Roller Finishing of Cylindrical Components BY Hans J. Naumann Hegenscheidt Corporation of America
Roller Finishing of Cylindrical Components BY Hans J. Naumann Hegenscheidt Corporation of America
Roller Finishing of Cylindrical Components BY Hans J. Naumann Hegenscheidt Corporation of America
MATERIAL FORMING
BY
Hans J. Naumann
ABSTRACT
R o l l e r f i n i s h i n g i s a r e c e n t l y developed s u r f a c e f i n i s h i n g
t e c h n i q u e b a s e d on t h e non c u t t i n g m e t a l c o l d f o r m i n g p r o c e s s .
High s p e c i f i c r o l l i n g f o r c e s a r e g e n e r a t e d i n t h e c o n t a c t zone
between t h e r o l l i n g t o o l s and t h e work p i e c e r e s u l t i n g i n
p l a s t i c d e f o r m a t i o n o f t h e s u r f a c e r o u g h n e s s . The m a g n i t u d e
o f t h e r e q u i r e d r o l l i n g f o r c e s depend g r e a t l y upon t h e h a r d -
n e s s o f t h e m a t e r i a l t o be r o l l e r f i n i s h e d . A s a r e s u l t o f t h e
s u r f a c e r o l l i n g , a d i a m e t e r r e d u c t i o n i s e x p e r i e n c e d which
a v e r a g e s t h e m a g n i t u d e o f a f u l l peak t o v a l l e y d e p t h . S u r f a c e
f i n i s h v a l u e s o f b e t t e r t h a n 5 KiVS a r e o b t a i n a b l e i n p r o d u c t i o n
from t u r n e d components o f more t h a n 125 M1S. Further distinct
a d v a n t a g e s o f r o l l e r f i n i s h i n g a r e i n c r e a s e o f h a r d n e s s and
b e a r i n g a r e a c o n t a c t , g e o m e t r y improvement and m a n u f a c t u r i n g
c o s t reduction i n producing a high q u a l i t y surface f i n i s h .
S i m p l i c i t y o f t o o l i n g and m a c h i n e s make t h e r o l l e r f i n i s h i n g
p r o c e s s more a t t r a c t i v e f o r any m a n u f a c t u r i n g i n d u s t r y .
I. INTRODUCTION
----
A. D e f i n i t i o n of t h e Process
R o l l e r f i n i s h j n g i s b a s i c a l l y a p r o c e s s t h r o u g h which
t h e s u r f a c c r o i l g h e s s o f p r e m a c h l n e d c y l i n d r i c a l components i s
c o l d worked o r c o l d formed t h r o u g h t h e u s e o f p r e c i s i o n r o l l i n g
t o o l s and h i g h s p e e i f j c r o l l i n g f o r c e s . T h i s d e f i n i t i o n o f t h e
r o l l e r f i n i s h i n g process i n d i c a t e s a very close r e l a t i o n s h i p
w i t h c o l d f o r m i n g . The name " r o l l e r f i n i s h i n g " , h o w e v e r ,
p r o n o u n c e s t h e r e l a t i o n s h i p w i t h t h e f i n i s h i n g p r o c e s s . To
d e t e r m i n e c l e a r l y u n d e r what m a n u f a c t u r i n g t e c h n i q u e r o l l e r
f i n i s h i n g has t o be c a t e g o r i z e d , it i s necessary t o d e f i n e t h e
c o l d f o r m i n g p r o c e s s . Cold f o r m i n g t o d a y u t i l i z e s s e c t i o n a l
c h a n g e s from 1 0 % t o 8 0 % . T h i s means t h a t c o l d f o r m i n g p r o d u c e s
p r e d o m i n a n t l y a macro g e o m e t r i c form change on t h e component.
R o l l e r f i n i s h i n g , on t h e c o n t r a r y , employs t h e c o l d f o r m i n g
p r o c e s s o n l y f o r i m p r o v i n g m i c r o g e o m e t r i c form a c c u r a c y . The
d e g r e e o f s e c t i o n a l c h a n g e i s m i n i m a l and n o t t r u l y c o m p a t i b l e
w i t h t h e d e f i n i t i o n f o r c o l d f o r m i n g . The r o l l e r f i n i s h i n g
p r o c e s s m u s t , t h e r e f o r e , b e c o n s i d e r e d a non c o a t i n g f i n i s h i n g
technique u t i l i z i n g cold forming only i n t h e o u t e r m a t e r i a l
l a y e r s . D e s p i t e t h e low d e g r e e o f m e t a l f l o w t a k i n g p l a c e i n
t h e r o l l e r f i n i s h i n g p r o c e s s , t h e w e l l known a d v a n t a g e s f o r
c o l d forming m e t a l s as s t r e n g t h i n c r e a s e , s i z e accuracy,
s u r f a c e q u a l i t y and low m a n u f a c t u r i n g c o s t a r e a l s o u t i l i z e d .
D e v e l o p m e-n t o f R o l l e r F i n i s h i n g
A l r e a d y ( 5 0 ) f i f t y y e a r s a g o , r o l l e r f i n i s h i n g was u s e d
by t h e i n d u s t r y . P r e d o m i n a n t l y t h e R a i l r o a d s employed t h i s
p r o c e s s u n d e r t h e name o f b u r n i s h i n g l o r f i n i s h i n g t h e s l e e v e
b e a r i n g s e a t s on r a i l r o a d a x l e s . T h i s p r o c e s s i s s t i l l employ-
ed t o d a y where t h e s l e e v e b e a r i n g s have n o t been r e p l a c e d by
anti-friction bearings. R o l l e r E i n i s h i n g was a n d i s a l s o known
by t h e i n d u s t r y u n d e r d i f f e r e n t names a s f o r e x a m p l e r o l l e r
p o l i s h i n g , p r e s s u r e p o l i s h i n g o r b e a r i n g i z i n g , a l l of which
d e s c r i b e t h e same b a s i c p r o c e s s u n d e r u s e o f s l i g h t l y v a r y i n g
t e c h n i q u e s . Even t h o u g h t h e s e s u r f a c e c o l d f o r m i n g p r o c e s s e s
w e r e known a n d u s e d much e a r l i e r t h a n m o s t o f t h e s u r f a c e
f i n i s h i n g t e c h n i q u e ? b a s e d on t h e a b r a s i v c p r i n c i p l e , r o l l e r
f i n i s h i n g has j u s t r c c e n t l y and predominantly i n Europe been
r e c o g n i z e d a s a n e f f i c i e n t and c o m p e t i t i v e s u r f a c e f i n i s h i n g
process.
The more e x t e n s i v e u s e o f t h e a b r a s i v e p r o c e s s e s i n t h e
p a s t i s p r o b a b l y r e a s o n e d by t h e f a c t t h a t t h e s e m a n u f a c t u r i n g
methods were s u b j e c t e d v e r y e a r l y t o s c i e n t i f i c r e s e a r c h . Thus
resulting i n a b e t t e r understanding of these processes, leading
t o t h e development o f p r o p e r t o o l i n g , machines and machining
techniques.
The i n t e n s i v e s c i e n t i f i c r e s e a r c h o f t h e r o l l e r f i n i s h -
i n g p r o c e s s d a t e s back o n l y (15) t o (20) y e a r s ( 1 , 2 , 3 , 4 ) . As
a r e s u l t h i g h p r o d u c t i v e t o o l s and machines were developed.
Within i t s scope o f s u i t n b i l i t y , r o l l e r f i n i s h i n g w i l l reduce
m a n u f a c t u r i n g c o s t ; i n c r e a s e r e l i a b i l i t y , and improve q u a l i t y .
Three b a s i c p r o c e s s e s a r e developed f o r r o l l i n g c y l i n -
d r i c a l components:
1, Roller Finishing
2, Size R o l l i n g
3, Deep Ilol l i n g
R e l a t e d proce.;ses a s s t r e s s r e l i e f r o l l i n g o r form
r o l l i n g a r e also cc;mnic?nly u s e d t e r m s T h e s e , however, d e s c r i b e
o n l y t h e p r e d o m i n a n ~ i yd e s i r e d e f f e c t s i n h e r e n t l y t y p i c a l f o r
t h e t h r e e b a ~ i cr o l i ~ n gp r o c e s s e s , (Figure #I)
The r e l a $ i o n s h i p b e t w e 2 n r o l l i n g f o r c e , m a t e r i a l
s t r e n g t h , t o o l i ~ r ga n d work p i e c e d i a m e t e r s , s u r l a c e r o u g h n e s s
a n d r o l l i n g t i m e w e r e n o t c l e a r l y u n d e r s t o o d when r o l l e r
f i n i s h i n g was j n i t i a l l y used. The o b t a i n e d r e s u l t s r e m a i n e d
q u i t e o f t e n u n a c c e p t a b l e , F l a k i n g o f t h e s u r f a c e was m o s t l y
e x p e r i e n c e d on Pow q u a l i t y s t e e l s e i t h e r d u r i n g t h e r o l l i n g
p r o c e s s o r a f t e r s u b j e c t i n g t h e r o l l e d component t o i t s o p e r a -
t i o n a l f u n c t i o n s . The e x p l a n a t i o n f o r t h i s s u r f a c e f a i l u r e was
f a l s e l y i n t e r p r e t e d a s r e s u l t i n g from b e n d i n g and s h e a r i n g o f
t h e s u r f a c e p e a k s r e m a i n i n g from t h e p r e p a r a t o r y t u r n i n g o r
g r i n d i n g o p e r a t i o n . S u r f a c e r o u g h n e s s t r a c e s showing an uneven
a m p l i f i c a t i o n between r o u g h n e s s w i d t h and r o u g h n e s s h e i g h t
s u p p o r t e d t h i s o p i n i o n . Comparing t h e t r u e r e l a t i o n s h i p
b e t w e e n r o u g h n e s s h e i g h t and w i d t h w i l l c l e a r l y show t h e
i m p o s s i b i l i t y of t h i s theory. (Figure # 2 )
A. M e t a l Flow
The work r o l l e r s f o r c e d a g a i n s t t h e s u r f a c e
peaks w i l l g e n e r a t e i n t h e p l a s t i f i c a t i o n
zone a s t e a d i l y i n c r e a s i n g c o m p r e s s i v e s t r e s s .
A t a cert.ain s t r e s s l e v e l , p l a s t i c flow o f t h e
m a t e r i a l w i l l occur i n t h e d i r e c t i o n of t h e
l e a s t r e s i s t a n c e , towards t h e s u r f a c e v a l l e y s .
T h i s , i n t u r n , w i l l l i f t t h e v a l l e y s up t o t h e
l e v e l o f t h e work r o l l e r . (Figure # 3 )
The m a g n i t u d e o f t h e p l a s t i c f l o w i s d e p e n d i n g upon t h e
II V I I 7I :
,
- I,f o r c e s used.
,~
L I n c e r t a i n a p p i i c a t i o i i s i t Is d e s i r a b l e
t o s e l e c t a r o l k j n g f o r c e which d o e s n o t p e r m i t t h e s u r f a c e
v a l l e y t o c l o s e up e n t i r e l y . The t y p i c a l c h a r a c t e r i s t i c s o f
s u c h a s u r f a c e a r e l u b r i c a t i o n c a p a b i l i t y , combined w i t h a
h i g h b e a r i n g a r e a c o n t a c t . A volume r e d u c t i o n on t h e p a r t
p i e c e does n o t t a k e p l a c e , however, t h e diameter w i l l reduce
a s a f u n c t i o n o f t h e s u r f a c e r o u g h n e s s b e f o r e and a f t e r
rolling.
B. Cold
-- Forming Zones
The r o l l e r f i n i s h i n g t h e o r y d e f i n e s t h r e e z o n e s i n t h e
c o n t a c t a r e a between t h e work r o l l e r and t h e work p i e c e .
( F i g u r e 84)
On t h e l e a d i n g e d g e o f t h e work r o l l e r i s t h e c o n t a c t
o r LEAD ZONE f o l l o w e d by t h e PLASTIFICATION ZONE and on t h e
t r a i l i n g p a r t o f t h e work r o l l e r , t h e FINISHING Z O N E . For
t h r o u g h V f & e do p e r a t i o n s t h e w o r k ' r o l l e r a x i s i s s l i g h t l y
i n c l i n e d r e l a t i v e t o t h e work p i e c e a x i s , s o t h a t a d r o p form
c o n t a c t i s g e n e r a t e d . The l e n g t h o f t h e d r o p form i s m a i n l y
d e t e r m i n e d by t h e work p i e c e h a r d n e s s , t h e r o u g h n e s s o r
w a v i n e s s o f t h e s u r f a c e o r t h e d e s i r e d f e e d r a t e . Most
commonly d r o p form l e n g t h s v a r y from 1 / 4 " t o 1-1/811. For
p l u n g e r o l l i n g o p e r a t i o n s t h e work r o l l e r a x i s must be
m a i n t a i n e d p a r a l l e l t o t h e work p i e c e a x i s i n o r d e r t o
g e n e r a t e a l i n e c o n t a c t . T h i s r e s u l t s i n an e l i m i n a t i o n o f
t h e f i n i s h i n g zone, which i n t u r n c o u l d r e q u i r e a f i n e r
s u r f a c e f i n i s h p r e p a r a t i o n compared w i t h t h e f e e d r o l l i n g
p r o c e s s . The s e t t i n g o f t h e l i n e c o n t a c t o v e r t h e r o l l e r o r
p a r t l e n g t h must c o n s i d e r t h e machine d e f l e c t i o n , p r e s e n t
under t h e required r o l l i n g f o r c e s .
The r o l l i n g f o r c e s r e q u i r e d f o r p l a s t i c i z i n g t h e
s u r f a c e r o u g h n e s s o f a component depend upon t h e s t r e n g t h o f
t h e work p i e c e m a t e r i a l , t h e l e n g t h o f t h e c o n t a c t f o r m , and
t h e s i z e o f t h e c o n t a c t i n g work p i e c e and work r o l l e r
d i a m e t e r s . The r o l l i n g f o r c e i s c a l c u l a t e d a c c o r d i n g t o t h e
following equation:
F = R o l l i n g Force = SRF x L x D (Lbs.)
C. L u b r i c a t i o n During R o l l e r F i n i s h i n g
R o l l e r f i n i s h i n g has t h e o b j e c t i v e t o produce a f i n e
s u r f a c e f i n i s h through r o l l i n g of t h e s u r f a c e roughness. This
c o l d w o r k i n g p r o c e s s , i f p r o p e r l y employed, w i l l p r o d u c e
s u r f a c e f i n i s h e s between 1 t o 5 RMS s t a r t i n g from a t u r n e d
s u r f a c e o f 125 t o 1 5 0 RMS f i n i s h . The f e e d r a t e s which can be
o b t a i n e d a r e c o m p a t i b l e w i t h f e e d r a t e s p r o d u c e d by t h e c e n t e r
l e s s g r i n d i n g p r o c e s s . Maximum f e e d s o f .04011 p e r work p i e c e
r e v o l u t i o n have been measured f o r t h e c e n t e r l e s s p r i n c i p l e .
Work p i e c e s made o f a m a t e r i a l w i t h low s u i t a b i l i t y f o r c o l d
w o r k i n g o r o f h i g h h a r d n e s s must be p r e p a r e d t o a r e l a t i v e l y ,
fine surface finish.
R o l l e r f i n i s h i n g w i l l reduce t h e diameter of t h e
components d e p e n d i n g upon t h e s u r f a c e r o u g h n e s s p r i o r t o
r o l l i n g and t h e s u r f a c e f i n i s h a f t e r r o l l i n g . The d i a m e t e r
r e d u c t i o n w i l l a v e r a g e a p p r o x i m a t e l y f o u r t i m e s t h e changed
RMS v a l u e i n m i l l i o n t h s o f a n i n c h . (Figure #14) Provided
t h a t t h e s u r f a c e r o u g h n e s s p r i o r t o r o l l i n g and t h e r o l l i n g
force a r e kept within a permissible v a r i a t i o n l i m i t , t h i s
d i a m e t e r r e d u c t i o n w i l l b e c o n s t a n t . The most a c c u r a t e way o f
d e t e r m i n i n g t h e d i a m e t e r o f r e d u c t i o n would be r o l l i n g t e s t s
a f t e r t h e p r o p e r machine s e t u p o r f i n i s h i n g e f f e c t have b e e n
o b t a i n e d . Work p i e c e s which r e q u i r e v e r y c l o s e d i m e n s i o n a l
t o l e r a n c e s must be machined t o a s i z e c o n s i d e r i n g t h e d i a m e t e r
r e d u c t i o n f o r s h a f t s o r d i a m e t e r i n c r e a s e f o r b o r e s . Even
though a f i n i s h g r i n d i n g o p e r a t i o n t o o b t a i n t h e r e q u i r e d
d i m e n s i o n a l a c c u r a c y m i g h t become n e c e s s a r y , r o l l e r f i n i s h i n g
s t i l l o f f e r s c o n s i d e r a b l e a d v a n t a g e s beyond s u r f a c e q u a l i t y .
A n o t h e r means t o o b t a i n h i g h d i m e n s i o n a l a c c u r a c y i s t o
p r e m a c h i n e t h e work p i e c e t o a r e l a t i v e l y c o a r s e s u r f a c e
f i n i s h o f a p p r o x i m a t e l y 150 t o 200 RMS. R o l l e r f i n i s h i n g w i t h
a m u l t i p l e work r o l l e r a t t a c h m e n t w i l l p r o v i d e t h e d e s i r e d
d i m e n s i o n a l a c c u r a c y . D i m e n s i o n a l d e v i a t i o n s r e s u l t i n g from
t h e p r e l i m i n a r y m a c h i n i n g o p e r a t i o n w i l l , however, l e a d t o a
v a r y i n g s u r f a c e f i n i s h and b e a r i n g a r e a c o n t a c t .
The s u r f a c e q u a l i t y of t h e component i s n o t o n l y d e t e r -
mined t h r o u g h t h e s u r f a c e r o u g h n e s s p r i o r t o r o l l i n g and t h e
h a r d n e s s o f t h e m a t e r i a l , b u t a l s o d e p e n d e n t upon t h e form a c -
c u r a c y . F i g u r e # I 5 shows t h e r o l l i n g r e s u l t s of i n a c c u r a t e l y
machined s u r f a c e s . I t s h o u l d a l s o b e m e n t i o n e d h e r e t h a t t h e
u s e of e x c e s s i v e r o l l e r f i n i s h i n g f o r c e s c o u l d c a u s e u n d e s i r -
a b l e c h a n g e s i n g e o m e t r y o f t h e component f o r example p i e c e
e l o n g a t i o n , t a p e r s on s h a f t e n d s , m e t a l f l o w i n t o g r o o v e s o r
small cross holes.
Of s i m i l a r n a t u r e c a n b e a c e r t a i n t y p e 01 s u r f a c e
f l a k i n g , sometimes e x p e r i e n c e d i n a l i n e p a t t e r n p a r a l l e l t o
t h e p a r t a x i s . T h i s t y p e o f f a i l u r e would p o i n t o u t t h a t
t h e p r e l i m i n a r y machining o p e r a t i o n h a s n o t undercut an
already existing surface crack. Failures cf this nature are
m o s t l y c a u s e d by a n o v e r l a p p i n g d u r i n g t h e c o l d d r a w i n g
o p e r a t i o n . G r i n d i n g w i l l n o t make t h e s e m i n u t e c r a c k s v i s i b l e
which c a n o n l y be d e t e c t e d by m a g n a f l u x i n g o r s i m i l a r
techniques. The hidden cracks, however, cause excessive noise
level and bearing wear during operation of the component.
Normally connected with these failures is also a bending of
the shaft since the stress balance has been disturbed.
Roller finishing does, as shown above, discover manu-
facturing insufficiencies which i n the pa.st have probably
never been properly recognized.
VIII. ADVANTAGES
--AND LIMITATIONS OF ROLLER FINISHING
The advantages provided by the roller finishinq process
are many. This new cold forming technique results primarily,
as the name already indicates, in the desired surface finish.
Under proper selection of the rolling forces, best suited
surface finishes for improved wear resistance can easily be
obtained. The degree of finish depends upon the application.
The bearing diameter for a seal for example, should not be
roller finished hclow a surface value of approximately 15 RMS.
The stem diameter of an engine valve, on the contrary, could
be roller finished to a surface value of 8 RMS provided that
the stationary valve guide is manufactured with a properly se-
lected surface roughness capable of lubrication oil retention.
Roller firrish.ing on the centerless principle will, as
the result of the tooling contact, improve the roundness
geometry of cylindrical components, This pertains especially
to the typical insufficiencies experienced with centerless
grinding as ch.atteu.or lobing. Badly chattered work pieces
will not be made perfc.ct throunh rnlling. The rate of u m d -
,AA L V I A I L
,-A.
The l i m i t o f t h e r o l l e r f i n i s h i n g p r o c e s s i s t h e [ l a r d
n e s s o f t h e component. R o l l e r f i n i s h i n g c a n s t i l l be e f i e c ~
i v e l y p e r f o r m e d s l i g h t l y above t h e g e n e r a l l i m i t s for
m a c h i n a b i l i t y , 4 0 t o 4 5 Rockwell "C". S u r f a c e h a r d n e s s ha<, n c ~
i n f l u e n c e on t h e s p e e d o r c y c l e t i m e . A component o f h ~ p , i i
h a r d n e s s l e v e l c a n , t h e r e f o r e , be r o l l e r f i n i s h e d i n t h c s ~ r n ~ ~
t i m e a s a low h a r d n e s s work p i e c e . P r o c e s s e s h a v e been
developed t o bypass t h e hardness s p e c i f i c a t i o n , f o r example
on p i s t o n r o d s . The i n d u c t i o n h a r d e n i n g o p e r a t i o n w i l l talsli
p l a c e a f t e r r o l l e r f i n i s h i n g . The r e s u l t a n t s u s f a c e oxiiia-t-;on
i s removed t h r o u g h a c h e m i c a l w a s h i n g p r o c e s s p r i o r . t o cllronzc~
p l a t i n g . Many a p p l i c a t i o n s , a s f o r example s h o c k n b s o r l ~ e r
r o d s , w i l l p e r m i t t o r e d u c e t h e h a r d n e s s l e v e l i n t o a raargc o f
a p p r o x i m a t e l y 4 0 Rockwell "C" which c a n b e h a n d l e d b y rol t e r
f i n i s h i n g and w i l l s t i l l p r o v i d e a hard enough s u r f a c e t o
avoid s u r f a c e s c r a t c h i n g during t h e assembly o r caused b y
material handling.
S m a l l b e a r i n g l e n g t h and c y l i n d e r b o r e s a r e p r e d o m i -
n a n t l y r o l l e r f i n i s h e d by m u l t i p l e work r o l l e r a t t a c h m e n t s ,
These a t t a c h m e n t s a r e m o s t l y mounted o n t o an e n g i n e o r t u r r e t
l a t h e , b u t a l s o u s e d a s s t a n d a r d t o o l i n g on s p e c i a l m a c h i n e s ,
( F i g u r e # 1 7 ) The d i a m e t e r a d j u s t m e n t . i s r e l a t i v e l y limited
and t h e s e t t i n g remai.ns c o n s t a n t d u r i . n g t h e r o l l i . n g o p e r a t i c o i ~ ,
Changes i n d i a m e t e r s i z e w i l l r e f l e c t o n t o t h e s u r f a c e f i n i s h ,
The work r o l l e r s a r e s y m m e t r i c a l l y a r r a n g e d and. r e t a i - n e d i n a.
manner which a l l o w s them t o p r o d u c e a d r o p form c o r - t a c t with
t h e work p i e c e . As a l r e a d y m e n t i o n e d , t h e s e f i x e d d i a m e t e r
a t t a c h m e n t s h a v e t h e d i s a d v a n t a g e o f r e q u i r i n g a g o o d sS z e
c o n t r o l p r i o r t o r o l l e r f i n i s h i n g ; sometimes even beyond t h e
drawing r e q u i r e m e n t s . E s p e c i a l l y w e l l s u i t e d a r e t h e s e a t ta.ch -
ments f o r i n t e r n a l r o l l e r f i n i s h i n g o p e r a t i o n s , T h e i r u s e f o r
e x t e r n a l work i s l i m i t e d and r e s t r i c t e d t o s h o r t b e a r i n g e x t c - n -
sions. S p e c i a l work r o l l e r f i n i s h i n g a t t a c h m e n t s f o r t a p e r s ,
c h a m f e r s , s p h e r e s and f i l l e t s a r e a l s o avail.a.ble on t h e s a m e
design p r i n c i p l e .
General purpose semi-automatic roller finishing
machines and single purpose fully-automatic machines are
available up to a maximum work piece diameter of 4".
(Figures #18 and #19) These machines work on the centerless
principle. The tooling can be adjusted to any desired drop
form or line contact. Feed rates are infinitely variable
within the machine capability. The required rolling forces
are generated by means of hydraulic pressure. Tooling and
machine are designed in a manner to provide optimum flexibi-
lity with regard to manual or automatic operation, adaptation
of loading devices or transfer lines. The diameter range of
a tool head can be utilized without adjustments, which make
the finishing effect independent of any diameter changes.
Machine setup and tool changes can be performed at a minimum
time to conform to high production requirements.
The two roll and single roll attachments are, in their
design, compatible. (Figure #20) The single roll attachment,
however, should only be used on diameter sizes which warrant
that no deflection of the work piece or the machine takes
place when rolling forces are applied.
WORKPIECE YPICAL ROLLING
DIAMETER (In.) PPLICATIONS FORCE (Lbs . )
The above chart shows the diameter ranges and the general
limitations of the rolling equipment. It further conveys a
picture o f the mostly used applications and the rolling
pressure requirements for the respective diameter ranges.
X. SUMMARY
Roller finishing of cylindrical components as discussed
above offers many advantages. The theory of the process has
been thoroughly developed as well as the design of tooling and
machines. A meaningful and successful application of this
new surface finishing technique does require to understand the
relationship between the specific rolling force, material
strength, contact length between tooling and work piece,
number of overrollings, and preliminary surface preparations.
If properly applied, roller finishing and its results will
satisfy the demands brought forward by today's progressive
industry in providing manufacturing cost reductions, increas-
ing performance reliability, and improving the component
quality. The roller finishing process of cylindrical
components will in the future, undoubtedly, gain a wide
acceptance because of the steadily increasing trend towards
metal cold forming.
REFERENCES :
1. Koenig H., "New Development in Finishing by
Rolling" (Translation) - "Neuere Entwicklungen in
der Feinbearbeitung durch Glattwalzen" "Das
Industrieblatt", Stuttgart, 60. Jahrgang 1960,
Heft 5 (Mai) , Seite 136..322. (Special Print)
2. Schimz K., "Roller Finishing as Cold Forming"
(Translation), "Das Oberflaechen Feinwalzen als
Kaltformverfahren", "Industrie-Anzeiger" Nr. 27
vom 1, April 1960, Verlag W. Giradet, Essen.
(Special Print)
3. Pahlitzsch G . , - Krohn P., "Roller Finishing of
Cylindrical Components up to 7/8" Ilia."
(Translation), "Ueber das Glattwalzen kreiszylin-
drischer Werkstuecke mit Durchmessern bis 20 MM."
Werkstattstechnik, 53. Jahrgang (1963) Heft 9 ,
S.447--453. (Special Print)
4. VDI - Standards No. 3177, March, 1963. "Surface
Rollingts (Translation) , VDI - Richtlinien.
"Oberflaechen-Feinwalzen" Verein Deutscher
Ingenieure, Maerz 1963 Handbuch Betriebstechnik.
k-d
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TOTAL HEIGHT 1 -- {
TOTAL TURNED SURFJ.CE AFTER ROLLING
HE!GHT
8
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ATTER XOL.LiNC
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F i g u r e 15, s h e e t 8 ,