Frequently Asked Questions
- What is roller burnishing?
- As a forming operation, roller burnishing, also called burnishing will generate top-quality mirror-finished component surfaces or surfaces with a pre-defined surface structure. This process is applicable whenever metal components with high or pre-defined surface quality are required, or the desired quality can not be achieved by machining in a reliable manner.
- What is deep rolling?
- Deep rolling, as a forming operation, significantly strengthens the boundary layers of a component. It is only in the case of deep rolling that three effects are achieved: smoothing the surface, induction of residual stresses into the rim zone and cold strengthening of boundary layers.
- What is the difference between roller burnishing and deep rolling?
- Roller burnishing and deep rolling are related processes. In both processes boundary layers of a work piece are plastified and formed by a rolling element, which can be a ball as well as a roller. The main difference is goal setting. The goal of roller burnishing is to achieve a specific surface quality in the form of a pre-defined roughness value, while deep rolling focuses on increasing the operational stability of the part. Although the increase of the component lifetime is based on roller burnishing, the induction of residual stresses and cold strengthening has a more significant influence.
- What is the difference between rolling, roller burnishing and deep rolling?
- Rolling is defined as machining a work piece by using tools with buffed active surfaces in order to obtain a certain level of dimensional and geometric quality, as well as a smooth surface condition (see VDI/VDE (Association of German Engineers/ Federation of Electro-technology Electronics Information Technology), policy 2032). This process results in glossy surfaces. The default tool for rolling is a roughened burnishing wheel, made of tool steel, carbide or ceramic. Rolling is often wrongly equated with roller burnishing and deep rolling. The rolled surface however, differs significantly in structure from a cold-formed roller burnished or deep rolled surface.
- What materials are suitable for roller burnishing and deep rolling?
- Roller burnishing and deep rolling can be applied to almost all metal materials. The areas of application currently extend from steels and cast materials to lightweight alloys such as aluminium, titanium and magnesium.
- What are the application areas of these processes?
- Application areas of roller burnishing and deep rolling include general engineering, automotive and aircraft construction, engine construction, as well as power plant and medical engineering. Roller burnishing is applied if metal components with high or pre-defined surface quality are requested, or the desired quality can not be achieved in a reliable manner by machining. When the need is for increasing the operational stability of a metal material or realizing solutions for lightweight-construction, deep rolling is applicable.
- What machines are suitable for roller burnishing and deep rolling tools?
- Roller burnishing and deep rolling tools can be used on almost any machine (e.g. conventional or CNC lathe, drilling machines, deep-hole drilling machines and machining centres). Therefore, a work piece can be roller burnished or deep rolled directly after machining it in one setting. In certain cases and on request, special deep rolling machines can be designed.
- Where to buy ECOROLL roller burnishing and deep rolling tools?
In close cooperation with our customers, demand-oriented tools and machines for rollers burnishing and deep rolling as well as processing cylinders are designed, manufactured and marketed throughout the world. Our global sales network ensures an individual and timely support of our customers and prospects. In almost every important industrial nation local partners are available at all times to develop customer-oriented solutions for your special application.
- How to install and repair ECOROLL tools?
Ecoroll offers a comprehensive service for installation, commissioning and repair of all tools and equipment.
- How to convert from an existing process to burnishing or deep rolling?
We focus on customer-oriented solutions. Since any case of application implies new challenges and questions, an individual assessment is necessary in order to meet your special requirements. Please contact us by using the contact form or call us directly. We look forward to hearing from you!
- What processes can be replaced by roller burnishing?
- All processes for production of high-quality component surfaces can be replaced by roller burnishing (e.g. precision turning, grinding, reaming, honing, super finishing, lap grinding, polishing). A combined manufacturing process of skiving and roller burnishing to produce hydraulic cylinders and cylinder tubes, has displaced the alternative manufacturing process honing almost completely because simultaneous skiving and roller burnishing is much more economical and faster. On a deep drilling machine the cylinder tube is simultaneously skived and roller burnished. The latest tool generation can even combine three manufacturing processes – counter boring, skiving and roller burnishing - in one step.
- What are the advantages of roller burnishing compared to competing processes?
What are the advantages of roller burnishing compared to competing processes?
Roller burnishing has proven for decades that it offers enormous economical and technical advantages in roughness areas Rz < 10 µm. Roller burnished surfaces are characterized along others by a high profile contact area. They also excel with their:
- Low surface roughness (Rz < 1 µm / Ra < 0,1 µm) or defined roughness,
- Reduced friction,
- Increased wear resistance,
- Rounded surface profile and
- Hardness increase of the rim zone through strain hardening.
- Short primary machining time,
- For use on conventional or CNC lathes,
- Complete machining in one setting,
- No removal of material,
- Easy reproduction,
- Low consumption of lubricants,
- Low noise emissions,
- No varying dimensions through tool wear.
- Is there any potential for cost reduction when converting to roller burnishing?
- Depending on the application, a cost reduction up to 50 % is possible when converting to roller burnishing. This is due to the fact that costly reworking can be avoided. Moreover, lower machining times and complete machining in one setting are possible. This results in lower costs for additional machines and in a significant reduction of primary and set-up times. Neither chips nor grinding sludge are produced which reduces environmental pollution and disposal costs, as well as wear of bearings and guiding paths of the machines.
- What work pieces are suitable for roller burnishing?
- With the latest ECOROLL tool technology hardened work pieces with up to 65 HRC can be roller burnished (e.g. oil pumps, valve seats, connecting rods, wave surfaces, inner surfaces of hydraulic cylinders, pistons, transmission components, clutch parts).
- What processes can be replaced by deep rolling?
- All mechanical (e.g. shot peening), thermal (e.g. laser hardening) and thermochemical (e.g. nitriding) process for increasing fatigue strength of a component can be replaced by deep rolling. Since any case of application implies new challenges and questions, an individual assessment is necessary in order to meet your special requirements. Please contact us by using the contact form (Link einfügen) or call us directly (Link zu Ansprechpartnern einfügen). We look forward to hearing from you!
- What are the advantages of deep rolling compared to competing processes?
Deep rolling is the only mechanical rim zone strain hardening process which results in smoothing the surface, the induction of compressive residual stresses and cold work hardening. It provides the following benefits:
- Significantly increases the life of a component (e.g. life of a crenated component can be increased by the factor of five. Notch effects are nearly eliminated by deep rolling.),
- Integrates seamlessly into the process chain,
- Enables process monitoring (especially important for safety-critical parts) and
- Enables greater and deeper residual stresses than shot peening.
- What work pieces are suitable for deep rolling?
- Deep rolling can be used for all metal workpieces whenever significant increases in the life of a component are necessary (e.g. alloy wheel rims, camshafts, medical instruments, railway axles, wheel discs of steam turbines).