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Roller Burnishing
Roller Burnishing Products
Process:
Roller Burnishing is a cold-working process
of metal displacement used as an alternative to metal removal. This
method rolls and compresses metal rather than cutting or abrading the
surface of the work piece. This technique achieves superior results at
a lesser cost than comparable operations such as grinding, honing or
polishing. The roller burnishing tool consists of a series of tapered
rolls which rotate around and against an inversely tapered mandrel.
This creates a mechanical advantage which allows the rolls to develop
a pressure that exceeds the yield point of the softer work piece.
These evenly-spaced rolls are highly polished and hardened to provide
the precision and accuracy necessary for the burnishing operation.
A machined metal surface consists of an irregular succession of peaks
and valleys which vary in height and width. Roller burnishing
compresses or irons-out the peaks into the valleys of the surface
structure. This is accomplished through the action of the rolls under
pressure between the mandrel tip and the part surface. Thus, material
displacement occurs which cold-flows the peaks into the microscopic
valleys resulting in a mirror-like finish.
Roller burnishing rolls out tool marks and surface irregularities,
generating a dense and uniform surface. Consistent part size is
controlled through a positive adjustment feature built into the tool.
This process produces a low micro-inch finish; a tough, work hardened,
wear and corrosion resistant surface, and maintains a precise part
diameter. The accurate sizing, fine finishing and work hardening
created by a Roll-A-Matic burnishing tool ensures the user a high
quality, long lasting and consistent product.
Roller Burnishing Advantages:
Accurate Size - Precise size requirements can be attained
quickly and easily with Roll-A-Matic burnishing tools. Size is
controlled by a simple, manual adjustment feature built into the tool
allowing a diameter adjustment in one-tenth increments. This
flexibility in the initial set-up provides selective fitting that can
be maintained throughout long production operations. Further
adjustments to compensate for wear are just as easy. This size control
characteristic can be utilized in any conventional machine with a
rotating spindle whether it is single or multipurpose, hand or machine
feed, automatic or automated.
Low, Smooth Micro Finish - Roller Burnishing delivers a
dense and uniform finish to any malleable metal without cutting or
abrading the surface. This process flows the metal, pressing and
rolling the peaks into the valleys while eliminating feathered edges,
residual cutting tool marks and reducing surface friction. Finish
requirements are met in seconds as compared to the multiple-step
operations of grinding, reaming, honing or lapping. Also, subsequent
operations such as gauging, extra parts handling and additional
machine usage are often eliminated.
Increased Surface Hardness - While roller burnishing cold works
the metal for part sizing and finishing, the surface is being work
hardened and strengthened. The cold-rolling condenses and refines the
grain structure of the metal, producing an increase of surface
hardness from 5% 10% within a penetration of .001” to .030” (.025 to
.762 mm). The process greatly reduces surface porosity, pits and
scratches leaving a dense and uniform finish. The work surface is made
corrosion and fatigue resistant, substantially increasing part life.
Long Tool Life - Long tool life is ensured with Roll-A-Matic
burnishing tools. All wear parts are manufactured from high grade
steel and heat treated for optimum hardness. The tools are able to
maintain size after thousands of operations under normal
circumstances. Whether they are used
in automated high production or hand operations, ROLL-A-MATIC tools
prove their durability. Even under the most adverse conditions,
Roll-A-Matic burnishing tools will consistently provide low
micro-finishes and accurately sized parts.
Basic Usage - Unskilled operators can produce close tolerance
work with consistent, precise and uniform results over thousands of
parts. Set-up simply entails setting the tool to the proper size which
takes less
than one minute and is done without the use of any tools whatsoever.
Diameter adjustments of .0001 are accomplished without removing the
tool from the spindle.
Capital Outlay Unnecessary - Additional machine investment is
not necessary or required to be able to utilize burnishing tools.
Roll-A-Matic tools can be used on any driven spindle machine and
can operate at the standard speeds and feeds found in most
conventional shop machines.
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