Upload
ronald-singleton
View
236
Download
4
Tags:
Embed Size (px)
Citation preview
2470/1e 1
...for a smooth operation ECOROLL
Saving Manufacturing CostsSaving Manufacturing Costsby Roller Burnishing and Deep Rollingby Roller Burnishing and Deep Rolling
(Presentation 2470/1e)
1. Introduction
2. Processes
3. Tools
4. Cost Reduction
5. Environmental Aspects
6. Application Examples
2470/1e 2
...damit alles glatt geht ECOROLL
RandschichtumformungPlastic Forming of Top LayerPlastic Forming of Top Layer
workpiece
rolling force
roller
...for a smooth operation ECOROLL
2470/1e 3
...damit alles glatt geht ECOROLL
Plastic Forming of Top LayerPlastic Forming of Top Layer
rollerrotation
feed
rotationworkpiece
...for a smooth operation ECOROLL
2470/1e 4
...damit alles glatt geht ECOROLL
Levelling of Surface ProfileLevelling of Surface Profile
pre-operation surface
roller burnished
...for a smooth operation ECOROLL
2470/1e 5
...damit alles glatt geht ECOROLL
Advantages of Roller Burnished SurfaceAdvantages of Roller Burnished Surface
•Low rouhgness
•High surface contact area
•Soft profile transitions
•No profile peaks, shallow pits only
•Hardness increase
•Better sliding properties
•Less wear
•Less galling and seizing
...for a smooth operation ECOROLL
2470/1e 6
•Short process time
•Applicable on virtually all machine tools
•Finishing in onre setting
Advantages of the Burnishing ProcessAdvantages of the Burnishing Process
•No material removal
•No wear of bearings ans slide ways
•Easy process controll
•Little lubrication required
•Low noise
•Long lasting tools
•No dimensional change by tool wear
...for a smooth operation ECOROLL
2470/1e 7
Process LimitsProcess Limits
Criteria Parameter Description Approx.FormingRatio
Hardness <42 bis 45 HRC Mechanical single and multi roller tools 20 : 1
>42 > 65 HRC Hydrostatic tools „ballpoint“ 10 : 1 bis 2 :1(ac. to hardness)
A4 8 % Suitable without restrictions 20 :1
Elongation tilrupture
A4 5 < 8% Test recommended 10 : 1
A4 < 5 % Rz 2 µm achievable 5 :1
Exception:Cast Iron
Rz 3 bis 4 µm achievable. Typical structure:Top plateaus and shallow pits.
5 :1
...for a smooth operation ECOROLL
2470/1e 8
Compressive Stress in Top LayerCompressive Stress in Top Layer
Compressive stress characteristicHG6 / hardened steel 600 HV
shot peened
Co
mp
ress
ive
str
ess
[Mp
a]
Depth [µm]
...for a smooth operation ECOROLL
2470/1e 9
Process ComparisonProcess Comparison
Roller Burnishing Deep Rolling
Task Achieving the specified surface
roughness
Increase of faitigue strength
Proof of quality Non destructive surface test With destructive methods on test spe-cimen only Faitigue test Measuring of compressive stresses
Corrective action Second pass possible Not possible on serial production com-ponents
Requirements Diameter adjustment or indication or adjustment of rolling
force
In process control of parameters: Rolling force Feed rate Speed Geometry
...for a smooth operation ECOROLL
2470/1e 10
... for a smooth operation ECOROLL
Deep Rolling versus Shot PeeningDeep Rolling versus Shot PeeningDeep Rolling+ Deeper penetration+ Compressive stress depends on load F+ F hydraulic or spring controlled+ Easy operation and reproduction+ Fast+ In one setting after cutting+ Access to bores and cavities+ Applicable on all machine tools- Predominantly for regular shapes
Shot peening+ Good for irregular shapes- Small grains- Irregular in shape and size- Rough surface- Compressive stress depends on
impact and coverage- Influenced by 12 parameters- Difficult to reproduce- Special equipment required- Only to handle by specialists- Time consuming- high transport costs- Long lead time- Difficult in cavities
2470/1e 11
... for a smooth operation ECOROLL
Economical Aspects of Deep RollingEconomical Aspects of Deep Rolling
•Weight reduction
•saving material
•elimination of heat treatment
•elimination of transports
•shorter lead time
•faster cash flow
•less investment
•less energy consumption
•less workshop space required
2470/1e 12
Multi Roller ToolsMulti Roller Tools
G: Bores
RA: O.D.‘s
...for a smooth operation ECOROLL
2470/1e 13
Single Roller ToolsSingle Roller Tools
EG14 EG5EGi5-32 EGI-xxF
...for a smooth operation ECOROLL
2470/1e 14
Hydrostatic tools „ballpoint“ HGHydrostatic tools „ballpoint“ HG
...for a smooth operation ECOROLL
2470/1e 15
Hydrostatic Tool HG6-5 Hydrostatic Tool HG6-5 with Integrated Pump with Integrated Pump
...for a smooth operation ECOROLL
2470/1e 16
Production Costs over Roughness Production Costs over Roughness
super finish,lapping
honing
grinding
turning
roller burnishing
Roughness
Man
ufac
turin
g co
sts
...for a smooth operation ECOROLL
2470/1e 17
Cost Reduction by Roller BurnishingCost Reduction by Roller Burnishing
•Process time
•handling (by complete finishing)
•short lead time
•less capital bound in WIP
•no waste disposal costs
•no costs for personnal protection (for noise, dust, fumes)
•low energy costs
...for a smooth operation ECOROLL
2470/1e 18
10-G Stratetgy10-G StratetgyRoller Burnishing RRoller Burnishing Rzz < 10µm < 10µm
Vergleich Feindrehen / 10-X ; Comparison Fine Turning / 10 - X
0
50
100
150
200
15x3
0
25x5
0
35x7
0
45x9
0
55x1
10
65x1
30
75x1
50
85x1
70
95x1
90D x L [mm]
Tim
e [
s]
Fine Turning
10-X
Einsparung / Savimg (%)
-20-10
01020304050
15x3
0
25x5
0
35x7
0
45x9
0
55x1
10
65x1
30
75x1
50
85x1
70
95x1
90
D x L [mm]
[%]
...for a smooth operation ECOROLL
2470/1e 19
... for a smooth operation ECOROLL
Economical Aspects of Deep RollingEconomical Aspects of Deep Rolling
•Weight reduction
•saving material
•elimination of heat treatment
•elimination of transports
•shorter lead time
•faster cash flow
•less investment
•less energy consumption
•less workshop space required
2470/1e 20
Environmental Aspects of Environmental Aspects of Roller BurnishingRoller Burnishing
•No material removal
•no dust or mud
•low energy consumption
•little coolant required
•low noise
...for a smooth operation ECOROLL
2470/1e 21
Roller Burnishing of Roller Burnishing of
Bearing and Seal SurfacesBearing and Seal Surfaces
Tool type G for bores
EG5 for bearing seats and seal surfaces
...for a smooth operation ECOROLL
2470/1e 22
Application ExampleApplication ExampleDifferential GearDifferential Gear
Process time 4 sPressure 150 bar
...for a smooth operation ECOROLL
2470/1e 23
Application ExampleApplication ExampleHydraulic CylindersHydraulic Cylinders
Skive Burnishing Tool RDZ for cylinder Tubes
Roller Burnishing of Piston Rod with EG14
...for a smooth operation ECOROLL
2470/1e 24
Speed 18 RPMFeed rate 0,4 mm/rev.
Process time 62 min
Application ExampleApplication ExampleLarge Bore (Bearing Housing)Large Bore (Bearing Housing)
...for a smooth operation ECOROLL
2470/1e 25
Speed 100 m/minFeed rate 0,3 mm/rev.Pressure 350 bar
Application ExampleApplication ExampleFlexible ShaftFlexible Shaft
...for a smooth operation ECOROLL
2470/1e 26
Wöhlerdiagram Wöhlerdiagram Flexible ShaftFlexible Shaft
...for a smooth operation ECOROLL
turned
hand polished
deep rolled with HG6