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Roller burnishing, hard roller burnishing and deep rolling reduce manufacturing costs compared to grinding, polishing,
honing, superfinish and shot peening. There are several cost saving effects: Process time reduction: The above processes work with parameters similar to cutting. Only one pass is required. So, the process time is about equal to a medium cutting operation. You can calculate the process time for your components under Time Saving / ROI Please find the saving by comparing the calculated time with the actual time requirements. Completion in one setting: ECOROLL tools fit to all machine tools like lathes, milling centers, drill presses and milling machines. They may be conventional or CNC controlled. This saves investment and personal. Eliminate auxiliary costs: Setting costs, transportation costs (external and in house) and work handling time are eliminated. Moreover, shorter lead time reduces capital binding. Fast ROI:The investment for ECOROLL tools is low compared to their benefit. This often results in return of investment within few month only. You can calculate your ROI under Time Saving / ROI. Please inquire the required tool and insert the investment and your data in the calculation page. You will be surprised about the online result. No waste disposal: There is no material removed. Therefore no dust or mud are generated and have to be removed and disposed. Examples:  Piston rods of hydraulic cylinders are turned near to final dimension and roller burnished in one setting. A hard chrome layer with typical thickness of 20 µm is applied. This saves at least 50% Chromium and energy as well. Furthermore, additional processes like grinding, superfinish and honing are eliminated. For example, roller burnishing of a piston rod Ø80 x 800 long takes 2,5 min. only at a speed vc = 200 m/min and a feed rate of f = 0,4 mm/rev. A surface quality of Ra < 0,2 µm is achieved. The tool used in this application is EG14. It is available ex stock with VDI shank and square shank as well. 
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The tool used in this application is EG14. It is available ex stock with VDI shank
and square shank as well. Cylinder tubes are preferably made from cold drawn precision tube. The bore is skived and roller burnished at the same time with combined skive burnishing tools. Feed rates of 2 to 2.5 m/min are achieved processing e.g. tubes with a 120 mm bore. with the advanced ECOROLL tools RDSE or RDZ  Large bores for e.g. for press cylinders are often machined on vertical lathes. The roller burnishing process takes about 50 min in this case and replaces a time consuming polishing process. 5 hours time saving per cylinder is achieved.  Ball zones of gears are roller burnished with the hydrostatic tool "ballpoint" HG6 in about 3 sec. They are mostly applied on multi spindle lathes. |
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