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Saving Manufacturing Costs by Roller Burnishing
and Deep Rolling (Presentation 2470/1e)
1. Introduction
2. Processes
3. Tools
4. Cost Reduction
5. Environmental Aspects
6. Application Examples
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Plastic Forming of Top Layer
workpiece
rolling force
roller
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Plastic Forming of Top Layer
roller
rotation
feed
workpiece
rotation
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Levelling of Surface Profile
pre-operation surface
roller burnished
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Advantages of Roller Burnished Surface

• Low rouhgness

• High surface contact area

• Soft profile transitions

• No profile peaks, shallow pits only

• Hardness increase

• Better sliding properties

• Less wear

• Less galling and seizing

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Advantages of the Burnishing Process

• Short process time

• Applicable on virtually all machine tools

• Finishing in onre setting

• No material removal

• No wear of bearings ans slide ways

• Easy process controll

• Little lubrication required

• Low noise

• Long lasting tools

• No dimensional change by tool wear

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Process Limits
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Compressive Stress in Top Layer
Compressive stress characteristic HG6 / hardened
steel 600 HV
shot peened
Compressive stress Mpa
Depth µm
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Process Comparison
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Deep Rolling versus Shot Peening
Deep Rolling Deeper penetration Compressive
stress depends on load F F hydraulic or spring
controlled Easy operation and reproduction
Fast In one setting after cutting Access to
bores and cavities Applicable on all machine
tools - Predominantly for regular shapes
Shot peening Good for irregular shapes - Small
grains - Irregular in shape and size - Rough
surface - Compressive stress depends on impact
and coverage - Influenced by 12 parameters -
Difficult to reproduce - Special equipment
required - Only to handle by specialists - Time
consuming - high transport costs - Long lead
time - Difficult in cavities
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Economical Aspects of Deep Rolling

• Weight reduction
• saving material
• elimination of heat treatment
• elimination of transports
• shorter lead time
• faster cash flow
• less investment
• less energy consumption
• less workshop space required

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Multi Roller Tools
G Bores RA O.D.s
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Single Roller Tools
EG14 EG5 EGi5-32 EGI-xxF
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Hydrostatic tools ballpoint HG
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Hydrostatic Tool HG6-5 with Integrated Pump
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Production Costs over Roughness
super finish, lapping
honing
Manufacturing costs
grinding
turning
roller burnishing
Roughness
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Cost Reduction by Roller Burnishing

• Process time
• handling (by complete finishing)
• short lead time
• less capital bound in WIP
• no waste disposal costs
• no costs for personnal protection
• (for noise, dust, fumes)
• low energy costs

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10-G Stratetgy Roller Burnishing Rz lt 10µm
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Economical Aspects of Deep Rolling

• Weight reduction
• saving material
• elimination of heat treatment
• elimination of transports
• shorter lead time
• faster cash flow
• less investment
• less energy consumption
• less workshop space required

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Environmental Aspects of Roller Burnishing

• No material removal
• no dust or mud
• low energy consumption
• little coolant required
• low noise

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Roller Burnishing of Bearing and Seal Surfaces


Tool type G for bores
EG5 for bearing seats and seal surfaces
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Application Example Differential Gear
Process time 4 s Pressure 150 bar
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Application Example Hydraulic Cylinders

Skive Burnishing Tool RDZ for cylinder Tubes
Roller Burnishing of Piston Rod with EG14
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Application Example Large Bore (Bearing Housing)
Speed 18 RPM Feed rate 0,4
mm/rev. Process time 62 min
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Application Example Flexible Shaft
Speed 100 m/min Feed rate 0,3
mm/rev. Pressure 350 bar
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Wöhlerdiagram Flexible Shaft
deep rolled with HG6
hand polished
turned