 3
1.2 -5
2-8
3 - 12
5 - 20
EG45-45F
160
250
EG45-45T
EG45-45F
EG45-40M
EG45-45T
EG45-45F
EG45-40M
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1000
EG45-45T
EG45-45F
EG45-45T
EG45-45F
EG45-40M
Workpiece 100 mm
Workpiece 250 mm
630
EG45-45T
EG45-45F
EG45-40M
Workpiece 25 mm
Workpiece 160 mm
400
EG45-45T
EG45-45F
EG45-45T
EG45-45F
EG45-45T
EG45-45F
6.3
8 - 63
How to order:
EG45140MR2.5VDI50
Design
version: see
illustrations
EG45, Design 2
Faces on the chuck side,
including adjacent llets
EG45, Design 3
Cylindrical surfaces, including adjacent llets
Feed direction: toward tailstock
Tool type
VDI shank
d
(mm)
Height
(mm)
h1
EG45-45T
EG45-40M
h2
40,50
60
40,50
60
EG45, Design 4
Faces on the tailstock side,
including adjacent llets
Square
shank
(mm)
p
63 81-110
Roller with
radius of 2.5 mm
Roller
diameter
and design
EG45, Design 1
Cylindrical surfaces,
including adjacent llets
Section 3
25 or 32
69
b
149
156
129
136
2
c
162
52
163
170
150
g
118
108
4
k
127
134
126
116
72
124
48
134
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27
Hydrostatic Tools
Hydrostatic Tools
ECOROLLs hydrostatic HG tools can roller burnish and deep roll even the most
complex contours and free-form surfaces. The HG tools can be applied with
CNC-controlled lathes, drills, milling machines and machining centers as well
as with manually controlled machines. HG tools can process materials up to a
hardness of 65 HRC.
This group of tools includes types
HG2 HG25.
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Section 4
Hydrostatic Tools
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29
Hydrostatic Tools
30
How to order:
HG tools are available in a wide variety of versions.
Please refer to the information on page 35 and the
naming conventions listed on the following page.
HG139L15SLK25
Tool type
and ball
size
Design
Setting
version
angle
L = left-handed
R = right-handed
K = ball (HGx6)
H = llet (HGx6)
Shank
size
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HG65E90VDI20Sauter
Tool type
and ball
size
Design
Setting
version
angle
E = one burnishing
element
Z = two burnishing
elements
Turret head
manufacturer
(only HGx-5
and HGx-6)
Section 4
90N
250N
500N
1000N
4000N
4000N
22.5
22.5
30
30
35
30
2 mm
4 mm
5 mm
6 mm
8.5 mm
8.5 mm
Hydrostatic Tools
35 mm
42 mm
50 mm
50 mm
69 mm
82 mm
Design version
Because HG tools can be used across a wide spectum of applications, many dierent design
versions are available. HG tools are classied by design version in addition to ball size. For example,
an HG6-2 tool has a ball with a 6 mm diameter and is used for burnishing inner diameters. The
following table lists the design versions and their related applications.
NOTE: The tools are listed as follows: HGx-y, where x indicates the ball size and y the design
version.
HG design
version
HGx-1
HGx-2
HGx-4
HGx-5
HGx-6
HGx-7
HGx-9
HGx-10
HGx-11
HGx-19
HGx-20
HGx-23
HGx-29
Application
Internal diameters (cylindrical and tapered bores)
Internal diameters (cylindrical bores)
Internal diameters (narrow cylindrical bores)
Complex contours (cylinders, tapers, faces, llets, spheres)
Spherical contours
Faces and free-form surfaces
Rotationally symmetrical surfaces (cylinders, tapers, faces, llets, spheres)
Spherical contours
Special tool design versions (e.g. internal diameters narrow cylindrical bores)
Rotationally symmetrical surfaces (cylinders, tapers, faces, radii, slanted faces and other
outer and inner contours)
3-point tool (3 burnishing balls), outer diameters of narrow cylinders
Complex external surfaces (such as transition area near steering knuckle radius)
2-point tool (2 burnishing balls), treats both sides of disc-like and thin-walled
components (such as turbine blades) in one pass
++49 (0) 5141-9865-0
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31
Hydrostatic Tools
HGx-2
32
HGx-2P
Available only with 6mm burnishing balls (HG6)
to a boring bar)
Diameter sizes 6 - 33 mm
How to order:
HG tools are available in many versions.
Please refer to the the information on page 35
and the following naming conventions.
HG139L15SLK25
Tool type
and ball
size
Design
Setting
version
angle
L = left-handed
R = right-handed
K = ball (HGx6)
H = llet (HGx6)
Shank
size
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HGx-5
Applied on CNC-controlled lathes equipped with tool
drive systems
Section 4
Hydrostatic Tools
HGx-9
For use with conventional and CNC-controlled lathes
Pressure supplied through the shank either from the side or the rear
HG2-9 for deep rolling only, comes with an integrated square shank but
HGx-10
Recommended for use
Swivelling device permits continuous adjustment of the inclination during the process
Both right- and left-handed tools available with standardized square shank heights for
standard tool-holding xtures
HGx-19
For roller burnishing and deep rolling hard materials up to 65 HRC
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33
Hydrostatic Tools
HGx-7
For roller burnishing and deep
HG4-7
HGx-20
For roller burnishing and deep rolling the outer surfaces of thin
Tool comes with a square shank, but other tool shanks are available
element rotates
HG6-20
HG6-29
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Features
Advantages
Noticeable increase in
fatigue strength
Improved surface quality
Machining can be
completed in one setting
Extra hardening process
unnecessary
Section 4
Hydrostatic Tools
The tools are listed as follows: HGx-y, where x indicates the ball size and y the design version. See also the naming
conventions on pages 30 and 31. The lettered dimensions refer to the diagrams pictured with the respective tools.
Tool
Diameter
range D
Rolling length T
131/161/206
401)
136
60/90/135
50
145
T+40
HG6-1
19
50/80/125
106
HG6-2
70
200/400/600/800
53
HG6-2P
40
200/300
38
40
120
200/350
HG13-2
125
800
60
63
90
1000
HG13-4
50
unlimited
49
260
Ball D
HG2-9E45-SL
Fillet R
> 2.5
HG2-9V70-SL
HG3-9E45-SL
>4
HG3-9V70-SL
b12)
57
61
205
45
68
72
216
10 or 80
69
73
217
84
228
33
216(148)
96
228(160)
276(208)
80
b2)
32
HG6-9._-SL(K)
>5
66
HG13-9._-SL(K)
> 10
80
HG6-9E270-SL(K)
>5
90
HG13-9E270-SL(K)
> 10
111 298(230)
HG6-5_-VDI
>5
100
HG6-5_-VDI
>5
109
HG13-5_-VDI
> 10
128
HG6-6_-VDI
HG6-6_-VDI40
8-70
HG13-6_-VDI
50-250
8-25
20-80
89
91
20
25
32
45
10 or 80
303)
adjust in 15 increments
142
130
20 or 30
50
109
164
40 or 50
85 or 100
162
178
60 or 80
125 or 160
20 or 30
50
40
85
by request
Contact angle
303)
innitely variable
40/50/60 by request
NOTES: 2) For operation without VDI shank other values apply. Please ask ECOROLL.
3) Adapters can be converted to accommodate setting angles of 0, 60 and 90. Please request modied dimensions.
++49 (0) 5141-9865-0
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35
Hydrostatic Tools
36
HGP 3.0
How to order:
Pump type: see below
HGP3.0
Pump
type
Max. Pressure
(bar)
HG3
HG6
HG13
HG25
HGP3
200
12
10
HGP4
400
Pump
Design
HGP 3.7
Description
.0
Portable (by hand), direct start/stop controls, pressure build-up without delay, no switch box
.2
Portable (on a cart), roller burnishing and deep rolling with pressure accumulator(s) and solenoid valve,
CNC control with M-function or with manual control cable, includes switch box
.3
Integrated into the machines coolant tank, roller burnishing and deep rolling without pressure accumulator,
CNC control with M-function , no switch box
.4
Integrated into the machines coolant tank, roller burnishing and deep rolling with pressure accumulator(s)
and solenoid valve, CNC control with M-function, no switch box
.5
Portable (on a cart), roller burnishing and deep rolling with pressure accumulators and solenoid valve,
CNC control with M-function or with manual control cable, includes switch box
.7
Portable (on a cart), roller burnishing and deep rolling without pressure accumulator, CNC control with
M-function or with manual control cable, no switch box
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Section 4
Hydrostatic Tools
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37
38
Deep rolling is the only metal improvement process that induces residual compressive stresses and
cold work while burnishing the workpieces surface to a high quality nish. The deep rolling process
combines these three eects to dramatically increase fatigue strength.
In deep rolling, one or more rollers or balls are pressed against the workpiece surface. When the pressure
in the contact zone exceeds the materials yield point, the material in the surface layer is plasticized and
formed. The resulting comparison stress depth prole according to Hertz demonstrates a maximum
value just below the surface layer and reaches nearly zero deep in the workpiece. While the surface
layer is plastically formed, at deeper levels only elastic formation occurs. The prole of the resulting
compressive stresses always cycles toward a minimum value just at or below the workpiece surface
where the greatest compressive stresses are induced.
During the process, the rollers subject the surface roughness peaks to the greatest load. As these peaks
are pressed down, the material ows to the sides, lling the valleys and raising the valley level. The
assumption that this process leads to surface compression is true only for porous materials. Depending
on the application, deep rolling changes the workpiece diameter or dimensions only within the -range.
Allowances can be made in the pre-machining stage to accommodate these slight variations.
Because the plastic deformation takes place below the materials recrystallization temperature, cold
working is induced. The plastic forming process introduces disruptions into the materials lattice
structure. The increased density caused by this structural change increases the surface layers strength
and can also prevent cracks or delay crack growth.
Deep rolling process
In its kinematics, the deep rolling process is similar to turning or milling. As shown in the illustrations on
the next page, deep rolling can be performed as a plunge-in process with in-feed (for small radii), with
linear feed, or with a special feed motion to accommodate free-form surfaces. To avoid the formation
of steep inclines at the workpiece surface, the deep rolling force and pressure is built up slowly. This
gradual increase prevents stress concentration.
Because the kinematics are relatively simple, the process can be applied on conventional machine
tools. Deep rolling tools including the hydrostatic HG ballpoint line can also be used with CNCcontrolled lathes and milling machines. On standard machines and machine tools, the components can
be deep rolled right after cutting in the same setting. Specialized machines can be used to deep roll
components such as crankshafts and piston rods in large series production.
www.ecoroll.com (00)1-513-248-4700
Section 5
This process works well for narrow, hard-toreach areas, such as screw threads or llets
with radii R < 4 mm.
Deep rolling: feed process
This process works well for machining
larger surfaces. The rotation and in-feed
movements required for the plungein process are supplemented here by a
simultaneous linear feed.
Both mechanical and hydrostatic tools can
be used for this process.
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39
40
Features
dimensions
Mounted onto the tool body
Advantages
Deep rolling combines the following three physical eects:
Induces deep residual compressive stresses which
No transport costs
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Parameters
a
26-65
b1
Shank d
(mm)
25
Section 5
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41
EF45
EF45
EF90
42
EF90
EF45
The roller is guided by a cage and supported by a support body
with large-scale needle bearings.
EF90
The roller is suspended within the roller retainer with a slide bearing
bolt. In addition, the roller mount swings such that the roller
automatically adjusts to the thread pitch. A set screw limits the
rollers pivoting angle.
Tool type
EF45-17
EF45-21
EF90
Max. rolling
force
Max.
machining
radius
Max. yield
strength
Machining
diameter
(kN)
(mm)
(N/mm2)
(mm)
10
20
1.2
4.0
10-250
1400
1.6
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40
Shank d
(mm)
b1
71
133
152
130
38
100
120
228
103
45
VDI 40
Features
FAK025
FAK025
FAK120
Section 5
FAK120
FAK025
The roller is suspended within the roller retainer with a slide bearing
bolt. In addition, the roller mount swings such that the roller
automatically adjusts to the thread pitch. A set screw limits the
rollers pivoting angle.
FAK120
The roller holder contains a nely machined, hardened roller with
two tapered roller bearings.
Tool type
FAK025
FAK120
Max.
rolling
force
Max.
machining
radius
Max. yield
strength
Machining
diameter
(kN)
(mm)
(N/mm2)
(mm)
20
1.6
1400
80
35
4.0
Shank d (mm)
b1
142
324
229
307
42
256
179
126
VDI 40
depends upon machine
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43
Processing Cylinders
44
Type SK Skiving
Heads
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Achieves a diameter
tolerance of IT8 or IT9 and a
surface nish of RZ < 1 m
Section 6
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45
Processing Cylinders
46
Through cold working, this forming process achieves a large surface contact area,
low surface roughness and increased hardness. Thus, in contrast to honed tubes,
the burnished cylinder surface has better sliding and wear properties.
ECOROLL skive-burnishing tools can be used with specially designed cylinder
processing machines or trepanning machines with BTA boring systems.
In addition, special versions are available for use with alternative thread
connections, including Sandvik or Sierra.
NOTE: The machine tool supplies the working pressure to the tool via a high
pressure hose with a quick coupling connection. When the process is complete,
the pressure is released, and the skiving knives and the rolling head collapse. The
tool can be quickly retracted without damaging the nished surface.
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Diameters 38 60 mm
The RDS tool equipped with the RETRAC system is designed to machine short
cylinders up to 6 m long (depending upon the cylinders diameter and the
stiness of the boring bar). The work cycle is extremely short because skiving and
burnishing take place in one pass.
RDS tools feature the following advantages:
Floating skiving knife with two reversible, high performance cutting inserts
Hydraulic RETRAC device retracts knife and roller head when the process is
nished, preventing damage to the nished workpiece
Design versions
Section 6
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47
Processing Cylinders
Diameters 60 455 mm
48
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While the OMEGA skiving head cuts the cylinders inner surface to the exact size and
form required, the roller head burnishes it. The simultaneous skiving and burnishing
process, together with increased cutting performance (cutting speeds up to 300 m
per minute and feeds of 3 6 mm per revolution), result in substantial cost savings.
The OMEGA skiving head is equipped with two, three or six oating knives arranged
to work in concert.
For simple applications
with no rippling:
an economical version
with 2 knives
Section 6
a version with
2 3 knives
For dicult applications
that require substantial
form correction in
a diameter range of
205 455 mm :
a version with 6 knives
The knives center themselves automatically so that each removes chips of nearly the same
thickness regardless of cylinder form deviation. Thus, RDO tools with OMEGA skiving heads
skive the tube clean without removing large amounts of material. This innovative knife
arrangement markedly improves the tubes circular form while preventing the formation
of ripples and polygon-shaped bores.
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49
Processing Cylinders
50
Limiting the oscillation of the knives, thereby reducing rippling along the
length of the cylinder
A precisely scaled central adjusting screw allows the knives to be adjusted even
when they are already mounted in the tool. The knives no longer need to be
pre-adjusted. (NOTE: the 6-knife OMEGA skiving head occasionally requires
pre-adjustment.) The only reason for disassembling the knives is to turn them (to
expose the other cutting edge) or to exchange them.
Advantages:
The skiving head and the rolling head are connected through a new interface. The
complete skiving head can be removed by unscrewing two set screws even while
the RDO tool is still mounted in the machine.
Advantages:
0.6 - 2.0
0.2
1.2 - 2.4
0.4
1.6 - 3.0
0.6
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NOTE:
The tool retainer is a BTA thread or
an S-thread with a compressed air
connection.
Separate skiving and roller burnishing
operations are recommended for
diameters larger than 455 mm.
Separate skiving heads are available
in this range to improve circular form
and/or machining allowance to less
than 3 mm.
All dimensions in mm
Tool type
Diameter
range D
BTA
boring bar
e
RDS11
38 < 44
33
RDS21.1
44 < 50
36
RDS21.2
RDSQ11
50 < 55
43
55 < 60
38 < 44
33
RDSQ21.1 44 < 50
36
RDSQ21.2
RDO34.1
50 < 55
43
55 < 60
Skiving knives
Diameter
Range
Nominal
0.04
Nominal
0.04
60 < 63
47
70 < 80
56
70 < 80
80 < 100
68
80 < 100
RDO44.1
82
RDO44.2
106
RDO54.1
118
RDO54.2
142
RDO34.2
RDO64.1
RDO64.2
178
Range
20 x 14
-0.05/-0.2
18 x 18
-0.05/+0.3
20 x 18
-0.05/+0.2
18 x 18
50 x 17
60 < 70
63 < 70
Roller head
Crosssection
Number of
rollers
Main dimensions
Roller
gxh
12
16
8
6 x 20
12
-0.05/+0.3
16
-0.05/+0.3
8 x 25
226
60 x 32
16
275
67
304
86
301
81
275
67
304
86
301
81
430
200
437
207
60 x 24
-0.05/+0.5
110
12
50 x 18
Section 6
120
482
121
540
241
125
609
282
136
641
326
14 x 35
20
Diameter range
mm
38 < 60
Rippling
problem?
none
RDO2 (2 knives)
60 < 400
RDO3 (3 knives)
60 < 400
moderate
RDO6 (6 knives)
substantial
Cutting speed
m/min.
Feed
mm/rev.
Motor capacity
kW
180
20
3
300
4
6
30 - 50
75
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51
Customized Tools
Features
52
Roller position
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Features
Section 7
Tool Function
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53
Customized Tools
54
www.ecoroll.com (00)1-513-248-4700
Features
Can be applied on almost all
machine tools with rotating
components
All ductile metals up to a
hardness of 45 HRC and a tensile
strength of 1400 N/mm2 can be
treated
On pre-machined surfaces, a
surface quality of Rz < 1 m
(Ra 0.2 m) can be achieved in
one pass
How it works
During the roller burnishing
process, the rollers are pressed
against the spherical workpiece
surface. This movement applies
the required burnishing force (F),
which is generated by the springs.
The workpieces rotational speed
determines the feed rate.
Advantages
Can be applied on CNCcontrolled and conventional
lathes
Complete processing in one
setting
Short work cycle
Extraneous set-up
and auxilliary
processing time
eliminated
No dust or grinding
residue
Minimal lubrication
required
(Oil or emulsion)
Section 7
Operating parameters
Circumferential speed: 100 m/min.
Feed rate: 0.05 0.20 mm per roller
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55
Application Examples
56
Anwendungsbereich
Werkzeug, Anwendung
Application process
Tool, Application
No.
Glattwalzen mit
mehrrolligen Werkzeugen
RP
201
RA
Schutzrohr fr Thermofhler /
Protector for sensor
202
RP
203
RK
204
205
206
RD
208
Hydraulikzylinder /
Hydraulic cylinder
209
RA
210
Glattwalzen mit
einrolligen Werkzeugen
HG
301
HG
Schaufelschwenklager /
Swivel bearing
302
EG
303
HG
304
EG
305
HG
306
HG
307
HG
308
HG
309
EG
310
EG
311
EG
312
HG
313
HG
Kaltwalzen fr Breitbandstraen /
Steel mill roller
314
HG
315
HG
Radialwellendichtring-Laufflche /
Rotary seal surface
316
EG
317
HG
318
HG
319
HG
320
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Nr.
Werkzeug, Anwendung
Application process
Tool, Application
No.
Glattwalzen mit
einrolligen Werkzeugen
HG
321
HG
Wandlergehuse /
Torque converter housing
322
HG
Ventil / Valve
323
HG
324
EG
325
HG
326
HG
327
HG
330
HG
331
HG
332
HG
Formdorn /
Mandrel for injection mold
333
HG
Pressdorn / Punch
334
HG
335
HG
Achswelle / Getriebewelle
Axle shaft / Gear shaft
336
HG
337
HG
501
HG
502
HG
503
HG
504
HG
505
EF
506
HG
507
HG
508
EF
509
HG
510
EF
Hochfeste Schraube /
High strength screw
511
Nr.
HG
512
EF
513
HG
Flugzeugfederbein /
Aircraft shock strut
514
www.ecoroll.com (00)1-513-248-4700
Section 8
Anwendungsbereich
Application Examples
57
ANWENDUNGSBEISPIEL
A P P L I C AT I O N E X A M P L E
201
WERKSTCK
Fahrwerksgetriebe
WORKPIECE
Gear box
Te i l v o n
Pa r t o f
Schienenfahrzeug
Fo r d e r u n g
Required finish
R Z < 1 m
R Z < 1 m
C45
C45
Fe s t i g k e i t
Te n s i l e s t r e n g t h
680 N/mm 2
680 N/mm 2
WERKZEUG
mehrrolliges
Planflchenwerkzeug RP
TOOL
Multiple roller face tool RP
Maschine
Milling center
Bohrwerk
DREHZAHL
80 min -1
Material
Material
Machine
80
Process time
12 seconds
Hauptzeit
12 Sekunden
AU F G A B E
M A C H I N I N G TA S K
ERGEBNISSE/VORTEILE
verbesserte Produktqualitt
kurze Bearbeitungszeit
R E S U LT S / A D VA N TA G E S
Schutzrohr fr Thermofhler /
Protector for sensor
202
WERKSTCK
Schutzrohr fr Thermofhler
WORKPIECE
Temperature sensor protector
Te i l v o n
Pa r t o f
Industriewaschmaschine
Material
Material
Edelstahl 1.4301
WERKZEUG
RA
TOOL
RA
Maschine
Machine
Drehmaschine
Conventional lathe
Geschwindigkeit
(m/min) 4
Drehzahl
Speed (m/min.)
180 min -1
180
Vo r s c h u b ( m m / U )
Fe e d r a t e ( m m / r e v. )
0,3
H AU P T Z E I T
4,4 Minuten
0.3
4
Rotation speed (RPM)
Process time
4.4 minutes
AU F G A B E
58
ANWENDUNGSBEISPIEL
A P P L I C AT I O N E X A M P L E
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M A C H I N I N G TA S K
203
WERKSTCK
Ventilsitz
WORKPIECE
Valve seat
Te i l v o n
Pa r t o f
Ventilgehuse
Valve housing
Fo r d e r u n g
Required finish
R Z < 1 m
R Z < 1 m
X12CrMoS17
Stainless steel
Fe s t i g k e i t
Te n s i l e s t r e n g t h
700-800 N/mm 2
700-800 N/mm 2
WERKZEUG
RP-30.00-25.00-MK
TOOL
RP-30.00-25.00-Mk
Maschine
Machine
CNC-Drehmaschine
CNC lathe
Drehzahl
60 min -1
60
Wa l z k r a f t
Burnishing force
400 N
400 N
Hauptzeit
Process time
10 Sekunden
10 seconds
Material
Material
AU F G A B E
Planseitige Dichtflche wird in einer Aufspannung
nach dem Drehen fertigbearbeitet
M A C H I N I N G TA S K
Finish the seal face in one setting after turning
ERGEBNISSE/VORTEILE
R Z < 0,5 m
Polieren entfllt
R E S U LT S / A D VA N TA G E S
R Z < 0.5 m
ANWENDUNGSBEISPIEL
A P P L I C AT I O N E X A M P L E
204
WERKSTCK
Lenkhebel
WORKPIECE
Steering lever
Te i l v o n
Pa r t o f
Pkw-Vorderachse
Fo r d e r u n g
Required finish
R Z < 2 m
R Z < 2 m
geschmiedeter Stahl
Forged steel
Fe s t i g k e i t
Te n s i l e s t r e n g t h
1100 N/mm 2
1100 N/mm 2
WERKZEUG
RK
TOOL
RK
Maschine
Machine
Transfermaschine
Transfer machine
Drehzahl
300 min -1
300
Vo r s c h u b ( m m / U )
Fe e d r a t e ( m m / r e v. )
0,4
0.4
Wa l z k r a f t ( N )
Load (N)
700
700
Hauptzeit
Process time
3 Sekunden
3 seconds
Material
Section 8
ANWENDUNGSBEISPIEL
A P P L I C AT I O N E X A M P L E
Application Examples
Material
AU F G A B E
Bohrung nach dem Reiben glattwalzen
M A C H I N I N G TA S K
Roller burnish the hole after reaming
ERGEBNISSE/VORTEILE
R Z < 1,5 m und hoher Materialtraganteil
kurze Bearbeitungszeit
R E S U LT S / A D VA N TA G E S
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59
ANWENDUNGSBEISPIEL
A P P L I C AT I O N E X A M P L E
205
WERKSTCK
Lngslenker
WORKPIECE
Rear wheel carrier
Te i l v o n
Pa r t o f
Pkw-Hinterachse
Fo r d e r u n g
Required finish
R Z < 6 m
R Z < 6 m
GGG 40
Fe s t i g k e i t
Te n s i l e s t r e n g t h
400 N/mm 2
400 N/mm 2
WERKZEUG
G2-70.00-1-ZS25
TOOL
G2-70.00-1-ZS25
Maschine
Machine
Transfermaschine
Geschwindigkeit (m/min)
Transfer machine
S p e e d ( m / m i n . ) 150
150
D r e h z a h l 680 min -1
Vo r s c h u b ( m m / U ) 1,6
H a u p t z e i t 2,5 Sekunden
680
Material
Material
Fe e d r a t e ( m m / r e v. ) 1.6
P r o c e s s t i m e 2.5 seconds
AU F G A B E
M A C H I N I N G TA S K
ANWENDUNGSBEISPIEL
A P P L I C AT I O N E X A M P L E
206
WERKSTCK
Pleuel
WORKPIECE
Connection rod
Te i l v o n
Pa r t o f
Otto-Motor
Combustion engine
Fo r d e r u n g
Required finish
R Z < 2 m
R Z < 2 m
WERKZEUG
G1.3-42.00
TOOL
G1.3-42.00
Geschwindigkeit
( m / m i n ) 160
D r e h z a h l 1200 min -1
Vo r s c h u b ( m m / U ) 0,8
S p e e d ( m / m i n . ) 160
R o t a t i o n s p e e d ( R P M ) 1200
Fe e d r a t e ( m m / r e v. ) 0.8
Material
Material
G1.2-22.00
S p e e d ( m / m i n . ) 110
R o t a t i o n s p e e d ( R P M ) 1600
Fe e d r a t e ( m m / r e v. ) 0.6
G1.2-22.00
Geschwindigkeit
( m / m i n ) 110
D r e h z a h l 1600 min -1
Vo r s c h u b ( m m / U ) 0,6
Process time
1.3 seconds
Hauptzeit
1,3 Sekunden
AU F G A B E
Glattwalzen des kleinen und groen Pleuelauges
ERGEBNISSE/VORTEILE
Verbesserung des Fgesitzes der Buchse - kleines Auge
60
www.ecoroll.com (00)1-513-248-4700
M A C H I N I N G TA S K
Roller burnish both bores
R E S U LT S / A D VA N TA G E S
ANWENDUNGSBEISPIEL
A P P L I C AT I O N E X A M P L E
WORKPIECE
Valve body
Te i l v o n
Pa r t o f
Regelarmatur
Control armature
Fo r d e r u n g
Required finish
R Z < 2 m
R Z < 2 m
rostfreier Edelstahl
Stainless steel
Fe s t i g k e i t
Te n s i l e s t r e n g t h
400 N/mm 2
400 N/mm 2
WERKZEUG
RD Sonderwerkzeug
mit 3-stufigem Durchmesser
44 / 45 / 46 mm
TOOL
RD special version
with 3-step diameter
44 / 45 / 46 mm
Material
Section 8
Material
208
Machine
Maschine
CNC lathe
CNC-Drehmaschine
S p e e d ( m / m i n . ) 150
Rotation speed
( R P M ) 1060
Fe e d r a t e
( m m / r e v. ) 0.5
Process time
Geschwindigkeit
( m / m i n ) 150
D r e h z a h l 1060 min -1
Vo r s c h u b ( m m / U ) 0,5
Hauptzeit
1,7 Sekunden
1.7 seconds
ERGEBNISSE/VORTEILE
Application Examples
R E S U LT S / A D VA N TA G E S
ANWENDUNGSBEISPIEL
A P P L I C AT I O N E X A M P L E
Hydraulikzylinder /
Hydraulic cylinder
209
WERKSTCK
Hydraulikzylinder
WORKPIECE
Hydraulic cylinder
Te i l v o n
Pa r t o f
Rotorblattverstellung
fr Hubschrauber
Fo r d e r u n g
Required finish
R Z < 2 m
R Z < 2 m
Stahl
Steel
Hr te
Hardness
40 HRC
40 HRC
Fe s t i g k e i t
Te n s i l e s t r e n g t h
1000 N/mm 2
1000 N/mm 2
WERKZEUG
G
TOOL
G
Maschine
Machine
CNC-Drehmaschine
CNC lathe
Geschwindigkeit
( m / m i n ) 150
D r e h z a h l 1000 min -1
Vo r s c h u b ( m m / U ) 0,5
Hauptzeit
S p e e d ( m / m i n . ) 150
Rotation speed
( R P M ) 1000
Fe e d r a t e ( m m / r e v. ) 0.5
Process time
42 Sekunden
42 seconds
Material
Material
ERGEBNISSE/VORTEILE
Reduzierung von Reibung und Dichtungsverschlei
R E S U LT S / A D VA N TA G E S
Reduced friction and wear on seal
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210
WERKSTCK
Gelenkwelle
WORKPIECE
Drive shaft
Te i l v o n
Pa r t o f
Hydraulikmotor
Hydraulic motor
Fo r d e r u n g
Required finish
R Z < 1 m
R Z < 1 m
1000 N/mm 2
1000 N/mm 2
WERKZEUG
mehrrolliges
Glattwalzwerkzeug RA
TOOL
Multiple roller
burnishing tool RA
Maschine
Machine
Bearbeitungszentrum
Milling center
Geschwindigkeit
( m / m i n ) 150
D r e h z a h l 2800 min -1
Vo r s c h u b ( m m / U ) 0,3
Hauptzeit
S p e e d ( m / m i n . ) 150
Rotation speed
( R P M ) 2800
Fe e d r a t e ( m m / r e v. ) 0.3
Process time
M a t e r i a l Stahl
H r t e 40 HRC
Fe s t i g k e i t
M a t e r i a l Steel
H a r d n e s s 40 HRC
Te n s i l e s t r e n g t h
AU F G A B E
Hoher Profiltraganteil wird zur Kraftbertragung
bentigt
M A C H I N I N G TA S K
High load bearing surface ratio required for
good load transmission
ERGEBNISSE/VORTEILE
verbesserte Produktqualitt
kurze Bearbeitungszeit
R E S U LT S / A D VA N TA G E S
ANWENDUNGSBEISPIEL
A P P L I C AT I O N E X A M P L E
WERKSTCK
Dichtsitz
WORKPIECE
Seal insert
Te i l v o n
Pa r t o f
Ventil
Valve
Fo r d e r u n g
Required finish
R Z < 1 m
R Z < 1 m
1.4301
Stainless steel
Fe s t i g k e i t
Te n s i l e s t r e n g t h
500-750 N/mm 2
500-750 N/mm 2
WERKZEUG
HG6-9L00-SL25
TOOL
HG6-9L00-SL25
Maschine
Machine
Mehrspindelautomat
D r e h z a h l 950 min -1
Vo r s c h u b ( m m / U ) 0,1
D r u c k ( b a r ) 60
Multi-spindle lathe
Material
Rotation speed
( R P M ) 950
Fe e d r a t e
( m m / r e v. ) 0.1
P r e s s u r e ( b a r ) 60
Process time
2,5 Sekunden
AU F G A B E
Planseitige Dichtflche wird in einer Aufspannung nach dem Drehen glattgewalzt
ERGEBNISSE/VORTEILE
Einsparung von manueller Polierarbeit
301
Material
Hauptzeit
62
ANWENDUNGSBEISPIEL
A P P L I C AT I O N E X A M P L E
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2.5 seconds
M A C H I N I N G TA S K
Roller burnish profiled seal face after turning
R E S U LT S / A D VA N TA G E S
Hand polishing eliminated
Schaufelschwenklager /
Swivel bearing
WERKSTCK
Schaufelschwenklager
WORKPIECE
Swivel bearing
Te i l v o n
Gehuse /
Housing
Bagger
Pa r t o f
Excavator shovel
Fo r d e r u n g
Required finish
R Z < 2 m
R Z < 2 m
M a t e r i a l GGG
H r t e 58-62 HRC
Material
WERKZEUG
HG6-2 und HG6-9
TOOL
HG6-2 and HG6-9
M a c h i n e CNC lathe
S p e e d ( m / m i n . ) 100
Maschine
CNC-Drehmaschine
Geschwindigkeit
( m / m i n ) 100
D r e h z a h l 220 min -1
Vo r s c h u b ( m m / U ) 0,1
D r u c k ( b a r ) 300
H a u p t z e i t 53 Sekunden
302
Rotation speed
( R P M ) 220
Fe e d r a t e ( m m / r e v. ) 0.1
P r e s s u r e ( b a r ) 300
P r o c e s s t i m e 53 seconds
Lagerzapfen/
Bearing shaft
AU F G A B E
AU F G A B E
ERGEBNISSE/VORTEILE
Zeitersparung
R E S U LT S / A D VA N TA G E S
ANWENDUNGSBEISPIEL
A P P L I C AT I O N E X A M P L E
Section 8
ANWENDUNGSBEISPIEL
A P P L I C AT I O N E X A M P L E
Application Examples
303
WORKPIECE
Bearing housing
Pa r t o f Roller press
R e q u i r e d f i n i s h R Z < 3 m
WERKSTCK
Lagergehuse
Te i l v o n Walzenpresse
Fo r d e r u n g R Z < 3 m
M a t e r i a l GGG 40
H r t e 170 HRB
Material
WERKZEUG
EG14
Maschine
TOOL
EG14
Karussell-Drehmaschine
Machine
Geschwindigkeit
( m / m i n ) 80
D r e h z a h l 18 min -1
Vo r s c h u b ( m m / U )
Vertical lathe
S p e e d ( m / m i n . ) 80
R o t a t i o n s p e e d ( R P M ) 18
Fe e d r a t e ( m m / r e v. ) 0.4
Dial gauge indication
( m m ) 0.5
P r o c e s s t i m e 62 minutes
0,4
Messuhranzeige
( m m ) 0,5
H a u p t z e i t 62 Minuten
AU F G A B E
M A C H I N I N G TA S K
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304
WERKSTCK
Dichtkegel
WORKPIECE
Seal cone
Te i l v o n
Pa r t o f
Flssigkeitsventil
Fluid valve
Fo r d e r u n g
Required finish
R Z < 1 m
R Z < 1 m
rostfreier Stahl
Stainless steel
Streckgrenze
Yield strength
240 N/mm 2
240 N/mm 2
WERKZEUG
HG6-9E30-SL25
TOOL
HG6-9E30-SL25
Maschine
Machine
CNC-Drehmaschine
CNC lathe
Geschwindigkeit
( m / m i n ) 180
D r e h z a h l 950 min -1
Vo r s c h u b ( m m / U ) 1
D r u c k ( b a r ) 80
Hauptzeit
S p e e d ( m / m i n . ) 180
Rotation speed
( R P M ) 950
Fe e d r a t e ( m m / r e v. ) 1
P r e s s u r e ( b a r ) 80
Process time
5,3 Sekunden
5.3 seconds
Material
Material
AU F G A B E
HG wurde gewhlt, da eine leichte Verrundung
der Kanten erwnscht ist
M A C H I N I N G TA S K
HG is the best choice for rounding corners
ERGEBNISSE/VORTEILE
Einsparung der bisherigen separaten Polieroperation
R E S U LT S / A D VA N TA G E S
Eliminates a separate polishing operation
ANWENDUNGSBEISPIEL
A P P L I C AT I O N E X A M P L E
305
WERKSTCK
Ringzylinder
WORKPIECE
Ring cylinder
Te i l v o n
Pa r t o f
Hydraulikkupplung
Hydraulic clutch
Fo r d e r u n g
Required finish
R Z < 2 m
R Z < 2 m
740 N/mm 2
740 N/mm 2
WERKZEUG
EG5-12F-VDI40
TOOL
EG5-12F-VDI40
Maschine
Machine
CNC-Drehmaschine
CNC lathe
Geschwindigkeit
( m / m i n ) 80
D r e h z a h l 210 min -1
Vo r s c h u b ( m m / U ) 0,2
M e u h r a n z e i g e ( m m ) 1,0
Hauptzeit
S p e e d ( m / m i n . ) 80
R o t a t i o n s p e e d ( R P M ) 210
Fe e d r a t e ( m m / r e v. ) 0.2
Dial gauge indication
( m m ) 1.0
Process time
M a t e r i a l Ck60
Fe s t i g k e i t
M a t e r i a l Ck60
Te n s i l e s t r e n g t h
AU F G A B E
Prozesssicherheit
Ausschu vermieden
Poliervorgang eingespart
64
ANWENDUNGSBEISPIEL
A P P L I C AT I O N E X A M P L E
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M A C H I N I N G TA S K
Reliable process
ANWENDUNGSBEISPIEL
A P P L I C AT I O N E X A M P L E
306
WORKPIECE
Bevel gear
Te i l v o n
Pa r t o f
Pkw-Differential
Fo r d e r u n g R Z < 2 m
M a t e r i a l 16CD4
H r t e 42 HRC
Fe s t i g k e i t 1000 N/mm 2
WERKZEUG
HG6 Glattwalzelement
an Spezialhalter
TOOL
HG6 burnishing element
on a special tool holder
Maschine
Machine
MehrspindelDrehmaschine MS50
(Index)
Multi-spindle lathe
(index MS250)
S p e e d ( m / m i n ) 150
Geschwindigkeit
( m / m i n ) 150
D r e h z a h l 1500 min -1
Vo r s c h u b ( m m / U ) 0,1
D r u c k ( b a r ) 150
H a u p t z e i t 4 Sekunden
R o t a t i o n s p e e d ( R P M ) 1500
Fe e d r a t e ( m m / r e v. ) 0.1
P r e s s u r e ( b a r ) 150
P r o c e s s t i m e 4 seconds
AU F G A B E
M A C H I N I N G TA S K
ERGEBNISSE/VORTEILE
R E S U LT S / A D VA N TA G E S
ANWENDUNGSBEISPIEL
A P P L I C AT I O N E X A M P L E
Steuerkolben /
Control valve piston
WERKSTCK
Steuerkolben
WORKPIECE
Control valve piston
Te i l v o n
Pa r t o f
Druckluft-Wegeventil
Fo r d e r u n g
Compressed air
control valve
R Z < 1 m
Required finish
M a t e r i a l C-Stahl
Fe s t i g k e i t 1000 N/mm 2
R Z < 1 m
WERKZEUG
HG6-9E00-SL20
1000 N/mm 2
307
M a t e r i a l C-Steel
Te n s i l e s t r e n g t h
TOOL
HG6-9E00-SL20
Maschine
CNC-Drehmaschine
Machine
Geschwindigkeit
( m / m i n ) 94
Drehzahl
3000 min
Section 8
WERKSTCK
Kegelrad
Application Examples
CNC lathe
S p e e d ( m / m i n . ) 94
Rotation speed
( R P M ) 3000
Fe e d r a t e ( m m / r e v. ) 0.1
P r e s s u r e ( b a r ) 100
P r o c e s s t i m e 12 seconds
-1
Vo r s c h u b ( m m / U )
0,1
D r u c k ( b a r ) 100
H a u p t z e i t 12 Sekunden
AU F G A B E
Kolben gleitet whrend des Schaltens durch O-Ringen,
daher sollen Radien ebenfalls geglttet werden
M A C H I N I N G TA S K
Machine the surface to ensure optimum
performance when piston slides through O-rings
ERGEBNISSE/VORTEILE
in einer Aufspannung einbaufertig bearbeitet
R E S U LT S / A D VA N TA G E S
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WORKPIECE
Servo piston
Te i l v o n
Pa r t o f
ABS-Bremssystem
Fo r d e r u n g
Required finish
R a 0,3 m
R a 0.3 m
C-Stahl
Carbon steel
Fe s t i g k e i t
Te n s i l e s t r e n g t h
600 N/mm 2
600 N/mm 2
WERKZEUG
HG6-9L00-SL25
TOOL
HG6-9E00-SL25
Maschine
Machine
Mehrspindelautomat
Multi-spindle lathe
S p e e d ( m / m i n . ) 230
Material
308
Material
Geschwindigkeit
( m / m i n ) 230
D r e h z a h l 6000 min -1
Vo r s c h u b ( m m / U ) 0,1
D r u c k ( b a r ) 120
H a u p t z e i t 0,6 Sekunden
Rotation speed
( R P M ) 6000
Fe e d r a t e ( m m / r e v. ) 0.1
P r e s s u r e ( b a r ) 120
P r o c e s s t i m e 0.6 seconds
AU F G A B E
Gesamte Kuppe einschlielich des Zentrums
wird glattgewalzt
M A C H I N I N G TA S K
Roller burnish rounded end, including center
ERGEBNISSE/VORTEILE
Einsparung der bisherigen separaten
Polieroperation
R E S U LT S / A D VA N TA G E S
Eliminates separate operation for polishing the
rounded end
ANWENDUNGSBEISPIEL
A P P L I C AT I O N E X A M P L E
309
WERKSTCK
Kegelbolzen
WORKPIECE
Taper bolt
Te i l v o n
Pa r t o f
rostfreie Metalldbel
Fo r d e r u n g
Required finish
R Z < 1,5 m
rostfreier Stahl
H r t e 300 HV
Stainless steel
H a r d n e s s 300 HV
WERKZEUG
HG6-11.2 (rotierend)
mit 6-8 Walzelementen
TOOL
HG6-11.2 (rotating)
with 6-8 burnishing elements
Maschine
Machine
Rundtisch-Drehautomat
Material
Material
Geschwindigkeit
( m / m i n ) 40-60
D r e h z a h l 1000 min -1
Vo r s c h u b ( m m / U ) 0,3
D r u c k ( b a r ) 120
H a u p t z e i t 3-4 Sekunden
1000
Fe e d r a t e ( m m / r e v. ) 0.3
P r e s s u r e ( b a r ) 120
P r o c e s s t i m e 3-4 seconds
AU F G A B E
sicheres Produkt
kurze Bearbeitungszeit
66
ANWENDUNGSBEISPIEL
A P P L I C AT I O N E X A M P L E
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M A C H I N I N G TA S K
In order for tap bolts to be approved for use,
the taper must be roller burnished
R E S U LT S / A D VA N TA G E S
Galling prevented
WORKPIECE
Piston rod
Te i l v o n
Pa r t o f
WERKSTCK
Hydraulikzylinder
310
Hydraulic cylinder
Fo r d e r u n g
Required finish
R Z < 1,5 m
M a t e r i a l C60V
H r t e 40 HRC
R Z < 1.5 m
M a t e r i a l C60V
H a r d n e s s 40 HRC
Fe s t i g k e i t
Te n s i l e s t r e n g t h
1000 N/mm 2
1000 N/mm 2
WERKZEUG
EG14-1-VDI50
CNC-Drehmaschine
TOOL
EG14-1-VDI50
M a c h i n e CNC lathe
S p e e d ( m / m i n . ) 135
Geschwindigkeit
( m / m i n ) 135
D r e h z a h l 500 min -1
Vo r s c h u b ( m m / U ) 0,2
M e u h r a n z e i g e ( m m ) 0,7
H a u p t z e i t 7,1 Minuten
Rotational speed
( R P M ) 500
Fe e d r a t e ( m m / r e v. ) 0.2
Dial gauge indication
( m m ) 0.7
P r o c e s s t i m e 7.1 minutes
Maschine
Beispiel / Example:
Durchmesser/Diameter = 85 mm
Lnge/Length = 715 mm
AU F G A B E
Die glattgewalzte Oberflche wird maverchromt
und ist nach dem Schwabbeln einbaufertig
ERGEBNISSE/VORTEILE
geringer Verbrauch von Chrom
Dichtungseigenschaften auf
M A C H I N I N G TA S K
ANWENDUNGSBEISPIEL
A P P L I C AT I O N E X A M P L E
311
WERKSTCK
Dichtbuchse
WORKPIECE
Seal bushing
Te i l v o n
Pa r t o f
Ventil
Valve
Fo r d e r u n g R Z < 1 m
Material
Required finish
Aluminium-Legierung
Fe s t i g k e i t
M a t e r i a l Aluminum alloy
Te n s i l e s t r e n g t h
300 N/mm 2
300 N/mm 2
WERKZEUG
EG14-2-VDI40
TOOL
EG14-2-VDI40
Maschine
Machine
CNC-Drehmaschine
CNC lathe
Geschwindigkeit
(m/min)
Speed (m/min)
100 (konstant)
Drehzahl
250-470
250-470 min -1
Fe e d r a t e ( m m / r e v. ) 0.2
Dial gauge indication
( m m ) 0.5
P r o c e s s t i m e 29 seconds
R Z < 1 m
100 (constant)
Vo r s c h u b ( m m / U ) 0,2
M e u h r a n z e i g e ( m m ) 0,5
H a u p t z e i t 29 Sekunden
ERGEBNISSE/VORTEILE
Zeiteinsparung
verbesserte Dichtung
Section 8
ANWENDUNGSBEISPIEL
A P P L I C AT I O N E X A M P L E
Application Examples
R E S U LT S / A D VA N TA G E S
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312
WERKSTCK
Grokurbelwelle
WORKPIECE
Crank shaft
Te i l v o n
Pa r t o f
Kolbenpumpe fr
Bohrsplung
Fo r d e r u n g R Z < 4 m
Vergtungsstahl
H r t e 42 HRC
Fe s t i g k e i t 1100 N/mm 2
Te n s i l e s t r e n g t h
Material
1 100 N/mm 2
TOOL
EG14-1-SL32
WERKZEUG
EG14-1-SL32
Machine
Maschine
CNC lathe
CNC-Drehmaschine
S p e e d ( m / m i n . ) 19
R o t a t i o n s p e e d ( R P M ) 20
Fe e d r a t e ( m m / r e v. ) 0.8
D i a l g a u g e i n d i c a t i o n ( m m ) 1.1
Process time
Geschwindigkeit
( m / m i n ) 19
D r e h z a h l 20 min -1
Vo r s c h u b ( m m / U ) 0,8
M e u h r a n z e i g e ( m m ) 1,1
H a u p t z e i t 18 Minuten, 40 Sekunden
18 minutes, 40 seconds
AU F G A B E
Unwucht lsst nur niedrige Drehzahl zu, daher ist
Oberflchengte nicht durch Drehen erreichbar
M A C H I N I N G TA S K
Because the eccentric mass requires a slow
machining speed, turning alone cannot produce
the required finish
ERGEBNISSE/VORTEILE
R E S U LT S / A D VA N TA G E S
ANWENDUNGSBEISPIEL
A P P L I C AT I O N E X A M P L E
313
WERKSTCK
Fhrungsrohr
WORKPIECE
Guide tube
Te i l v o n
Pa r t o f
Fahrzeughebebhne
Fo r d e r u n g
Required finish
R Z < 2 m
R Z < 2 m
600 N/mm 2
600 N/mm 2
WERKZEUG
HG13-9R15-SL25
TOOL
HG13-9R15-SL25
Maschine
Machine
konventionelle
Drehmaschine
Conventional lathe
S p e e d ( m / m i n . ) 240
Geschwindigkeit
( m / m i n ) 240
D r e h z a h l 300 min -1
Vo r s c h u b ( m m / U ) 0,5
D r u c k ( b a r ) 120
H a u p t z e i t 17 Minuten
Rotation speed
( R P M ) 300
Fe e d r a t e ( m m / r e v. ) 0.5
P r e s s u r e ( b a r ) 120
P r o c e s s t i m e 17 minutes
68
ANWENDUNGSBEISPIEL
A P P L I C AT I O N E X A M P L E
AU F G A B E
gezogene Przisionsstahlrohre werden vor dem
Glattwalzen spitzenlos geschliffen
M A C H I N I N G TA S K
Roller burnish cold drawn precision tubes after
performing centerless grinding
ERGEBNISSE/VORTEILE
Drehen als Vorbearbeitung nicht mehr
erforderlich, da HG Werkzeug Rundheitsfehler und
Durchmessertoleranzen automatisch kompensiert
R E S U LT S / A D VA N TA G E S
No pre-process turning necessary because the
hydrostatic tool compensates for the tubes
diameter tolerances
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Kaltwalzen fr Breitbandstraen /
Steel mill roller
WERKSTCK
Kaltwalzen fr Breitbandstraen
WORKPIECE
Steel mill roller
Te i l v o n
Pa r t o f
Walzwerk
Fo r d e r u n g
Hrtesteigerung
M a t e r i a l Hartguss
H r t e 65 Shore B
314
Required finish
7000 mm
Increased hardness
M a t e r i a l Chilled cast iron
H a r d n e s s 65 Shore B
850 mm
WERKZEUG
HG13-9R15-SL32 mit
Hydraulikaggregat HGP1.8
mit Khlschmierstoff-Tank
Maschine
Walzen-Drehmaschine
Geschwindigkeit
( m / m i n ) 250
D r e h z a h l 93 min -1
Vo r s c h u b ( m m / U ) 0,25
D r u c k ( b a r ) 250
H a u p t z e i t 5 Stunden
TOOL
HG13-9R15-SL32 with
hydraulic pump HGP1.8
with coolant-lubricant
tank
Machine
Roller lathe
S p e e d ( m / m i n ) 250
R o t a t i o n s p e e d ( R P M ) 93
Fe e d r a t e ( m m / r e v. ) 0.25
P r e s s u r e ( b a r ) 250
P r o c e s s t i m e 5 hours
AU F G A B E
Erhhung der Hrte zur Steigerung der
Standzeit gefordert
M A C H I N I N G TA S K
Increase hardness to improve fatigue strength
and service life
ERGEBNISSE/VORTEILE
Hrte > 70 Shore, Sollwert erreicht
R E S U LT S / A D VA N TA G E S
Hardness increased to 70 Shore
ANWENDUNGSBEISPIEL
A P P L I C AT I O N E X A M P L E
Section 8
ANWENDUNGSBEISPIEL
A P P L I C AT I O N E X A M P L E
Application Examples
315
WERKSTCK
Dsenkern
WORKPIECE
Extrusion tool core
Te i l v o n
Pa r t o f
Extrusionswerkzeug
fr Kunststoffrohre
Fo r d e r u n g R Z < 1 m
rostfreier Stahl
Stainless steel
Fe s t i g k e i t
Te n s i l e s t r e n g t h
750 N/mm 2
750 N/mm 2
WERKZEUG
HG13-9R00-SL25
TOOL
HG13-9R00-SL25
Maschine
Machine
CNC-Drehmaschine
CNC lathe
Geschwindigkeit
( m / m i n ) 200
Vo r s c h u b ( m m / U ) 0,1
Druck (bar) 90
H a u p t z e i t 3 Minuten
S p e e d ( m / m i n . ) 200
Fe e d r a t e ( m m / r e v. ) 0.1
P r e s s u r e ( b a r ) 90
P r o c e s s t i m e 3 minutes
Required finish
R Z < 1 m
Material
Material
AU F G A B E
Glattwalzen, da glattgewalzte Oberflchen fr
Extrusionswerkzeuge bestens geeignet sind
M A C H I N I N G TA S K
Roller burnish surface to better facilitate the
plastic extrusion process
ERGEBNISSE/VORTEILE
Zeiteinsparung von 1,5 Stunden pro Teil
R E S U LT S / A D VA N TA G E S
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Radialwellendichtring - Laufche /
Rotary seal surface
WERKSTCK
Radialwellendichtring Laufflche
Te i l v o n Wandlergetriebe
316
WORKPIECE
Rotary seal surface
Pa r t o f
Torque converter
Required finish
R a = 0.2 - 0.4 m
Fo r d e r u n g
Material
R a = 0,2 - 0,4 m
M a t e r i a l Einsatzstahl
H r t e 58-60 HRC
Carbonized steel
H a r d n e s s 58-60 HRC
TOOL
HG6-1E15-ZS40
M a c h i n e CNC lathe
S p e e d ( m / m i n . ) 150
WERKZEUG
HG6-1E15-ZS40
Maschine
CNC-Drehmaschine
Rotation speed
( R P M ) 1060
Fe e d r a t e ( m m / r e v. ) 0.1
P r e s s u r e ( b a r ) 400
P r o c e s s t i m e 25 seconds
Geschwindigkeit
( m / m i n ) 150
D r e h z a h l 1060 min -1
Vo r s c h u b ( m m / U ) 0,1
D r u c k ( b a r ) 400
H a u p t z e i t 25 Sekunden
AU F G A B E
kurze Bearbeitungszeit
70
ANWENDUNGSBEISPIEL
A P P L I C AT I O N E X A M P L E
M A C H I N I N G TA S K
ANWENDUNGSBEISPIEL
A P P L I C AT I O N E X A M P L E
317
WERKSTCK
Schwungrad
WORKPIECE
Fly wheel
Te i l v o n
Pa r t o f
Pkw
Passenger car
Fo r d e r u n g R Z < 6 m
(Produktionstoleranz)
M a t e r i a l GGG 40
Fe s t i g k e i t 400 N/mm 2
R e q u i r e d f i n i s h R Z < 6 m
(Production tolerance)
M a t e r i a l Nodular cast iron
Te n s i l e s t r e n g t h 400 N/mm 2
WERKZEUG
EG45-1-40M-VDI40
TOOL
EG45-1-40M-VDI40
Maschine
Machine
CNC-Drehmaschine
CNC lathe
Geschwindigkeit
( m / m i n ) 150
D r e h z a h l 300 min -1
Vo r s c h u b ( m m / U ) 0,5
M e s s u h r a n z e i g e ( m m ) 0,4
H a u p t z e i t 19 Sekunden
S p e e d ( m / m i n . ) 150
R o t a t i o n s p e e d ( R P M ) 300
Fe e d r a t e ( m m / r e v. ) 0.5
Dial gauge indication
( m m ) 0.4
P r o c e s s t i m e 19 seconds
AU F G A B E
M A C H I N I N G TA S K
ERGEBNISSE/VORTEILE
Ausschu vermieden
Prozesssicherheit hergestellt
R E S U LT S / A D VA N TA G E S
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WORKPIECE
Ball stud
Te i l v o n
Pa r t o f
Pkw
Passenger car
Fo r d e r u n g
Required finish
R Z < 2 m
R Z < 2 m
geschmiedeter Stahl
Forged steel
Fe s t i g k e i t
Te n s i l e s t r e n g t h
1000 N/mm 2
1000 N/mm 2
WERKZEUG
HG6-6K22-VDI40
Maschine
TOOL
HG6-6K22-VDI40
M a c h i n e CNC lathe
CNC-Drehmaschine
Speed (m/min.)
Geschwindigkeit
( m / m i n ) 250 (konstant)
D r e h z a h l variabel
Vo r s c h u b ( m m / U ) 0,1
D r u c k ( b a r ) 160
H a u p t z e i t 3,8 Sekunden
250 (constant)
Material
318
Material
variable
Fe e d r a t e ( m m / r e v. ) 0.1
P r e s s u r e ( b a r ) 160
P r o c e s s t i m e 3.8 seconds
AU F G A B E
M A C H I N I N G TA S K
ANWENDUNGSBEISPIEL
A P P L I C AT I O N E X A M P L E
319
WERKSTCK
Bremskolben
WORKPIECE
Brake piston
Te i l v o n
Pa r t o f
Schienenfahrzeug-Bremse
Fo r d e r u n g R Z < 2 m
(Hartglattwalzen)
Material
Material
Cr-Ni Stahl
H r t e 58-60 HRC
Cr-Ni Steel
H a r d n e s s 58-60 HRC
WERKZEUG
HG6-5E00-VDI40
TOOL
HG6-5E00-VDI40
Maschine
Machine
CNC-Drehmaschine
CNC lathe
Geschwindigkeit
( m / m i n ) 100
D r e h z a h l 720 min -1
Vo r s c h u b ( m m / U ) 0,08
D r u c k ( b a r ) 400
H a u p t z e i t 1,7 Minuten
S p e e d ( m / m i n . ) 100
Rotation speed
( R P M ) 720
Fe e d r a t e ( m m / r e v. ) 0.08
P r e s s u r e ( b a r ) 400
P r o c e s s t i m e 1.7 minutes
AU F G A B E
hhere Produktionssicherheit
kurze Bearbeitungszeit
kein Umspannen
Section 8
ANWENDUNGSBEISPIEL
A P P L I C AT I O N E X A M P L E
Application Examples
M A C H I N I N G TA S K
No resetting necessary
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71
WORKPIECE
Cam shaft
Te i l v o n
Pa r t o f
Pkw-Motor
Fo r d e r u n g
Required finish
R Z < 2 m
(Reibwert reduzieren)
R Z < 2 m
(Reduce friction)
Material
Material
Schalenhartguss
H r t e 55 HRC
WERKZEUG
HG6-9 Sonderausfhrung
mit verlngertem Hub
TOOL
HG6-9 special version
with extended stroke
Maschine
Machine
Drehmaschine
D r e h z a h l 40 min -1
Lathe
320
R o t a t i o n s p e e d ( R P M ) 40
Fe e d r a t e ( m m / r e v. ) 0.1
P r e s s u r e ( b a r ) 200
Vo r s c h u b ( m m / U ) 0,1
D r u c k ( b a r ) 200
AU F G A B E
Durch Hartglattwalzen soll Reibungskoeffizient
verringert und Verschleifestigkeit erhht werden
M A C H I N I N G TA S K
Hard roller burnishing to reduce coefficient of
friction and increase wear resistance
ERGEBNISSE/VORTEILE
Hrte 6% gesteigert
R E S U LT S / A D VA N TA G E S
Hardness increased by 6%
ANWENDUNGSBEISPIEL
A P P L I C AT I O N E X A M P L E
WERKSTCK
Ventilkappe
WORKPIECE
Valve cap
Te i l v o n
Pa r t o f
Pkw-Motor
Fo r d e r u n g
Required finish
R Z < 2 m
R Z < 2 m
M a t e r i a l Hartguss
H r t e 58 HRC
321
Material
WERKZEUG
HG6-9R00-SL25
TOOL
HG6-9R00-SL25
Maschine
konventionelle Drehmaschine
Machine
Geschwindigkeit
( m / m i n ) 100
Vo r s c h u b
( m m / U ) 0,08
D r u c k ( b a r ) 250
H a u p t z e i t 16 Sekunden
Fe e d r a t e
( m m / r e v. ) 0.08
P r e s s u r e ( b a r ) 250
P r o c e s s t i m e 16 seconds
AU F G A B E
Hrtesteigerung und lngere Lebensdauer
erwartet
ERGEBNISSE/VORTEILE
Lebensdauer im gefeuerten Motor 50% lnger,
jedoch nicht im Komponenten-Teststand
72
ANWENDUNGSBEISPIEL
A P P L I C AT I O N E X A M P L E
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Conventional lathe
S p e e d ( m / m i n . ) 100
M A C H I N I N G TA S K
Increase hardness and service life
R E S U LT S / A D VA N TA G E S
Service life increased 50% in actual engine,
though these results were not repeated in the
engine test stand
Wandlergehuse /
Torque converter housing
322
WORKPIECE
Torque converter housing
WERKSTCK
Wandlergehuse
Pa r t o f
Te i l v o n
Automatik-Getriebe
Fo r d e r u n g
Required finish
R Z < 4 m
R Z < 4 m
Material
Material
Fe s t i g k e i t
Te n s i l e s t r e n g t h
450 N/mm 2
450 N/mm 2
WERKZEUG
HG13-9L15-SL25
TOOL
HG13-9L15-SL25
Maschine
Machine
Vertikal-Drehmaschine
Vertical lathe
Geschwindigkeit
( m / m i n ) 200
D r e h z a h l 1270 min -1
Vo r s c h u b ( m m / U ) 0 , 2 5
D r u c k ( b a r ) 80
H a u p t z e i t 36 Sekunden
S p e e d ( m / m i n . ) 200
Rotation speed
( R P M ) 1270
Fe e d r a t e
( m m / r e v. ) 0.25
P r e s s u r e ( b a r ) 80
P r o c e s s t i m e 36 seconds
AU F G A B E
Oberflche soll gute Gleiteigenschaften aufweisen
M A C H I N I N G TA S K
Surface requires good sliding properties
ERGEBNISSE/VORTEILE
kurze Bearbeitungszeit
R E S U LT S / A D VA N TA G E S
ANWENDUNGSBEISPIEL
A P P L I C AT I O N E X A M P L E
Ventil / Valve
323
WERKSTCK
Ventil
WORKPIECE
Valve
Te i l v o n
Pa r t o f
Dieselmotor
Diesel engine
Fo r d e r u n g
Required finish
erhhte Dauerfestigkeit
M a t e r i a l Stahl
H r t e 55 HRC
WERKZEUG
HG13-9E270-SL25
TOOL
HG13-9E270-SL25
Maschine
Machine
CNC-Drehmaschine
CNC lathe
Geschwindigkeit
( m / m i n ) 150
D r e h z a h l 1200 min -1
Vo r s c h u b
( m m / U ) 0,25
D r u c k ( b a r ) 250
Hauptzeit
S p e e d ( m / m i n . ) 150
Rotation speed
( R P M ) 1200
Fe e d r a t e
( m m / r e v. ) 0.25
P r e s s u r e ( b a r ) 250
Process time
2,5 Minuten
2.5 minutes
AU F G A B E
Festwalzen von unterem Schaftteil, Radius und
Teller in 2 Zonen
M A C H I N I N G TA S K
Deep rolling of lower shaft, radius and disc
in 2 zones
ERGEBNISSE/VORTEILE
verbesserte Produktqualitt: Erhhung der
Dauerfestigkeit auf 250%
R E S U LT S / A D VA N TA G E S
Improved product quality: fatigue strength
increased 250%
Section 8
ANWENDUNGSBEISPIEL
A P P L I C AT I O N E X A M P L E
Application Examples
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73
324
WERKSTCK
Kupplungsscheibe /
Bremsscheibe
WORKPIECE
Clutch disc /Brake disc
Te i l v o n
Nutzfahrzeug
Fo r d e r u n g R Z < 4 m
M a t e r i a l Sphroguss
Fe s t i g k e i t 600 N/mm 2
Required finish
Pa r t o f
R Z < 4 m
M a t e r i a l Nodular iron
Te n s i l e s t r e n g t h
600 N/mm 2
WERKZEUG
HG13-11.3P mit
2 gegenberliegenden
Walzelementen
TOOL
HG13-11.3P with
2 burnishing elements
Machine
Maschine
Double spindle
CNC lathe
2-Spindel
CNC-Drehmaschine
S p e e d ( m / m i n . ) 250
Rotation speed (RPM)
Geschwindigkeit
( m / m i n ) 250
D r e h z a h l 470 min -1
Vo r s c h u b ( m m / U ) 0,2
D r u c k ( b a r ) 120
H a u p t z e i t 32 Sekunden
470
Fe e d r a t e ( m m / r e v. ) 0.2
P r e s s u r e ( b a r ) 120
P r o c e s s t i m e 32 seconds
AU F G A B E
beidseitige, gleichzeitige Bearbeitung
M A C H I N I N G TA S K
To machine both sides simultaneously
ERGEBNISSE/VORTEILE
wesentliche Kostensenkung durch
greren Vorschub beim Drehen
lngere Schneidenstandzeit
weniger Werkzeugwechsel
R E S U LT S / A D VA N TA G E S
Significant cost reduction due to
greater feed rate during turning
ANWENDUNGSBEISPIEL
A P P L I C AT I O N E X A M P L E
325
WERKSTCK
Wanne
WORKPIECE
Half pipe
Te i l v o n
Pa r t o f
Industrie-Heimangel
Fo r d e r u n g R Z < 3 m
M a t e r i a l 1.4401
Streckgrenze
Yield strength
200 N/mm 2
200 N/mm 2
WERKZEUG
4 x EG14-1-SL00
an 4-FlgelWerkzeugtrger
TOOL
4 x EG14-1-SL00
on a 4 wing tool carrier
Maschine
Machine
Spezial-Frsmaschine
Geschwindigkeit
( m / m i n ) 50
D r e h z a h l 7 min -1
Vo r s c h u b ( m m / U ) 3,2
M e s s u h r a n z e i g e ( m m ) 0,8
H a u p t z e i t 157 Minuten
EG14-1
AU F G A B E
74
ANWENDUNGSBEISPIEL
A P P L I C AT I O N E X A M P L E
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157 minutes
M A C H I N I N G TA S K
326
WERKSTCK
Ventilgehuse
WORKPIECE
Valve housing
Te i l v o n
Pa r t o f
Armatur
Armature
Fo r d e r u n g R Z < 1 m
Material
Required finish
rostfreier Stahl
Fe s t i g k e i t
M a t e r i a l Stainless steel
Te n s i l e s t r e n g t h
400 N/mm 2
400 N/mm 2
WERKZEUG
HG13-4X
TOOL
HG13-4X
Maschine
Machine
Spezialmaschine
Special machine
Geschwindigkeit
( m / m i n ) 200
D r e h z a h l 900 min -1
Vo r s c h u b ( m m / U ) 0,2
D r u c k ( b a r ) 100
H a u p t z e i t 15 Sekunden
S p e e d ( m / m i n . ) 200
Rotation speed
( R P M ) 900
Fe e d r a t e ( m m / r e v. ) 0.2
P r e s s u r e ( b a r ) 100
P r o c e s s t i m e 15 seconds
R Z < 1 m
AU F G A B E
M A C H I N I N G TA S K
ANWENDUNGSBEISPIEL
A P P L I C AT I O N E X A M P L E
327
WERKSTCK
Bremstrommel
WORKPIECE
Brake drum
Te i l v o n
Pa r t o f
Motorrad
Motorcycle
Fo r d e r u n g
Required finish
R Z < 4 m
R Z < 4 m
WERKZEUG
HG6-2
TOOL
HG6-2
Maschine
Machine
CNC-Drehmaschine
CNC lathe
Geschwindigkeit
( m / m i n ) 180
D r e h z a h l 380 min -1
Vo r s c h u b ( m m / U ) 0,2
D r u c k ( b a r ) 100
H a u p t z e i t 40 Sekunden
S p e e d ( m / m i n . ) 180
R o t a t i o n s p e e d ( R P M ) 380
Fe e d r a t e ( m m / r e v. ) o.2
P r e s s u r e ( b a r ) 100
P r o c e s s t i m e 40 seconds
M a t e r i a l GGG
AU F G A B E
weniger Verschlei
hhere Sicherheit
Section 8
ANWENDUNGSBEISPIEL
A P P L I C AT I O N E X A M P L E
Application Examples
M A C H I N I N G TA S K
Less wear
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75
WORKPIECE
Glass forming mandrel
Te i l v o n
Pa r t o f
Werkzeug fr
Glasflaschen
Fo r d e r u n g
R Z < 2 m
330
Required finish
R Z < 2 m
M a t e r i a l Steel
H a r d n e s s 55 HRC
Av e r a g e ( m m ) 35
Av e r a g e l e n g t h ( m m ) 135
M a t e r i a l Stahl
H r t e 55 HRC
m i t t l e r e r ( m m ) 35
m i t t l e r e L n g e ( m m ) 135
TOOL
HG6-9L65-SLK20
HG6-9L15-SLK20
WERKZEUG
HG6-9L65-SLK20
HG6-9L15-SLK20
Machine
Maschine
CNC lathe
CNC-Drehmaschine
G e s c h w i n d i g k e i t ( m / m i n ) 200
D r e h z a h l 1800 min -1
Vo r s c h u b ( m m / U ) 0,1
D r u c k ( b a r ) 300
H a u p t z e i t 45 Sekunden
AU F G A B E
Hrtezunahme
gleichmige Qualitt
S p e e d ( m / m i n . ) 200
R o t a t i o n s p e e d ( R P M ) 1800
Fe e d r a t e ( m m / r e v. ) o.1
P r e s s u r e ( b a r ) 300
P r o c e s s t i m e 45 seconds
M A C H I N I N G TA S K
Consistent quality
ANWENDUNGSBEISPIEL
A P P L I C AT I O N E X A M P L E
331
WERKSTCK
Rolle
WORKPIECE
Roller for rocker arm
Te i l v o n
Pa r t o f
Dieselmotor
Diesel engine
Fo r d e r u n g
Required finish
R max. < 1 m
R max. < 1 m
Einsatzstahl
H r t e 59-63 HRC
Case-hardened steel
H a r d n e s s 59-63 HRC
Bohrungsdurchmesser
( m m ) 45
L n g e ( m m ) 50
B o r e d i a m e t e r ( m m ) 45
L e n g t h ( m m ) 50
WERKZEUG
HG6-1-VDI40
TOOL
HG6-1-VDI40
Maschine
Machine
CNC-Drehmaschine
CNC lathe
Geschwindigkeit
( m / m i n ) 125
D r e h z a h l 900 min -1
Vo r s c h u b ( m m / U ) 0,08
D r u c k ( b a r ) 400
H a u p t z e i t 43 Sekunden
S p e e d ( m / m i n . ) 125
Rotation speed
( R P M ) 900
Fe e d r a t e ( m m / r e v. ) 0.08
P r e s s u r e ( b a r ) 400
P r o c e s s t i m e 43 seconds
Material
Material
AU F G A B E
Hartglattwalzen in einer Aufspannung nach dem
Hartdrehen
ERGEBNISSE/VORTEILE
Einsparung des separaten Lppvorganges
76
ANWENDUNGSBEISPIEL
A P P L I C AT I O N E X A M P L E
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M A C H I N I N G TA S K
Roller burnishing in one setting after hard turning
R E S U LT S / A D VA N TA G E S
Process time saved: no separate lapping
operation required
332
WERKSTCK
Schneckenwelle
WORKPIECE
Helix shaft
Te i l v o n
Pa r t o f
Spritzgussmaschine
Fo r d e r u n g R Z < 1 m
M a t e r i a l Vergtungsstahl
H r t e 55 HRC
B o h r u n g s d u r c h m e s s e r ( m m ) 26
L n g e ( m m ) 80
WERKZEUG
HG6-1-VDI40 mit
Hydraulikaggregat HGP1.4
TOOL
HG6-1-VDI40 with
hydraulic pump unit HGP1.4
Maschine
Machine
CNC-Drehmaschine
CNC lathe
Geschwindigkeit
( m / m i n ) 73
D r e h z a h l 900 min -1
Vo r s c h u b ( m m / U ) 0,08
D r u c k ( b a r ) 300
H a u p t z e i t 67 Sekunden
S p e e d ( m / m i n . ) 73
R o t a t i o n s p e e d ( R P M ) 900
Fe e d r a t e ( m m / r e v. ) 0.08
P r e s s u r e ( b a r ) 300
P r o c e s s t i m e 67 seconds
AU F G A B E
M A C H I N I N G TA S K
ANWENDUNGSBEISPIEL
A P P L I C AT I O N E X A M P L E
Section 8
ANWENDUNGSBEISPIEL
A P P L I C AT I O N E X A M P L E
Application Examples
333
WERKSTCK
Formdorn
WORKPIECE
Mandrel for injection mold
Te i l v o n
Pa r t o f
Spritzgussform
Fo r d e r u n g R Z < 1 m
Werkzeugstahl
H r t e 48-52 HRC
M a t e r i a l Tool steel
H a r d n e s s 48-52 HRC
Av e r a g e ( m m ) 45
L e n g t h ( m m ) 250
Required finish
R Z < 1 m
Material
m i t t l e r e r ( m m ) 45
L n g e ( m m ) 250
WERKZEUG
HG6-11E00-VDI20 mit
Hydraulikaggregat HGP1.3
TOOL
HG6-11E00-VDI20 with
hydraulic pump unit HGP1.3
M a c h i n e CNC lathe
S p e e d ( m / m i n . ) 180
Maschine
CNC-Drehmaschine
Geschwindigkeit
( m / m i n ) 180
mittlere Drehzahl
Av e r a g e r o t a t i o n s p e e d
( R P M ) 1280
Fe e d r a t e ( m m / r e v. ) 0.1
P r e s s u r e ( b a r ) 250
P r o c e s s t i m e 120 seconds
1280 min -1
Vo r s c h u b ( m m / U ) 0,1
D r u c k ( b a r ) 250
H a u p t z e i t 120 Sekunden
AU F G A B E
M A C H I N I N G TA S K
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ANWENDUNGSBEISPIEL
A P P L I C AT I O N E X A M P L E
Pressdorn / Punch
WERKSTCK
Pressdorn
WORKPIECE
Punch
Te i l v o n
Pa r t o f
Prgewerkzeug
Forming tool
Fo r d e r u n g
Required finish
R a < 0,1 m
R a < 0.1 m
M a t e r i a l Tool steel
H a r d n e s s 64 +1 HRC
D i a m e t e r ( m m ) 15
Material
Werkzeugstahl
H r t e 64 +1 HRC
334
D u r c h m e s s e r ( m m ) 15
TOOL
HG6-9E00-SL25 with
hydraulic pump unit HGP1.3
WERKZEUG
HG6-9E00-SL25 mit
Hydraulikaggregat HGP1.3
Machine
Maschine
CNC lathe
C NC-Drehmaschine
S p e e d ( m / m i n . ) 40
Av e r a g e r o t a t i o n s p e e d
( R P M ) 640
Fe e d r a t e ( m m / r e v. ) 0.08
P r e s s u r e ( b a r ) 400
P r o c e s s t i m e 18 seconds
G e s c h w i n d i g k e i t ( m / m i n ) 40
m i t t l e r e D r e h z a h l 640 min -1
Vo r s c h u b ( m m / U ) 0,08
D r u c k ( b a r ) 400
H a u p t z e i t 18 Sekunden
AU F G A B E
Hartglattwalzen der Kuppe ber das Zentrum
und die Signierung
M A C H I N I N G TA S K
Hard roller burnish the entire rounded end,
including the center and engraved lettering
ERGEBNISSE/VORTEILE
Zeiteinsparung durch Wegfall eine separaten
Arbeitsganges
R E S U LT S / A D VA N TA G E S
Process time saved: no hand polishing required
WORKPIECE
Control piston
Te i l v o n
Pa r t o f
Hydraulikventil
Fo r d e r u n g R Z < 1 m
Hydraulic valve
Stahl, vakuumgehrtet
H r t e 52 HRC
D u r c h m e s s e r ( m m ) 25
L n g e ( m m ) 80
Material
335
Required finish
R Z < 1 m
Material
WERKZEUG
HG6-9E00-SL25
TOOL
HG6-9E00-SL25
M a c h i n e CNC lathe
S p e e d ( m / m i n . ) 120
Maschine
CNC-Drehmaschine
Geschwindigkeit
( m / m i n ) 120
D r e h z a h l 1530 min -1
Vo r s c h u b ( m m / U ) 0,08
D r u c k ( b a r ) 320
H a u p t z e i t 39 Sekunden
78
ANWENDUNGSBEISPIEL
A P P L I C AT I O N E X A M P L E
Rotation speed
( R P M ) 1530
Fe e d r a t e ( m m / r e v. ) 0.08
P r e s s u r e ( b a r ) 320
P r o c e s s t i m e 39 seconds
AU F G A B E
Die Bearbeitung erfolgt in einer Aufspannung
nach dem Hartdrehen
M A C H I N I N G TA S K
Roller burnishing takes place in one setting
after hard turning
ERGEBNISSE/VORTEILE
Einsparung von Schleifen und Auenhonen
durch Glattwalzen
R E S U LT S / A D VA N TA G E S
Process time saved: no subsequent honing or
grinding necessary
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Achswelle / Getriebewelle
Axle shaft / Gear shaft
WERKSTCK
Achswelle / Getriebewelle
Te i l v o n Ackerschlepper
Fo r d e r u n g R Z < 0,8 - 2,5 m
M a t e r i a l Einsatzstahl
H r t e 58-60 HRC
WORKPIECE
Axle shaft / Gear shaft
Pa r t o f Tractor
Te i l 1 / Pa r t 1
Durchmesser/Diameter = 30 mm
Lnge/Length = 35 mm
Required finish
WERKZEUG
angetriebenes Werkzeug
HG6-5E30-VDI40
TOOL
Driven tool HG6-5E30-VDI40
with integrated pump
M a c h i n e CNC lathe
S p e e d ( m / m i n . ) 150
Maschine
CNC-Drehmaschine
Geschwindigkeit
( m / m i n ) 150
D r e h z a h l ( Te i l 1 )
1600 min -1
D r e h z a h l ( Te i l 2 )
336
Te i l 2 / Pa r t 2
Durchmesser/Diameter = 90 mm
Lnge/Length = 25 mm
530 min -1
Vo r s c h u b
( m m / U ) 0,1
D r u c k ( b a r ) 400
H a u p t z e i t ( Te i l 1 ) 13 Sekunden
H a u p t z e i t ( Te i l 2 ) 28 Sekunden
AU F G A B E
R o t a t i o n s p e e d ( Pa r t 1 )
( R P M ) 1600
R o t a t i o n s p e e d ( Pa r t 2 )
( R P M ) 530
Fe e d r a t e ( m m / r e v. ) 0.1
P r e s s u r e ( b a r ) 400
P r o c e s s t i m e ( Pa r t 1 ) 13 seconds
P r o c e s s t i m e ( Pa r t 2 ) 28 seconds
M A C H I N I N G TA S K
ANWENDUNGSBEISPIEL
A P P L I C AT I O N E X A M P L E
337
WERKSTCK
Schaftkegelrad
mit diversen Durchmesser
WORKPIECE
Gear shaft
with various diameters
Te i l v o n
Pa r t o f
Fahrzeuggetriebe
Automotive gear
Fo r d e r u n g
Required finish
R Z < 1 m
R Z < 1 m
Einsatzstahl
H r t e 60-62 HRC
WERKZEUG
HG6-9
TOOL
HG6-9
Maschine
Machine
CNC-Drehmaschine
CNC lathe
Geschwindigkeit
( m / m i n ) 150
Vo r s c h u b ( m m / U ) 0,2
D r u c k ( b a r ) 400
Hauptzeit
S p e e d ( m / m i n . ) 150
Fe e d r a t e ( m m / r e v. ) 0.2
P r e s s u r e ( b a r ) 400
Process time
Material
Section 8
ANWENDUNGSBEISPIEL
A P P L I C AT I O N E X A M P L E
Application Examples
Material
3 seconds
3 Sekunden
AU F G A B E
Hartglattwalzen von Dichtungs- und
Lageraufflchen nach dem Hartdrehen
M A C H I N I N G TA S K
Hard roller burnish the seal and bearing seats
after hard turning
ERGEBNISSE/VORTEILE
Einsparung des Schleifens
R E S U LT S / A D VA N TA G E S
Shorter process time: no grinding required
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ANWENDUNGSBEISPIEL
A P P L I C AT I O N E X A M P L E
WORKPIECE
Turbine wheel
Te i l v o n
Pa r t o f
Dampfturbine
Steam turbine
Fo r d e r u n g
Required finish
Spannungsrisskorrosion
vermeiden
Material
Material
Vergtungsstahl
H r t e 45 HRC
Fe s t i g k e i t
Te n s i l e s t r e n g t h
1200 N/mm 2
1200 N/mm 2
WERKZEUG
HG13-9E270-SL32
TOOL
HG13-9E270-SL32
Maschine
Machine
Karusselldrehmaschine
Vertical lathe
Geschwindigkeit
( m / m i n ) 100
D r e h z a h l 25-40 min -1
Vo r s c h u b ( m m / U ) 0,44
D r u c k ( b a r ) 200
H a u p t z e i t 60 Minuten
S p e e d ( m / m i n . ) 100
Rotation speed
( R P M ) 25-40
Fe e d r a t e ( m m / r e v. ) 0.44
P r e s s u r e ( b a r ) 200
P r o c e s s t i m e 60 minutes
AU F G A B E
M A C H I N I N G TA S K
Deep roll the curved area between the hub and outer rim
ANWENDUNGSBEISPIEL
A P P L I C AT I O N E X A M P L E
502
WERKSTCK
Sicherungsbohrung
WORKPIECE
Securing bore
Te i l v o n
Pa r t o f
Turbinenscheibe
fr Dampfturbine
Material
Material
Vergtungsstahl
H r t e 45 HRC
Te n s i l e s t r e n g t h
1300 N/mm 2
Fe s t i g k e i t
1300 N/mm 2
TOOL
HG6-1E15ZS40DD
HG6-1E20ZS40DD
WERKZEUG
HG6-1E15ZS40DD
HG6-1E20ZS40DD
Machine
Maschine
Milling center
Bearbeitungszentrum
D r e h z a h l 90 min -1
Rotation speed
( R P M ) 90
Fe e d r a t e
( m m / r e v. ) 0.25
P r e s s u r e ( b a r ) 250
P r o c e s s t i m e 15 minutes
Vo r s c h u b
( m m / U ) 0,25
D r u c k ( b a r ) 250
H a u p t z e i t 15 Minuten
80
501
AU F G A B E
M A C H I N I N G TA S K
ERGEBNISSE/VORTEILE
R E S U LT S / A D VA N TA G E S
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503
WERKSTCK
Kegelstiftbohrung
WORKPIECE
Taper pin hole
Te i l v o n
Pa r t o f
Turbinenscheibe fr Dampfturbine
Material
Material
Vergtungsstahl
H r t e 45 HRC
Fe s t i g k e i t
Te n s i l e s t r e n g t h
1300 N/mm 2
1300 N/mm 2
WERKZEUG
HG3-11
TOOL
HG3-11
Maschine
Machine
Radialbohrmaschine
Vertical drill
Geschwindigkeit
( m / m i n ) 25
D r e h z a h l 660 min -1
Vo r s c h u b ( m m / U ) 0,2
D r u c k ( b a r ) 250
H a u p t z e i t 75 Sekunden
S p e e d ( m / m i n . ) 25
Rotation speed
( R P M ) 660
Fe e d r a t e ( m m / r e v. ) 0.2
P r e s s u r e ( b a r ) 250
P r o c e s s t i m e 75 seconds
AU F G A B E
M A C H I N I N G TA S K
ERGEBNISSE/VORTEILE
R E S U LT S / A D VA N TA G E S
ANWENDUNGSBEISPIEL
A P P L I C AT I O N E X A M P L E
Section 8
ANWENDUNGSBEISPIEL
A P P L I C AT I O N E X A M P L E
Application Examples
504
WERKSTCK
Dehnschraube
WORKPIECE
Tension bolt
Te i l v o n
Pa r t o f
FlugzeugTriebwerksaufhngung
M a t e r i a l Titan-Legierung
Fe s t i g k e i t
1600 N/mm 2
Te n s i l e s t r e n g t h
1600 N/mm 2
TOOL
HG6-9R00-SL25
WERKZEUG
HG6-9R00-SL25
Machine
Maschine
CNC lathe
CNC-Drehmaschine
S p e e d ( m / m i n . ) 60
Rotation speed (RPM)
Geschwindigkeit
( m / m i n ) 60
Drehzahl
1000
Fe e d r a t e ( m m / r e v. )
0.3
1000 min -1
P r e s s u r e ( b a r ) 250
Process time
Vo r s c h u b ( m m / U )
0,3
28 seconds
D r u c k ( b a r ) 250
H a u p t z e i t 28 Sekunden
AU F G A B E
Erhhung der Dauerfestigkeit durch Festwalzen
M A C H I N I N G TA S K
Deep rolling to improve fatigue strength
ERGEBNISSE/VORTEILE
R E S U LT S / A D VA N TA G E S
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ANWENDUNGSBEISPIEL
A P P L I C AT I O N E X A M P L E
WORKPIECE
Flexible shaft
Te i l v o n
Pa r t o f
Exzenterschneckenpumpe
Material
Material
Vergtungsstahl
Fe s t i g k e i t
Te n s i l e s t r e n g t h
1600 N/mm 2
1600 N/mm 2
WERKZEUG
HG6-5E00-VDI50
TOOL
HG6-5E00-VDI50
Maschine
Machine
CNC-Drehmaschine
CNC lathe
Geschwindigkeit
( m / m i n ) 100
Vo r s c h u b ( m m / U ) 0,3
D r u c k ( b a r ) 350
S p e e d ( m / m i n . ) 100
Fe e d r a t e ( m m / r e v. ) 0.3
P r e s s u r e ( b a r ) 350
AU F G A B E
Bei einem Teil der Anwendungen wird der
gesamte eingeschnrte Bereich festgewalzt,
bei anderen nur die Radien
M A C H I N I N G TA S K
Some of the applications required deep rolling
of the entire neck length, others required deep
rolling just the fillet
ERGEBNISSE/VORTEILE
Erhhung der Dauerfestigkeit um 40%
R E S U LT S / A D VA N TA G E S
Fatigue strength increased by 40%
ANWENDUNGSBEISPIEL
A P P L I C AT I O N E X A M P L E
82
505
506
WERKSTCK
API-Kegelgewinde
WORKPIECE
API thread pin (tapered)
Te i l v o n
Pa r t o f
Verbindung fr
Erdltiefbohrgert
Fo r d e r u n g
Required result
hhere Betriebsfestigkeit
M a t e r i a l 42 CrMo 4 V
Fe s t i g k e i t 1200 N/mm 2
S t r e c k g r e n z e 900 N/mm 2
WERKZEUG
EF90-025-R0,8-VDI50
TOOL
EF90-025-R0.8-VDI50
Maschine
Machine
CNC-Drehmaschine
CNC lathe
Geschwindigkeit
( m / m i n ) 20
D r e h z a h l 53 min -1
Vo r s c h u b ( m m / U ) 6,35
M e s s u h r a n z e i g e ( m m ) 0,9
Wa l z k r a f t ( N ) 8500
H a u p t z e i t 53 Sekunden
S p e e d ( m / m i n . ) 20
R o t a t i o n s p e e d ( R P M ) 53
Fe e d r a t e ( m m / r e v. ) 6.35
Dial gauge indication
( m m ) 0.9
B u r n i s h i n g f o r c e ( N ) 8500
P r o c e s s t i m e 53 seconds
AU F G A B E
M A C H I N I N G TA S K
ERGEBNISSE/VORTEILE
Prozesszeit verkrzt
R E S U LT S / A D VA N TA G E S
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WORKPIECE
Tie bar
Te i l v o n
Pa r t o f
Spritzgussmaschine
Material
Material
Vergtungsstahl
H r t e 42 HRC
Fe s t i g k e i t
Te n s i l e s t r e n g t h
1000 N/mm 2
1000 N/mm 2
Streckgrenze
Y i e l d s t r e n g t h 650 N/mm 2
D i a m e t e r ( m m ) 32-100
650 N/mm 2
507
Durchmesser (mm)
32-100
TOOL
HG6-9R00-SL32
WERKZEUG
HG6-9R00-SL32
D r e h z a h l 100 min -1
Vo r s c h u b ( m m / U ) 0,2
D r u c k ( b a r ) 350
H a u p t z e i t 2,5 Minuten
Rotation speed
( R P M ) 100
Fe e d r a t e ( m m / r e v. ) 0.2
P r e s s u r e ( b a r ) 350
P r o c e s s t i m e 2.5 minutes
AU F G A B E
M A C H I N I N G TA S K
ERGEBNISSE/VORTEILE
Im Teststand dauerfest
R E S U LT S / A D VA N TA G E S
ANWENDUNGSBEISPIEL
A P P L I C AT I O N E X A M P L E
508
WERKSTCK
Kurbelwelle
WORKPIECE
Crank shaft
Te i l v o n
Pa r t o f
Kolbenkompressor
M a t e r i a l GGG 60
H r t e 55 HRC
WERKZEUG
HG13R mit Profilrolle
TOOL
HG13R with profile roller
Maschine
Machine
CNC-Drehmaschine
CNC lathe
Geschwindigkeit
(m/min) 8
D r e h z a h l 60 min -1
Vo r s c h u b ( m m / U ) 0
Speed (m/min.) 8
R o t a t i o n s p e e d ( R P M ) 60
Fe e d r a t e ( m m / r e v. ) 0
(Einstichverfahren)
D r u c k ( b a r ) 400
D r u c k a u f b a u 0>400 bar, Druck halten
D r u c k a b b a u 400>50 bar
(Auf- und Abbau jeweils 5 Sekunden)
H a u p t z e i t 30 Sekunden
AU F G A B E
Section 8
ANWENDUNGSBEISPIEL
A P P L I C AT I O N E X A M P L E
Application Examples
(plunge process)
P r e s s u r e ( b a r ) 400
P r e s s u r e b u i l d - u p 0>400 bar, hold pressure steady
P r e s s u r e r e l e a s e 400>50 bar
(for build-up and release allow 5 seconds each)
P r o c e s s t i m e 30 seconds
M A C H I N I N G TA S K
The crank shafts are fixed in the center for deep rolling
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ANWENDUNGSBEISPIEL
A P P L I C AT I O N E X A M P L E
WERKSTCK
Zylinderbuchse
Te i l v o n Schiffsdiesel
M a t e r i a l GGG 40
Fe s t i g k e i t 400 N/mm 2
WORKPIECE
Cylinder liner
Pa r t o f
Auendurchmesser
( m m ) ca. 300
H o h l k e h l e R a d i u s ( m m ) 2,5
WERKZEUG
EF45-1-VDI40
TOOL
EF45-1-VDI40
M a c h i n e CNC lathe
S p e e d ( m / m i n . ) 50
Maschine
CNC-Drehmaschine
G e s c h w i n d i g k e i t ( m / m i n ) 50
D r e h z a h l 50 min -1
Vo r s c h u b ( m m / U ) 0
R o t a t i o n s p e e d ( R P M ) 50
Fe e d r a t e ( m m / r e v. ) 0
(plunge process)
(Einstichverfahren)
B u r n i s h i n g f o r c e ( k N ) 10
P r o c e s s t i m e 18 seconds
Fe s t w a l z k r a f t ( k N ) 10
H a u p t z e i t 18 Sekunden
AU F G A B E
konstante Kraft>10 kN
Kraftabbau 10>0 kN
jeweils 5 Umdrehungen
ERGEBNISSE/VORTEILE
M A C H I N I N G TA S K
Deep roll the fillet to prevent fatigue cracks
R E S U LT S / A D VA N TA G E S
ANWENDUNGSBEISPIEL
A P P L I C AT I O N E X A M P L E
510
WERKSTCK
Radflansch
WORKPIECE
Wheel flange
Te i l v o n
Pa r t o f
Pkw-Vorderachse
M a t e r i a l G Stahl
H r t e 40 HRC
Fe s t i g k e i t 1000 N/mm 2
S t r e c k g r e n z e 700 N/mm 2
Auendurchmesser (mm)
38 und 45
38 and 45
Fi l l e t r a d i u s ( m m ) 5
WERKZEUG
HG6-9R30-SLK25 und
HG6-9R60-SLK25
TOOL
HG6-9R30-SLK25 and
HG6-9R60-SLK25
M a c h i n e CNC lathe
S p e e d ( m / m i n . ) 100
Maschine
CNC-Drehmaschine
R o t a t i o n s p e e d ( R P M ) 800
Fe e d r a t e ( m m / r e v. ) 0.2
P r e s s u r e ( b a r ) 250
P r o c e s s t i m e 25 seconds
Geschwindigkeit
( m / m i n ) 100
D r e h z a h l 800 min -1
Vo r s c h u b ( m m / U ) 0,2
D r u c k ( b a r ) 250
H a u p t z e i t 25 Sekunden
AU F G A B E
Betriebssicherheit erhht
84
509
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M A C H I N I N G TA S K
Hochfeste Schraube /
High strength screw
511
WORKPIECE
High strength screw
WERKSTCK
hochfeste Schraube
Pa r t o f
Te i l v o n
Pkw-Vorderachse
M a t e r i a l Stahl
(Schmiederohlingen)
H r t e 48 HRC
Fe s t i g k e i t 1400 N/mm 2
S t r e c k g r e n z e 1000 N/mm 2
Te n s i l e s t r e n g t h
1400 N/mm 2
Yield strength
1000 N/mm 2
Fi l l e t r a d i u s ( m m ) 2
WERKZEUG
EF45
TOOL
EF45
Maschine
M a c h i n e CNC lathe
Speed (m/min.) 5
Rotation speed
( R P M ) 140
P r o c e s s t i m e 7 seconds
CNC-Drehmaschine
Geschwindigkeit
(m/min) 5
D r e h z a h l 140 min -1
H a u p t z e i t 7 Sekunden
AU F G A B E
Betriebssicherheit erhht
M A C H I N I N G TA S K
Section 8
ANWENDUNGSBEISPIEL
A P P L I C AT I O N E X A M P L E
Application Examples
R E S U LT S / A D VA N TA G E S
ANWENDUNGSBEISPIEL
A P P L I C AT I O N E X A M P L E
512
WERKSTCK
Hohlwelle
WORKPIECE
Hollow shaft
Te i l v o n
Pa r t o f
Spezialmaschine
M a t e r i a l Stahl
Special machine
M a t e r i a l Steel
Fe s t i g k e i t
Te n s i l e s t r e n g t h
1100 N/mm 2
1100 N/mm 2
WERKZEUG
HG13-2
TOOL
HG13-2
Maschine
Machine
CNC-Drehmaschine
CNC lathe
Geschwindigkeit
( m / m i n ) 120
D r e h z a h l 225 min -1
Vo r s c h u b ( m m / U ) 0,5
D r u c k ( b a r ) 130
H a u p t z e i t 14 Minuten
S p e e d ( m / m i n . ) 120
R o t a t i o n s p e e d ( R P M ) 225
Fe e d r a t e ( m m / r e v. ) 0.5
P r e s s u r e ( b a r ) 130
P r o c e s s t i m e 14 minutes
AU F G A B E
M A C H I N I N G TA S K
ERGEBNISSE/VORTEILE
hhere Sicherheit
R E S U LT S / A D VA N TA G E S
Increased reliability
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85
ANWENDUNGSBEISPIEL
A P P L I C AT I O N E X A M P L E
Flugzeug
Material
AluminiumLegierung
WORKPIECE
Wheel rim
Te i l 1 Hohlkehle-Radius (3 mm)
in Lagerbohrung
Einstichverfahren mit RK
Pa r t o f
Aircraft
Material
Aluminum alloy
T O O L ( Pa r t 1 )
RK
M a c h i n e CNC lathe
S p e e d ( m / m i n . ) 40
WERKZEUG
( Te i l 1 )
RK
Maschine
CNC-Drehmaschine
Rotation speed
( R P M ) 140
P r o c e s s t i m e 6 seconds
G e s c h w i n d i g k e i t ( m / m i n ) 40
D r e h z a h l 140 min -1
H a u p t z e i t 6 Sekunden
W E R K Z E U G ( Te i l 2 )
EF90
M a s c h i n e CNC-Drehmaschine
G e s c h w i n d i g k e i t ( m / m i n ) 150
D r e h z a h l 140 min -1
Vo r s c h u b ( m m / U ) 0,3
H a u p t z e i t 15 Sekunden
Te i l 2 Hohlkehle-Radius (6 mm)
des Felgenkrpers
Vorschubverfahren mit EF90
Pa r t 2 Fillet radius (6 mm)
in the wheel rim body
Feed process with EF90
AU F G A B E
Das EF90 walzt den Radius im Radkrper im Vorschubverfahren und fhrt dabei eine programmgesteuerte Kurve aus
ERGEBNISSE/VORTEILE
Flugzeugfederbein /
Aircraft shock strut
W E R K Z E U G ( Pa r t 2 )
EF90
M a c h i n e CNC lathe
S p e e d ( m / m i n . ) 150
Rotation speed
( R P M ) 140
Fe e d r a t e ( m m / r e v. ) 0.3
P r o c e s s t i m e 15 seconds
M A C H I N I N G TA S K
The RK tool deep rolls the bearing bores undercut in a plunge process in about 15 revolutions
ANWENDUNGSBEISPIEL
A P P L I C AT I O N E X A M P L E
514
WERKSTCK
Federbein
WORKPIECE
Shock strut
Te i l v o n
Pa r t o f
Flugzeug
Aircraft
WERKZEUG
HG6-1
TOOL
HG6-1
Maschine
Machine
CNC-Drehmaschine
CNC lathe
Geschwindigkeit
( m / m i n ) 100
D r e h z a h l 270 min -1
Vo r s c h u b ( m m / U ) 0,3
H a u p t z e i t 110 Sekunden
S p e e d ( m / m i n . ) 100
Rotation speed
( R P M ) 270
Fe e d r a t e ( m m / r e v. ) 0.3
P r o c e s s t i m e 110 seconds
AU F G A B E
86
513
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M A C H I N I N G TA S K
Section 8
Application Examples
TURNED
ROLLER BURNISHED
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87
Appendix
88
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Section 9
Appendix
Maximum roughness up to Rz = 4 m
Ra value up to 0.6 m
Drawing 2
Maximum roughness up to Rz = 8 m
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89
Surface Characteristics
Surface structure determines wear behavior
On sliding surfaces, protruding peaks can lead to increased friction and premature wear.
Plateau-like surfaces with pronounced grooves provide good lubrication and the best
sliding properties.
The prole characteristics demonstrated by the material curve provide quick information
regarding the surface structure.
An Overview of
Appendix
Its easy to describe the fractional size of a m: one, two or three places after the decimal point.
This graphic presents in a dierent context.
90
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Section 9
Appendix
Reduce costs
Substantial cost savings are realized when expensive technologies such as grinding or honing
are replaced by a more cost eective treatment. Cost savings accrue rst of all because the roller
burnishing and deep rolling work
cycle is signicantly shorter than
the alternative processes.
Non-productive time is cut down
dramatically because ECOROLL
roller burnishing and deep rolling
tools oer complete processing
on one machine in one setting
with no change-over. Its no longer
necessary to transport the part
between two or more machines.
And nally, these processes
produce no dust or residue, saving
disposal costs.
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91
Metal Surface
Improvement
Increased
fatigue
strength
Smooth
surfaces