Advantages and disadvantages of roller burnishing process

Roller burnishing process is a kind of non-chip machining, which exerts certain pressure on the workpiece surface through certain forms of roller burnishing tools. The plastic deformation of metal is used to smooth the uneven surface of workpiece at normal temperature, so as to change the surface structure, mechanical properties, shape and size. Therefore, this method can achieve two purposes of finishing and strengthening at the same time.

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Advantages of roller burnishing pressure:

After the surface of the metal workpiece is rolled and processed, the hardness of the workpiece surface is strengthened and the yield point is increased.

The performance, fatigue strength, wear resistance and corrosion resistance of workpiece have been improved obviously.

The roller burnishing process is easy to master, and can be processed by ordinary drilling machine. Ordinary operators can process the mirror precision, micron precision parts!

The comprehensive cost of roller burnishing tool is low, which is 10-100 times lower than the cost of grinding machine, quilting machine and ultrasonic rolling.

The deficiency in roller burnishing process:

The surface of the workpiece will be hardened by rolling, and there is obvious stratification between this layer and the inner material, which is easy to cause the surface to fall off.

The rigidity of roller burnishing tool is large, which damages the guide rail of the transmission mechanism of the machine tool and seriously damages the precision and life of the machine tool.

It can not satisfy the processing of rigid parts such as thin-walled pipe fittings.

The fatigue strength of the workpiece can be improved by using roller burnishing tools

The fatigue strength of the workpiece can be improved by using roller burnishing tools.

While improving the surface roughness of workpiece, the residual compressive stress will be generated in the surface layer which can improve the fatigue strength of workpiece.

By comparing the residual stress distribution of SUS304 after turning and rolling, it can be seen that the residual compressive stress in the workpiece after rolling is the maximum depth of shear stress from 0.08 to 0.10mm.

The results of the internal pressure fatigue failure test for the same shaped sample show that: The residual compressive force in the circular direction of workpiece after rolling can inhibit the occurrence of cracks near the fatigue limit and increase the fatigue strength by 30%.

What’s the effect of roller burnishing process on workpiece performance?

What’s the effect of rolling process of workpiece performance?

Surface quality of roller burnishing tool‘s rolling process has the following effects on workpiece performance:

①The effect on wear resistance

The surface roughness has a great influence on the initial wear of friction pairs. But not the less roughness, the more wear-resistant. Under certain working conditions, there is an optimal parameter value of the surface of friction pair , which is about 0.32 ~ 1.25 m.

②Effects of fatigue strength

Under the action of alternating to load, the surface roughness and defect from workpiece are easy to cause stress concentration and fatigue crack damage. For some important parts that bear alternating loads, such as the junction of crankshaft crank and shaft neck, roller burnishing should be carried out to reduce the surface roughness and improve the fatigue strength.

③Effects of corrosion resistance

The rougher the surface of the workpiece, the easier it is to accumulate corrosive substances. The deeper the valley, the effects of the infiltration and corrosion are the stronger. Therefore, to reduce the surface roughness of the parts, it can improve the corrosion properties of the parts.

④Effects of parts’ quality

The rough surface of parts will increase the gap of parts after wear and tear, change the nature of parts, reduce the precision and rigidity of parts, and affect the stability and reliability of operation. Therefore, the surface roughness parameter value of the workpiece with the required parts must be limited.

Why is rolling technology used so widely in precision machining?

The roller burnishing process is a kind of non-chip processing, and the whole process can be accomplished by applying pressure to the surface of the workpiece by a certain form of rolling tool. Roller burnishing tool is at room temperature using the principle of the metal plastic deformation, rolling flat surface uneven places, to change the surface structure, mechanical properties, shape and size to achieve the effect. Therefore, this method can achieve smooth processing and strengthen two purposes at the same time. The surface strength of metal workpiece is strengthened after surface rolling, and the performance of workpiece, fatigue strength, abrasion resistance and corrosion resistance are obviously improved. After rolling, the hardness of the workpiece can be increased by 15 ~ 30%, while the wear resistance increases by 15%.

Rolling processing can increase surface roughness from Ra6.3 to Ra2.4 ~ Ra0.2. And there is a high production efficiency, some of which can be completed in a few minutes or seconds.

Rolling process can solve some key problems which are not easy to be realized. For example, the machining of a large cylinder block. At the same time, it is also suitable for the finishing machining of special holes or the finishing process of some special materials.

Rolling process is widely used in all large, medium and small factories. In terms of processing quality, production efficiency, production cost and other aspects, roller burnishing process is a superior processing method. In some respects, it can completely replace fine grinding, grinding and honing.

At present, the processing method of the rolling tool by external force can be divided into three types: mechanical, rolling and spring.

According to the processing nature, it can be divided into light finishing and intensive processing.

The roller burnishing tool has the advantages that the machining center does not have. Because the roller burnishing tool can be simple and low cost to carry out the ultra-precision machining of parts. It has been widely used in the automotive industry, such as precision machinery, chemical and household appliances.