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.

Conditions to be satisfied for the roller burnishing tool for processing hydraulic cylinder and cylinder hole

Roller burnishing tool has a variety of structures. When using this tool for workpieces required by certain surface plastic deformation processes, a specific tool is required.

For example, roller burnishing tools for processing hydraulic cylinder and cylinder hole should meet the following requirements:

For processing workpieces with 2-4 precision, the surface finish of the hole should be 9 ~ 10;
Rolling parts and supporting parts shall have high mechanical strength and hardness (H R C= 58);
The roller burnishing tool can be kept stable after adjusting the tool according to the diameter of the workpiece;
The workpiece can be returned freely after the completion of the workpiece processing, the workpiece with a length of 50-10mm after the trial processing also can be returned freely;
Simple structure, good technology, and easy to replace roller burnishing tool’s parts (rollers and support cones).

How to select and use roller burnishing tool?

Selection and use of roller burnishing tool

Usage: the standard type of the roller tool includes the clamping part of morse taper shank and straight shank.

The rolling process is different from the cutting process, which does not require large torque. It can also be used in small power machine tools. The roller burnishing tool can be installed on drilling machine, lathe, hexagon lathe, boring machine, drilling machine and other equipment for processing without special equipment.

Ball burnishing pressure:

When the ball is rolled, the ball can rotate freely, that is, in the direction of main motion and feed direction, it can roll without sliding. Therefore, the surface quality of processed parts is good. The ball rolling pressure can usually obtain a very low surface roughness (Ra0.2μm～0.10μm). Under the condition that the other process parameters are matched, the surface quality of the rolled part can also reach Ra0.05. At the same time, due to the ball and the surface of the workpiece interface is relatively small, therefore, under the condition of the same unit pressure can decrease the total pressure, especially suitable for the outer surface of the small slender precision parts and thin wall parts of inner hole roller.

The ball burnishing tool is simple in structure and light in weight. When the ball is worn, the low price standard ball can be adopted to reduce the cost to a certain extent.

The disadvantage is that the service life of ball burnishing tool is too low, and the ball usually needs to be replaced after 10h ~ 12h continuous use.

Shaft burnishing pressure:

Like a ball burnishing, shaft burnishing not only get a better surface roughness, and overcomes the drawback low life of ball burnishing, also can be used in a large feed, rolling usually use 0.75mm/r-0.80mm/r, so the production efficiency is high.

Turning tool rolling pressure:

The structure is basically the same as that of the tool with replaceable alloy blade, and the operation is the same as that of the tool. Diamond tool head is used in turning tool rolling, which is suitable for high hardness.

In using the roller burnishing tool, we know that it is very important to know the selection, adjustment and model of the roller burnishing tool. The rotation of the roll head and the driving force of the product are all necessary to improve the smoothness of the product. Of course, in addition to these, the conditions of the roller burnishing tool are particularly important, such as the adjustment range of theroller burnishing tool, the size of the workpiece being rolled, the hardness of the metal material and the roll pressure allowance.

Application advantages – The effect after roller burnishing

Advantages of roller burnishing

It is safe, convenient and accurate to control precision.

Roller burnishing tools advantages are:

1. Improve the surface roughness, and the roughness can basically reach the Ra less than 0.08um.
2. Correction of roundness, the ellipticity can be less than 0.01mm.
3. Improve the hardness of the surface to eliminate the deformation of the force and increase the hardness of HV to 40.
4. After processing, the residual stress layer and fatigue strength increased by 30%.
5. Improve the quality, reduce wear, and prolong the service life of the parts, but the processing cost of the parts is reduced.

Roller burnishing tool application advantages – The effect after burnishing

High efficiency – a few seconds can process the surface to the desired surface precision, the efficiency is 5-20 times of grinding and 10-50 times more than the turning.

High quality – the mirror accuracy of the first step in the realization of Ra0.05-0.1um; The surface is extruded and hardened, wear resistance and fatigue strength are improved. The dimensional precision can be stable for a long time.

Economy – no need for large equipment capital, land, power consumption, waste disposal and other inputs; You don’t need a professional mechanic.

Convenient – can be installed in any rotation and feed equipment, without professional training can process the burnishing precision.

Environmental protection – no chip (protection), low energy consumption.

Safety – no cutting tool without cutting edge.

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