Overview: The document provides a comprehensive overview of ECOROLL AG Werkzeugtechnik's solutions for mechanical metal surface improvement, focusing on roller burnishing and deep rolling processes. These processes are essential for achieving high-quality surface finishes and enhancing the durability of metal components across various industries, including automotive, medical, and renewable energy.
Roller Burnishing: Roller burnishing is a forming process used to create smooth, high-quality surfaces. It involves plastifying and forming the workpiece's edge layer using rollers or balls. This process is advantageous for achieving low roughness, increased wear resistance, and enhanced surface hardness. It is applicable to conventional and CNC-controlled machines, offering short cycle times and minimal lubrication requirements.
Deep Rolling: Deep rolling is a process that enhances a component's edge zone properties by generating compressive stresses, cold working, and smoothing the surface. It significantly increases fatigue strength and service life, making it suitable for components subjected to dynamic stress. Deep rolling is cost-effective and can be integrated into existing process chains, applicable to a wide range of metal materials.
Process Similarities and Differences: Both roller burnishing and deep rolling can be performed on various machine tools and are suitable for different applications, including automotive and aerospace industries. The primary difference lies in their objectives: roller burnishing focuses on achieving specific surface quality, while deep rolling aims to enhance fatigue strength. Quality control for roller burnishing involves physical measurement, whereas deep rolling requires service life testing and residual stress measurements.
Technological Advancements: ECOROLL, in collaboration with KOMET Brinkhaus, has developed the "ToolScope" monitoring system for real-time process monitoring and documentation, ensuring reliable reproduction of process parameters, especially for safety-critical components.
Applications and Benefits: The document highlights the economic and technological advantages of these processes, such as reduced friction, increased wear resistance, and the ability to process materials with high initial hardness. These processes are applicable across various sectors, including automotive, medical, and renewable energy industries.
Process Monitoring and Cost-Effective Processes: Process monitoring for mechanical and hydrostatic tools allows real-time recording of process parameters, reducing rejected parts and ensuring consistent quality. Converting production processes to roller burnishing or deep rolling can reduce costs by over 50% compared to grinding, polishing, or honing. This is due to shorter processing times, elimination of reworking, and reduced environmental impact.
Differences Between Rolling, Roller Burnishing, and Deep Rolling: Rolling is often confused with roller burnishing and deep rolling. According to VDI/VDE standard 2032, rolling is defined as fine machining using tools with roughened surfaces to improve workpiece quality. ECOROLL does not sell tools for rolling as per this definition.
Processing Cylinder Tubes: The OMEGA system by ECOROLL combines skiving and roller burnishing, replacing honing for hydraulic cylinders and tubes. It offers improved precision, quick tool setting, and easy replacement of wear parts. The system allows complete processing on CNC-controlled lathes, reducing auxiliary process time and eliminating the need for deep hole drilling machinery.
ECOROLL Product Overview: ECOROLL offers a range of tools for roller burnishing, deep rolling, and machining cylinder tubes. The tools are modular and suitable for various workpieces and geometries. The overview provides guidance on selecting the right tool for specific applications.
Multi-Roller Mechanical Tools: ECOROLL's mechanical tools with multiple rollers are used for roller burnishing. They feature easy diameter adjustment, high precision, and reliable function. These tools can be used on CNC-controlled machines and require minimal lubrication. They are designed for machining cylindrical bores, plane faces, tapers, and ball-shaped areas.
Features and Advantages: ECOROLL tools can be used up to tolerance class IT8 and machine materials with tensile strength up to 1400 N/mm². They achieve high surface quality and are suitable for use on various machine tools. The tools offer short cycle times, easy diameter adjustment, and minimal lubrication requirements.
Specifications: Tools are available in multiple types, including RA, RP, RK, RKA, RH, RHA, MZG, and EG series, each designed for specific machining tasks. Tools can handle circumferential speeds up to 250 m/min and feed rates between 0.05 – 0.3 mm/rev. They are suitable for materials with tensile strength up to 1400 N/mm² and hardness up to HRC 45.
Design: Each tool consists of a basic tool body and a burnishing head, with interchangeable components for different diameter ranges. Tool bodies are equipped with Morse tapers or straight shanks, and some models include disc spring assemblies for optimal performance.
Parameters: Burnishing lengths are limited for standard shanks, but tools with unlimited lengths are available. Maximum burnishing force for deep rolling tools is 40 kN, with machining radii up to 4.0 mm.
Advantages: Tools offer reliable function, high accuracy, and cost-effectiveness due to short work cycles. They require minimal lubrication and have low energy consumption. Wear parts are easy to exchange, and tools can be used with various machine types.
Ordering Information: Key details required include tool body type, workpiece dimensions, shank type, and specific application needs. Tool designations are generated based on parameters like diameter, shank type, and specific machining requirements.
Overview: This document provides detailed specifications and guidelines for the EG5 series of single-roller mechanical tools used for roller burnishing on CNC-controlled or conventional lathes. The tools are designed for machining cylindrical surfaces, plane faces, and contours, achieving high surface quality and efficiency.
Specifications: Tools are suitable for all metal materials with tensile strength up to 1400 N/mm² and hardness up to HRC 45. Surface quality achievable: Rz < 1 µm / Ra ≤ 0.2 µm. Symmetrical design allows for right or left-hand operation. Maximum circumferential speed: 300 m/min; maximum feed rate: 1 mm/rev.
Tool Versions: Version 1: For machining bores and cylindrical surfaces. Version 2: For machining plane faces. Version 3: For machining cylindrical surfaces with feed toward the tailstock.
Design Features: Tools consist of a tool body, burnishing head, and tool shank with a spring assembly. Dial gauge or measurement system for spring force indication. Burnishing head includes a roller and support roller with needle bearing.
Advantages: Short work cycle and elimination of changeover time. No dust or residue, minimal lubrication required. Adjustable support positioning for variable burnishing force. Easy exchange of wear parts.
Ordering Information: Specify shank diameter, application, and component drawing. Available in multiple versions with different burnishing heads and shank types (VDI or square shank).
Additional Tool Types: EG14: For machining external surfaces and cylindrical/tapered bores. EG45: For machining transition radii, fillets, and contours. EG90: For machining cylinders, internal/external tapers, and plane faces.
Overview: The document provides detailed specifications and features of various deep rolling tools used for enhancing the surface finish and fatigue strength of components. These tools are applicable for both internal and external threads, as well as cylindrical surfaces, and are compatible with conventional and CNC-controlled lathes.
Specifications and Parameters: Maximum circumferential speed for most tools is 20 m/min, with some tools allowing up to 100 m/min. Burnishing force varies across tools, ranging from 15 kN to 60 kN. Tools are designed to handle materials with tensile strengths up to 1400 N/mm².
Tool Types and Features: Type EF45: Designed for deep rolling fillets with a maximum burnishing force of 20 kN. Type EF90: Suitable for deep rolling thread root radii on external threads, featuring automatic roller angle setting and compatibility with both right-hand and left-hand threads. Type HF90: Hydraulic tool for external threads, capable of handling high burnishing forces up to 20 kN. Type EFI90: Designed for internal threads with features similar to EF90, including automatic roller angle adjustment. Type HFI90: Hydraulic tool for internal threads, supporting high burnishing forces up to 40 kN. Type FA: Used for deep rolling large radii in thread roots, with a maximum force of 60 kN. Type FAK90 and FAK120: Designed for external threads and large fillets, respectively, with features for automatic adjustment and high-speed operations.
Ordering Information: For ordering any tool, the following information is required: type of tool retainer and machine tool, component drawing, thread dimensions, thread root radius, and material properties. Special shanks and retainers are available upon request.
Design and Advantages: Most tools feature a tool body with a spring assembly for low friction and progressive action. They are equipped with mechanisms to compensate for minor positioning errors and allow for complete processing in one setting. The tools are designed to minimize radial forces transferred to the machine, enhancing operational efficiency.
Overview of HG Series Tools: The HG series tools are designed for roller burnishing and deep rolling of complex contours, particularly in hardened steel and alloys up to 65 HRC. The core component is a burnishing element with a ball insert that operates hydrostatically, using a cooling lubricant to create a bearing for the ball. This allows for surface deformation at defined pressures.
Specifications and Variants: The tools are classified by ball size, ranging from 1.2 mm to 28 mm, with various versions available for different machining needs. The HG6 tool, for example, features a 6 mm diameter ball. Tools in the HG series can also be used for dry machining with compressed air and oil as the pressure medium.
Applications and Procedures: The HG series is versatile, suitable for both external and internal machining. External applications include cylindrical, tapered, and plane surfaces, while internal applications cover cylindrical bores and complex internal contours. The tools can be used on conventional and CNC-controlled lathes, with specific models designed for different machining tasks.
Advantages: Using HG tools increases the fatigue strength and service life of components by inducing compressive stresses and smoothing surfaces. The hydrostatically loaded ball rotates without contact, even at high speeds, reducing environmental stress and costs associated with lubricants.
Design and Ordering: The HG series offers modular designs with ball diameters from 2 to 25 mm. Tools are designated by ball size and version, with specific applications for each version. For example, HG6-2 is suitable for machining cylindrical bores.
Pressure Supply and Monitoring: HG tools require a hydraulic unit and high-pressure supply for operation. The burnishing force is pressure-dependent, allowing for process monitoring to ensure consistent product quality. The HGP hydraulic units provide pressure for tools without integrated pumps, available in mobile or fixed versions.
Overview: The document provides detailed technical specifications and descriptions of various tools and systems used in the machining of hydraulic cylinders and cylinder tubes, specifically focusing on the ECOROLL HG Series and OMEGA system.
HG Series Accessories: Rotating Unions: Essential for CNC-controlled lathes with turrets, ensuring uninterrupted pressure supply. The DE rotating union supplies a single tool, while the DS can supply up to four tools. ToolScope: A process monitoring system for deep rolling with HG tools, providing continuous monitoring and documentation of critical process parameters. It features self-teaching capabilities, accurate signal recording, and touchscreen operation.
OMEGA System for Cylinder Tubes: Combination of Skiving and Roller Burnishing: The OMEGA system integrates skiving and roller burnishing in one tool, offering speed and cost-effectiveness over traditional honing methods. Tool Variants: The system includes various tool configurations (RDO, RIO, RIOA, RIOF, RIOK) for different machining needs, such as pre-drilling, skiving, and roller burnishing. Design and Features: Tools are designed for easy diameter adjustment, quick coupling, and replacement of wear parts. The system supports both RETRAC and international control systems.
Technical Specifications: Parameters: Detailed specifications for tool diameter ranges, circumferential speeds, and feed rates are provided for different tool types. Ordering Information: Instructions on selecting the appropriate tool series based on control system design, cylinder length, and material characteristics.
Advantages: Improved machining accuracy and reduced processing time. Capability to handle tubes with significant form faults in one pass. Enhanced tool longevity and reduced auxiliary processing time.
Conclusion: The document outlines the advanced capabilities of ECOROLL's machining tools and systems, emphasizing their efficiency, precision, and adaptability to various machining requirements.
Features and Advantages: ECOROLL offers complete processing of cylinder tubes using CNC-controlled lathes and machining centers. Skiving and roller burnishing are performed in one pass, eliminating the need for deep hole drilling machines. The tools, such as Type GZ and SKIO, offer high accuracy and reliability, with diameter tolerances of IT8 to IT9. The process is cost-effective as it does not require purchasing a deep hole drilling machine.
Design and Specifications: Type SKIO tools are based on the OMEGA principle, featuring floating skiving knives and integrated control pistons. Type GZ tools are similar to standard roller
burnishing tools but include internal flushing. Both types require specific cooling-lubricant amounts and pressures, with detailed parameters for tool circumferential speed and feed rates.
Process Monitoring with ToolScope: ToolScope is a monitoring system developed in collaboration with Komet Brinkhaus GmbH. It provides real-time monitoring and documentation of process parameters, ensuring compliance with safety standards and reducing rejects. The system features online visualization, automatic documentation, and error signal processing.
Application Examples: Various machining tasks are detailed, showcasing the use of ECOROLL tools in improving surface finishes and reducing process times. Examples include roller burnishing of gear boxes, seal bushings, rear wheel carriers, and more, highlighting the advantages of improved product quality and time savings.
Deep Rolling Applications: Deep rolling is used to enhance the fatigue strength of components such as cylinder liners and wheel rims. The process involves controlled rolling force applications to prevent fatigue cracks and improve service reliability.
Specifications and Procedures: Machining Tasks: Various tasks are outlined for different components such as aircraft wheel rims, bevel gears, seal inserts, swivel bearings, ball studs, brake pistons, cam shafts, glass forming mandrels, helix shafts, control valve pistons, turbine wheels, tension bolts, flexible shafts, wheel flanges, and hollow shafts. Each task specifies the workpiece, part, material, tensile strength, hardness, and required finish. Tools and Techniques: The document details the use of specific tools like HG6 burnishing elements, HG13 tools, and others, along with parameters such as rotation speed, feed rate, and process time for each machining task.
Results and Advantages: Improvements in service strength, reduced process times, increased surface hardness, and enhanced reliability are common advantages across different applications. Specific results include a 5-fold improvement in service strength for aircraft wheel rims, reduced friction for cam shafts, and increased fatigue strength for tension bolts and flexible shafts.
Surface Measurement Parameters: Ra (Arithmetical Mean Roughness): Describes the mean deviation from the center line of the surface roughness profile, with limited statistical value. Rz (Maximum Roughness Depth): Measures the range of surface roughness by calculating the average of the maximum profile heights of five measuring sections. R3Z (Daimler Benz Parameter): Evaluates porous or sintered surfaces by measuring the vertical distance between the third-largest profile peak and the third-deepest profile valley. Rq (Quadratic Mean Roughness): Provides a statistically significant measure of surface roughness, expressing the standard deviation of profile peaks and valleys.
Recommendations and Best Practices: Surface structure significantly influences wear behavior, with plateau-like surfaces offering better lubrication and sliding properties. Proper machining and surface finishing techniques can enhance component reliability and performance.
Surface Characteristics and Measurement: The document discusses surface profiles with varying material percentages, highlighting their impact on wear behavior. A low percentage of material results in poor wear behavior, while a higher percentage improves it. Measurements are provided for different sections, emphasizing the precision required in surface analysis.
Improved Surface and Part Quality: Roller burnishing and deep rolling are presented as technologies that enhance metal component quality by smoothing surfaces and inducing compressive stresses. This process increases fatigue strength and reduces production costs by eliminating the need for additional processing steps.
Benefits of Roller Burnishing and Deep Rolling: These processes offer significant cost savings by replacing more expensive technologies like grinding or honing. They reduce auxiliary processing time and eliminate dust or residue, further cutting costs. The document outlines the advantages of these methods, including increased surface hardness and wear resistance.
Processing Cylinders: Roller burnishing and deep rolling are described as economic alternatives for producing high-quality component surfaces. They are compatible with conventional and CNC-controlled machines, offering complete processing in one setting and significantly increasing service life and fatigue strength.
ECOROLL AG Werkzeugtechnik Overview: ECOROLL AG provides solutions for metal surface processing, emphasizing their global sales network and customer-oriented approach. The company has been designing tools and machines for roller burnishing and deep rolling since 1969, with a focus on innovation and customer collaboration.
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