There are many problems to be paid attention to in the use of roller burnishing tool and other precision machining, otherwise, the size and performance of the workpiece will be damaged instead of the expected effect. We introduce several common problems that may affect the workpiece rolling and burnishing:
(1) The hardness of the billet is closely related to the rolling process. If the hardness is too high, the life of the rolling tool will decrease rapidly. The hardness of the material must be less than HRC37-40. Increasing the hardness of the material will also cause the increase of radial force of rolling pressure.
For example, when the hardness of No. 45 steel increases to HRC5, it will cause the radial force of rolling pressure to increase by 10% ~ 20%, which will cause the increase of the tool’s pressure output force and the increase of the middle diameter tolerance level of the workpiece being rolled.
After rolling, the hardness of the workpiece can be increased by 15% to 30%, while the wear resistance can be increased by 15%.
(2) The hardness uniformity and structure uniformity of billet materials have a great influence on rolling performance. The uneven hardness of the material will lead to accidental error of rolling pressure parameters, resulting in the unevenness of the tooth profile.
(3) Whether the surface of the billet is defective or not also has a significant effect on rolling effect. If there are bubbles and non-metallic impurities, the workpiece rolled finish will produce cracks and other phenomena, which will greatly affect the service life of the roller burnishing tool.
(4) The diameter margin and tolerance of the billet have a great influence on the quality of the workpiece. If the diameter margin is too large, it will lead to the distortion of the workpiece due to the excess metal contained in the roller tool, and even lead to the damage of the roller head.
If the diameter of the billet is too small, it will be scrapped because there is not enough metal supplement to make the workpiece not up to the design size. The diameter of billet not only depends on the specification precision of workpiece. It is also directly related to the selection of type and processing parameters of roller burnishing tools.
Comprehensive the above four points, we need to be clear the workpiece before using roller tool, need to clearly know its hardness, dimensional tolerance, form and location tolerance, the adjusting range of rolling head, the precision of the workpiece, the precision of the rolling head, some surface defects of the workpiece itself, etc. All of these are the key factors to improve the smoothness of products with roller burnishing tool.
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