EP1372903A1 - Method for producing a deep rolling roller, and deep rolling roller - Google Patents

Method for producing a deep rolling roller, and deep rolling roller

Info

Publication number
EP1372903A1
EP1372903A1 EP02727379A EP02727379A EP1372903A1 EP 1372903 A1 EP1372903 A1 EP 1372903A1 EP 02727379 A EP02727379 A EP 02727379A EP 02727379 A EP02727379 A EP 02727379A EP 1372903 A1 EP1372903 A1 EP 1372903A1
Authority
EP
European Patent Office
Prior art keywords
deep
rolling
rolling roller
roller
smooth
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP02727379A
Other languages
German (de)
French (fr)
Inventor
Siegfried Bagusche
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Hegenscheidt MFD GmbH and Co KG
Original Assignee
Hegenscheidt MFD GmbH and Co KG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Hegenscheidt MFD GmbH and Co KG filed Critical Hegenscheidt MFD GmbH and Co KG
Publication of EP1372903A1 publication Critical patent/EP1372903A1/en
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21H—MAKING PARTICULAR METAL OBJECTS BY ROLLING, e.g. SCREWS, WHEELS, RINGS, BARRELS, BALLS
    • B21H7/00—Making articles not provided for in the preceding groups, e.g. agricultural tools, dinner forks, knives, spoons
    • B21H7/18—Making articles not provided for in the preceding groups, e.g. agricultural tools, dinner forks, knives, spoons grooved pins; Rolling grooves, e.g. oil grooves, in articles
    • B21H7/182—Rolling annular grooves
    • B21H7/185—Filet rolling, e.g. of crankshafts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21H—MAKING PARTICULAR METAL OBJECTS BY ROLLING, e.g. SCREWS, WHEELS, RINGS, BARRELS, BALLS
    • B21H1/00—Making articles shaped as bodies of revolution
    • B21H1/14—Making articles shaped as bodies of revolution balls, rollers, cone rollers, or like bodies
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P9/00—Treating or finishing surfaces mechanically, with or without calibrating, primarily to resist wear or impact, e.g. smoothing or roughening turbine blades or bearings; Features of such surfaces not otherwise provided for, their treatment being unspecified
    • B23P9/02—Treating or finishing by applying pressure, e.g. knurling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
    • B24B5/00—Machines or devices designed for grinding surfaces of revolution on work, including those which also grind adjacent plane surfaces; Accessories therefor
    • B24B5/36—Single-purpose machines or devices
    • B24B5/42—Single-purpose machines or devices for grinding crankshafts or crankpins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21H—MAKING PARTICULAR METAL OBJECTS BY ROLLING, e.g. SCREWS, WHEELS, RINGS, BARRELS, BALLS
    • B21H7/00—Making articles not provided for in the preceding groups, e.g. agricultural tools, dinner forks, knives, spoons
    • B21H7/18—Making articles not provided for in the preceding groups, e.g. agricultural tools, dinner forks, knives, spoons grooved pins; Rolling grooves, e.g. oil grooves, in articles
    • B21H7/182—Rolling annular grooves
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49544—Roller making
    • Y10T29/49565—One-piece roller making

Definitions

  • the deep rolling roller is part of a tool for deep rolling radii or recesses on crankshaft bearing or crank pins for motor vehicle engines.
  • the deep rolling rollers are among the smallest of those parts that form the complex deep rolling tool.
  • Two deep rolling rolls, which are arranged within a single deep rolling tool, are customary; but there are also deep rolling tools that have only a single deep rolling roller.
  • the deep rolling rollers engage directly with the workpiece, a crankshaft or a camshaft. There, under the pressure of the deep rolling force, they cause a local plastic deformation on the workpiece, the size and depth of which is determined by the shape of the deep rolling rollers and the deep rolling force. At the same time, residual compressive stresses are also introduced into the workpiece.
  • the number of deep rolling tools in engagement depends on the number of bearing or crank pins. All of the deep rolling tools are arranged in a single machine. Organs of the deep rolling machine control the movements of the deep rolling tools, other organs generate the deep rolling forces and also control their course over the circumference of the workpiece.
  • a deep rolling tool of the type mentioned and a method for producing deep rolling rolls have become known, for example, from US Pat. No. 5,806,184. Then a deep rolling roll is obtained by sawing a blank from the end of a cylindrical bar made of tool steel. The sawn-off blank is then hardened and brought into the form of a deep-rolling roller by grinding. This can also be followed by a second grinding in order to obtain the desired dimensions of the deep rolling roller. In any case, the second grinding is carried out using a centerless grinding process. In the end the Form and dimensionally correct deep rolling roller polished.
  • the well-known deep rolling roller consists of materials from the groups CPM-REX 76, ASP-60M-2 or ASP-60M-4, which are powder-metallurgically manufactured steels and has degrees of hardness between 63 and 70 Rockwell C. In addition, other tool steels are also used.
  • the inventor of the present invention is also aware of other manufacturing processes for producing deep-rolling rolls by turning on lathes, without such processes having been published to the knowledge of the inventor.
  • the deep rolling rolls produced by turning also consist of the aforementioned materials and have the aforementioned degrees of hardness.
  • the structure of the known materials which are predominantly sintered metals, is the cause of the fact that during the shaping of the deep rolling rollers, machining marks are created on the body of the deep rolling roller by turning and / or grinding. These are microscopically fine turning grooves, notches and pores on the surface of the deep-rolling roller, which cause the deep-rolling roller to come to a standstill when the deep-rolling roller is subsequently used.
  • the service life of the deep rolling rollers regularly determines the failure of the entire deep rolling tool and makes it necessary to replace it.
  • Experience has shown that if a deep rolling tool fails, all other deep rolling tools of a deep rolling machine are replaced at the same time as a precaution.
  • the same procedure is followed when stopping deep rolling machines after a predetermined operating time based on experience.
  • the availability of individual deep rolling machines also determines how many deep rolling machines have to be operated at the same time in order to meet the specified production figures.
  • the service life of deep rolling tools is also influenced by the type, shape and material of the workpieces to be machined, such as the crank or camshafts of automotive engines.
  • the task for the present invention results from the above circumstances to increase the service life of deep-rolling rolls and to improve their shape accuracy. At the same time, the service life of individual deep rolling tools is to be increased and the downtime of deep rolling machines is to be reduced. The economy of the deep rolling operation is to be improved overall.
  • the object is achieved by a manufacturing process for deep rolling rolls, in which
  • the body of a deep rolling roller is preformed by turning, grinding or laser forming at the end of a cylindrical rod made of tool steel,
  • the severed deep-rolling roller is smoothly rolled in the area of its largest circumference and, if necessary, made to measure,
  • the smooth rolling process step is the smooth rolling process step. Not only are the microscopic defects leveled on the toroidal surface area of the largest circumference of the deep-rolling roller, i.e. smoothed, but the rounding radius of the deep-rolling roller in the area of the largest diameter is maintained with the same high degree of accuracy with regard to shape and dimension as with the plastic deformation the known manufacturing process was previously not possible.
  • the smooth rolling of the deep rolling roller can be accompanied by mass rolling, whereby the largest diameter of the deep rolling roller is determined. At the same time, the service life of the deep rolling rollers is significantly increased; Tool fatigue no longer occurs from the outside as before, but at most appears as structural fatigue from the inside of the deep rolling roller.
  • Such a guide roller has a central projecting collar on its outer circumference, which forms a radius on both sides with the rest of the body of the guide roller.
  • this radius of the guide roller adapted to the shape and size of the deep-rolling roller, the deep-rolling roller is supported on the guide roller and is guided at the same time.
  • the smooth rolling of this area of the guide rollers can also increase the life of both the deep rolling roller and the guide roller itself.
  • the deep-rolling roller 1 is part of a deep-rolling tool which is known per se for deep-rolling radii or punctures on crankshafts of motor vehicle engines.
  • the deep rolling roller 1 has approximated it geometric shape of a truncated cone.
  • the deep rolling roller 1 is strongly rounded.
  • the radius of curvature of the deep-rolling roller 1 is indicated by the arrow 3 in FIG. 3. Due to the rounding in the area 2 of the largest outer circumference, the deep-rolling roller 1 in this area 2 is given the shape of a To 4, to which a short truncated cone 5 is connected in order to describe the outer shape of the deep-rolling roller 1.
  • this truncated cone shape there are also deep rolling rolls that have a rather disc-shaped configuration.
  • the deep-rolling roller 1 is smoothed in the area 2 of its largest outer circumference. For this purpose, it is run without further guidance, i.e. centerless, clamped between a set of smooth rolling rolls.
  • the set of smooth rolling rolls consists of the cylindrical smooth rolling rolls 6, 7 and 8, which, as can be seen from FIG. 1, are arranged in the geometric configuration of a triangle.
  • the smooth rolling rolls 6, 7 and 8 are each rotatable about their longitudinal axes 9, 10 and 11.
  • the largest smooth rolling roller 6 is drivable and rotates clockwise 12, for example.
  • Each of three smooth rolling rolls 6, 7 and 8 has a circumferential groove 13, irrespective of the respective diameter of the smooth rolling roll 6, 7 or 8.
  • the circumferential grooves 13 of all three smooth rolling rolls 6, 7 and 8 have approximately the same depth and the same rounding radius 3.
  • the deep rolling roller 1 is clamped between the smooth rolling rollers 6, 7 and 8.
  • the smooth rolling roller 6 rotates clockwise 12 and takes the other two smooth rolling rollers 7 and 8 along with the rotating deep rolling roller 1.
  • the deep rolling roller 1 is guided in the circumferential grooves 13 of all three smooth rolling rollers 6, 7 and 8.
  • About the two A smooth rolling force 14 is applied to the smooth rolling rolls 7 and 8.
  • the deep rolling roller 1 is simultaneously rolled in the area 2 of its largest outer circumference by all three smooth rolling rollers 6, 7 and 8, ie locally plastically deformed. Any traces of the previous processing present in area 2 disappear and the rounding radius 3 of the tom 4 of the deep-rolling roller 1 is set.
  • the predetermined largest diameter 15 of the deep rolling roller 1 is also set with the smooth rolling.
  • the smooth rolling force 14 can also be applied via the driven smooth rolling roller 6.
  • the drive can also be initiated by one or both of the smooth rolling rollers 7 or 8, each of which has a smaller diameter than the smooth rolling roller 6, as can be seen from FIGS. 1 and 2.
  • the smooth rolling cycle is only a few overruns of the To s 4.
  • the smooth rolling force 14 depends on the size and the material of the deep rolling roller 1 and is previously determined experimentally.
  • the deep rolling roller 1 is removed by moving at least one of the smooth rolling rollers 6, 7 or 8 into an open position. A further deep-rolling roller 1 is then introduced between these smooth-rolling rollers 6, 7 and 8 and the previously opened smooth-rolling roller 6, 7 or 8 is returned to the working position, as shown in FIG. 1.
  • the process of clamping and unclamping a deep rolling roller 1 can take place automatically.
  • the smooth-rolled deep-rolling roller 1 is then hardened.
  • the smooth-rolled and hardened deep-rolling roller 1 is finally fed to the last process step of polishing.
  • the entire surface of the deep rolling roller 1 is tempered in a manner known per se. The dimensions and shape of the deep rolling roller 1 are no longer changed by the polishing.
  • the guide rollers of deep rolling tools can also be treated.
  • smooth rolling rollers 6, 7 and 8 provided with circumferential grooves 13
  • smooth rolling rollers will be used which have a projecting outer circumference without the need for a separate description.

Abstract

The invention relates to a method for producing a deep rolling roller (1) for a deep rolling tool for deep rolling radii or passes on the bearing and crank pins of the crankshafts of automotive engines. The inventive method is characterized by the following steps: turning the body of the deep rolling roller (1) from tool steel, separating the turned deep rolling roller (1), roller-finishing the deep rolling roller (1) in the area (2) of its largest diameter, hardening the roller-finished deep rolling roller (1), and polishing the hardened deep rolling roller (1).

Description

„Verfahren zur Herstellung einer Festwalzrolle und Festwalzrolle" "Process for producing a deep rolling roller and deep rolling roller"
Die Festwalzrolle ist Teil eines Werkzeugs zum Festwalzen von Radien oder Einstichen an Lager- oder Hubzapfen von Kurbelwellen für KfZ- otoren. Die Festwalzrollen gehören mit zu den kleinsten jener Teile, welche das komplexe Festwalzwerkzeug bilden. Üblich sind zwei Festwalzrollen, die innerhalb eines einzelnen Festwalzwerkzeugs angeordnet sind; aber es gibt auch Festwalzwerkzeuge, die nur eine einzelne Festwalzrolle aufweisen. Die Festwalzrollen treten unmittelbar mit dem Werkstück, einer Kurbel- oder auch einer Nockenwelle, in Eingriff. Dort bewirken sie unter dem Druck der Festwalzkraft eine örtliche plastische Verformung an dem Werkstück, deren Grosse und Tiefe von der Form der Festwalzrollen und der Festwalzkraft bestimmt wird. Zugleich werden auch Druckeigenspannungen in das Werkstück eingebracht. Üblicherweise sind mehrere Festwalzwerkzeuge am selben Werkstück gleichzeitig im Eingriff. Bei einer Kurbelwelle richtet sich die Anzahl der im Eingriff stehenden Festwalzwerkzeuge nach der Anzahl der Lager- oder Hubzapfen. Dabei ist die Gesamtheit der Festwalzwerkzeuge jeweils in einer einzelnen Maschine angeordnet. Organe der Festwalzmaschine steuern die Bewegungen der Festwalzwerkzeuge, andere Organe erzeugen die Festwalzkräfte und steuern auch deren Verlauf über dem Umfang des Werkstücks.The deep rolling roller is part of a tool for deep rolling radii or recesses on crankshaft bearing or crank pins for motor vehicle engines. The deep rolling rollers are among the smallest of those parts that form the complex deep rolling tool. Two deep rolling rolls, which are arranged within a single deep rolling tool, are customary; but there are also deep rolling tools that have only a single deep rolling roller. The deep rolling rollers engage directly with the workpiece, a crankshaft or a camshaft. There, under the pressure of the deep rolling force, they cause a local plastic deformation on the workpiece, the size and depth of which is determined by the shape of the deep rolling rollers and the deep rolling force. At the same time, residual compressive stresses are also introduced into the workpiece. Usually several deep rolling tools are engaged on the same workpiece at the same time. In the case of a crankshaft, the number of deep rolling tools in engagement depends on the number of bearing or crank pins. All of the deep rolling tools are arranged in a single machine. Organs of the deep rolling machine control the movements of the deep rolling tools, other organs generate the deep rolling forces and also control their course over the circumference of the workpiece.
Ein Festwalzwerkzeug der genannten Art und ein Verfahren zur Herstellung von Festwalzrollen sind beispielsweise aus der US-PS 5,806,184 bekannt geworden. Danach wird eine Festwalzrolle durch Absägen eines Rohlings vom Ende einer zylindrischen Stange aus Werkzeugstahl gewonnen. Der abgesägte Rohling wird sodann gehärtet und durch Schleifen in die Form einer Festwalzrolle gebracht. Daran kann sich auch noch ein zweites Schleifen anschliessen, um die gewünschten Abmessungen der Festwalzrolle zu erhalten. Jedenfalls erfolgt das zweite Schleifen mit einem spitzenlosen Schleifverfahren. Zum Schluss wird die form- und massgerechte Festwalzrolle poliert. Die bekannte Festwalzrolle besteht aus Werkstoffen der Gruppen CPM-REX 76, ASP-60M-2 oder ASP-60M- 4, welches pulvermetallurgisch hergestellte Stähle sind und weist Härtegrade zwischen 63 und 70 Rockwell C auf. Daneben kommen aber auch noch andere Werkzeugstähle zur Anwendung.A deep rolling tool of the type mentioned and a method for producing deep rolling rolls have become known, for example, from US Pat. No. 5,806,184. Then a deep rolling roll is obtained by sawing a blank from the end of a cylindrical bar made of tool steel. The sawn-off blank is then hardened and brought into the form of a deep-rolling roller by grinding. This can also be followed by a second grinding in order to obtain the desired dimensions of the deep rolling roller. In any case, the second grinding is carried out using a centerless grinding process. In the end the Form and dimensionally correct deep rolling roller polished. The well-known deep rolling roller consists of materials from the groups CPM-REX 76, ASP-60M-2 or ASP-60M-4, which are powder-metallurgically manufactured steels and has degrees of hardness between 63 and 70 Rockwell C. In addition, other tool steels are also used.
Dem Erfinder der vorliegenden Erfindung sind auch noch weitere Herstellungsverfahren zum Fertigen von Festwalzrollen durch Drehen auf Drehmaschinen bekannt, ohne dass solche Verfahren nach Wissen des Erfinders bisher veröffentlicht wurden. Auch die durch Drehen erzeugten Festwalzrollen bestehen aus den vorgenannten Werkstoffen und weisen die vorgenannten Härtegrade auf.The inventor of the present invention is also aware of other manufacturing processes for producing deep-rolling rolls by turning on lathes, without such processes having been published to the knowledge of the inventor. The deep rolling rolls produced by turning also consist of the aforementioned materials and have the aforementioned degrees of hardness.
Das Gefüge der bekannten Werkstoffe, es handelt sich überwiegend um Sintermetalle, ist ursächlich dafür, dass bei der Formgebung der Festwalzrollen durch Drehen und/oder Schleifen Bearbeitungsspuren auf dem Körper der Festwalzrolle entstehen. Dabei handelt es sich um mikroskopisch feine Drehrillen, Kerben und Poren auf der Oberfläche der Festwalzrolle, die beim späteren Gebrauch der Festwalzrolle als extrem hochbelastetes Festwalzwerkzeug zum Erliegen desselben führen. Mit anderen Worten, die Standzeiten der Festwalzrollen bestimmen regelmässig den Ausfall des gesamten Festwalzwerkzeugs und machen dessen Austausch erforderlich. Das aber bedingt Stillstandzeiten der Festwalzmaschine und senkt deren Verfügbarkeit. Erfahrungsgemäss werden beim Ausfall eines Festwalzwerkzeugs vorsorglich sofort alle übrigen Festwalzwerkzeuge einer Festwalzmaschine zugleich mit erneuert. In gleicher Weise wird verfahren beim Stillsetzen von Festwalzmaschinen nach Ablauf einer vorbestimmten, auf Erfahrungen gestützten Betriebszeit. Die Verfügbarkeit einzelner Festwalzmaschinen ist aber auch zugleich bestimmend dafür, wie viele Festwalzmaschinen gleichzeitig betrieben werden müssen, um vorgegebne Produktionszahlen zu erfüllen. Schliesslich werden die Standzeiten von Festwalzwerkzeugen auch noch beeinflusst von der Art, der Form und dem Werkstoff der zu bearbeitenden Werkstücke, wie Kurbel, oder Nockenwellen von KfZ-Motoren.The structure of the known materials, which are predominantly sintered metals, is the cause of the fact that during the shaping of the deep rolling rollers, machining marks are created on the body of the deep rolling roller by turning and / or grinding. These are microscopically fine turning grooves, notches and pores on the surface of the deep-rolling roller, which cause the deep-rolling roller to come to a standstill when the deep-rolling roller is subsequently used. In other words, the service life of the deep rolling rollers regularly determines the failure of the entire deep rolling tool and makes it necessary to replace it. However, this means that the deep-rolling machine is idle and reduces its availability. Experience has shown that if a deep rolling tool fails, all other deep rolling tools of a deep rolling machine are replaced at the same time as a precaution. The same procedure is followed when stopping deep rolling machines after a predetermined operating time based on experience. The availability of individual deep rolling machines also determines how many deep rolling machines have to be operated at the same time in order to meet the specified production figures. Finally, the service life of deep rolling tools is also influenced by the type, shape and material of the workpieces to be machined, such as the crank or camshafts of automotive engines.
Aus den vorstehenden Gegebenheiten resultiert die Aufgabe für die vorliegende Erfindung, die Lebensdauer von Festwalzrollen zu erhöhen und deren Formgenauigkeit zu verbessern. Damit einhergehend soll zugleich die Standzeit einzelner Festwalzwerkzeuge vergrössert und somit die Stillstandszeit von Festwalzmaschinen verringert werden. Die Wirtschaftlichkeit der Festwalzoperation soll insgesamt verbessert werden.The task for the present invention results from the above circumstances to increase the service life of deep-rolling rolls and to improve their shape accuracy. At the same time, the service life of individual deep rolling tools is to be increased and the downtime of deep rolling machines is to be reduced. The economy of the deep rolling operation is to be improved overall.
Die Aufgabe wird durch ein Herstellverfahren für Festwalzrollen gelöst, bei welchemThe object is achieved by a manufacturing process for deep rolling rolls, in which
- der Körper einer Festwalzrolle durch Drehen, Schleifen oder Laserformen am Ende einer zylindrischen Stange aus Werkzeugstahl vorgeformt wird,- the body of a deep rolling roller is preformed by turning, grinding or laser forming at the end of a cylindrical rod made of tool steel,
- der vorgeformte Körper der Festwalzrolle vom Ende der Stange abgetrennt wird,- the preformed body of the deep rolling roller is separated from the end of the rod,
- die abgetrennte Festwalzrolle im Bereich ihres grössten Umfangs glatt und gegebenenfalls auf Mass gewalzt wird,the severed deep-rolling roller is smoothly rolled in the area of its largest circumference and, if necessary, made to measure,
- die glattgewalzte Festwalzrolle gehärtet wird und- The smooth rolled deep rolling roller is hardened and
- die gehärtete Festwalzrolle zum Schluss poliert wird.- The hardened deep rolling roller is finally polished.
Besondere Bedeutung kommt bei diesem Verfahren dem Verfahrensschritt des Glattwalzens zu. Hierbei werden nicht nur die mikroskopisch kleinen Defekte auf dem toroidalen Flächenbereich des grössten Umfangs der Festwalzrolle eingeebnet, d.h. geglättet, sondern durch die plastische Verformung wird der Abrundungsradius der Festwalzrolle im Bereich des grössten Durchmessers mit so hoher Genauigkeit hinsichtlich Form und Abmessung eingehalten, wie das mit den bekannten Herstellungsverfahren bisher nicht möglich war. Zusätzlich kann mit dem Glattwalzen der Festwalzrolle ein Masswalzen einhergehen, wodurch der grösste Durchmesser der Festwalzrolle festgelegt wird. Zugleich wird die Lebensdauer der Festwalzrollen deutlich erhöht; die Werkzeugermüdung tritt nicht mehr wie bisher von aussen ein, sondern stellt sich allenfalls als Gefügeermüdung vom Inneren der Festwalzrolle her ein.Of particular importance in this process is the smooth rolling process step. Not only are the microscopic defects leveled on the toroidal surface area of the largest circumference of the deep-rolling roller, i.e. smoothed, but the rounding radius of the deep-rolling roller in the area of the largest diameter is maintained with the same high degree of accuracy with regard to shape and dimension as with the plastic deformation the known manufacturing process was previously not possible. In addition, the smooth rolling of the deep rolling roller can be accompanied by mass rolling, whereby the largest diameter of the deep rolling roller is determined. At the same time, the service life of the deep rolling rollers is significantly increased; Tool fatigue no longer occurs from the outside as before, but at most appears as structural fatigue from the inside of the deep rolling roller.
Weitere vorteilhafte Ausgestaltungen des Herstellungsverfahrens sowie einer nach dem Verfahren hergestellten Festwalzrolle ergeben sich aus den Merkmalen der einzelnen Unteransprüche. Darüber hinaus ist das Verfahren in einer über die bisher geschilderte hinausgehenden vorteilhaften Ausgestaltung auch auf die Führungsrolle anwendbar, auf welcher sich innerhalb eines Festwalzwerkzeugs in der Regel zwei Festwalzrollen abstützen.Further advantageous refinements of the production method and a deep-rolling roller produced by the method result from the features of the individual subclaims. In addition, the method can also be applied to the guide roller in an advantageous embodiment going beyond that described above, on which two deep-rolling rollers are generally supported within a deep-rolling tool.
Eine solche Führungsrolle hat auf ihrem Aussenumfang einen mittleren vorspringenden Bund, der mit dem übrigen Körper der Führungsrolle zu beiden Seiten einen Radius bildet. In diesem, an die Form und Grosse der Festwalzrolle angepassten Radius der Führungsrolle, stützt sich die Festwalzrolle auf der Führungsrolle ab und wird dabei zugleich geführt. Das Glattwalzen dieses Bereiches der Führungsrollen kann ebenfalls zu einer Erhöhung der Lebensdauer sowohl der Festwalzrolle als auch der Führungsrolle selbst führen.Such a guide roller has a central projecting collar on its outer circumference, which forms a radius on both sides with the rest of the body of the guide roller. In this radius of the guide roller, adapted to the shape and size of the deep-rolling roller, the deep-rolling roller is supported on the guide roller and is guided at the same time. The smooth rolling of this area of the guide rollers can also increase the life of both the deep rolling roller and the guide roller itself.
Nachfolgend wird die Erfindung an einem Ausführungsbeispiel näher beschrieben. Es zeigen in jeweils stark vereinfachter, annähernd massstäblicherThe invention is described in more detail below using an exemplary embodiment. They each show in a greatly simplified, almost to scale
Darstellung das Glattwalzen einer Festwalzrolle dieRepresentation of the smooth rolling of a deep rolling roller
. Fig. 1 in der Vorderansicht,, 1 in front view,
. Fig. 2 in der Seitenansicht und, Fig. 2 in side view and
. Fig. 3 in einem vergrösserten Ausschnitt X der Fig. 2, 3 in an enlarged section X of FIG. 2nd
Die Festwalzrolle 1 ist Teil eines an sich bekannten Festwalzwerkzeugs zum Festwaizen von Radien oder Einstichen an Kurbelwellen von KfZ-Motoren. Wie im Beispiel der Fig. 2 erkennbar, hat die Festwalzrolle 1 die angenähert geometrische Form eines Kegel stumpfes. Im Bereich 2 ihres grössten Aussenumfangs ist die Festwalzrolle 1 stark abgerundet. Der Abrundungsradius der Festwalzrolle 1 wird durch den Pfeil 3 in der Fig. 3 angedeutet. Durch die Abrundung im Bereich 2 des grössten Aussenumfangs erhält die Festwalzrolle 1 in diesem Bereich 2 die Formgestalt eines To s 4, an den sich ein kurzer Kegelstumpf 5 anschliesst, um die äussere Form der Festwalzrolle 1 zu umschreiben. Neben dieser Kegel stumpfform gibt es aber auch Festwalzrollen, die eine eher scheibenförmige Konfiguration aufweisen.The deep-rolling roller 1 is part of a deep-rolling tool which is known per se for deep-rolling radii or punctures on crankshafts of motor vehicle engines. As can be seen in the example of FIG. 2, the deep rolling roller 1 has approximated it geometric shape of a truncated cone. In the area 2 of its largest outer circumference, the deep rolling roller 1 is strongly rounded. The radius of curvature of the deep-rolling roller 1 is indicated by the arrow 3 in FIG. 3. Due to the rounding in the area 2 of the largest outer circumference, the deep-rolling roller 1 in this area 2 is given the shape of a To 4, to which a short truncated cone 5 is connected in order to describe the outer shape of the deep-rolling roller 1. In addition to this truncated cone shape, there are also deep rolling rolls that have a rather disc-shaped configuration.
Nach der vorausgegangenen Formgebung sei es durch Drehen, Schleifen, Laserbearbeitung oder eine geeignete Kombination solcher Verfahren, und dem Abtrennen von einer zylindrischen Stange aus Werkzeugstahl wird die Festwalzrolle 1 im Bereich 2 ihres grössten Aussenumfangs glattgewalzt. Dazu wird sie ohne weitere Führung, d.h. spitzenlos, zwischen einen Satz von Glattwalzrollen eingespannt. Der Satz von Glattwalzrollen besteht aus den zylindrischen Glattwalzrollen 6, 7 und 8, die, wie aus der Fig. 1 erkennbar, in der geometrischen Konfiguration eines Dreiecks angeordnet sind. Die Glattwalzrollen 6, 7 und 8 sind jeweils um ihre Längsachsen 9, 10 und 11 drehbar. Die grösste Glattwalzrolle 6 ist antreibbar und dreht beispielsweise im Uhrzeigersinne 12.According to the previous shaping, be it by turning, grinding, laser processing or a suitable combination of such processes, and the separation from a cylindrical rod made of tool steel, the deep-rolling roller 1 is smoothed in the area 2 of its largest outer circumference. For this purpose, it is run without further guidance, i.e. centerless, clamped between a set of smooth rolling rolls. The set of smooth rolling rolls consists of the cylindrical smooth rolling rolls 6, 7 and 8, which, as can be seen from FIG. 1, are arranged in the geometric configuration of a triangle. The smooth rolling rolls 6, 7 and 8 are each rotatable about their longitudinal axes 9, 10 and 11. The largest smooth rolling roller 6 is drivable and rotates clockwise 12, for example.
Jede äer drei Glattwalzrollen 6, 7 und 8 weist eine Umfangsrille 13 auf, ungeachtet des jeweiligen Durchmessers der Glattwalzrolle 6, 7 oder 8. Die Umfangsrillen 13 aller drei Glattwalzrollen 6, 7 und 8 haben annähernd die gleiche Tiefe und den gleichen Abrundungsradius 3.Each of three smooth rolling rolls 6, 7 and 8 has a circumferential groove 13, irrespective of the respective diameter of the smooth rolling roll 6, 7 or 8. The circumferential grooves 13 of all three smooth rolling rolls 6, 7 and 8 have approximately the same depth and the same rounding radius 3.
Während des Glattwalzens ist die Festwalzrolle 1 zwischen den Glattwalzrollen 6, 7 und 8 eingespannt. Dabei dreht sich die Glattwalzrolle 6 im Uhrzeigersinne 12 und nimmt über die sich mitdrehende Festwalzrolle 1 die beiden anderen Glattwalzrollen 7 und 8 mit. Zugleich wird die Festwalzrolle 1 in den Umfangsrillen 13 aller drei Glattwalzrollen 6, 7 und 8 geführt. Über die beiden Glattwalzrollen 7 und 8 wird eine Glattwalzkraft 14 aufgebracht. Unter der Wirkung der Glattwalzkraft 14 wird die Festwalzrolle 1 im Bereich 2 ihres grössten Aussenumfangs von allen drei Glattwalzrollen 6, 7 und 8 gleichzeitig glattgewalzt, d.h. örtlich plastisch verformt. Dabei verschwinden etwaige, in dem Bereich 2 vorhandene Spuren der vorausgegangenen Bearbeitung und der Abrundungsradius 3 des Toms 4 der Festwalzrolle 1 wird eingestellt. Beim Masswalzen wird zugleich mit dem Glattwalzen auch noch der vorgegebene grösste Durchmesser 15 der Festwalzrolle 1 eingestellt. Anstatt über die Glattwalzrollen 7 und 8 kann die Glattwalzkraft 14 auch über die angetriebene Glattwalzrolle 6 aufgebracht werden. Anstelle des Antriebs durch die Glattwalzrolle 6 mit dem grössten Durchmesser kann der Antrieb auch durch eine oder beide der Glattwalzrollen 7 oder 8 eingeleitet werden, die gegenüber der Glattwalzrolle 6 jeweils einen kleineren Durchmesser haben, wie das aus den Fig. 1 und 2 erkennbar ist.During the smooth rolling, the deep rolling roller 1 is clamped between the smooth rolling rollers 6, 7 and 8. The smooth rolling roller 6 rotates clockwise 12 and takes the other two smooth rolling rollers 7 and 8 along with the rotating deep rolling roller 1. At the same time, the deep rolling roller 1 is guided in the circumferential grooves 13 of all three smooth rolling rollers 6, 7 and 8. About the two A smooth rolling force 14 is applied to the smooth rolling rolls 7 and 8. Under the action of the smooth rolling force 14, the deep rolling roller 1 is simultaneously rolled in the area 2 of its largest outer circumference by all three smooth rolling rollers 6, 7 and 8, ie locally plastically deformed. Any traces of the previous processing present in area 2 disappear and the rounding radius 3 of the tom 4 of the deep-rolling roller 1 is set. In the case of sizing rolling, the predetermined largest diameter 15 of the deep rolling roller 1 is also set with the smooth rolling. Instead of using the smooth rolling rollers 7 and 8, the smooth rolling force 14 can also be applied via the driven smooth rolling roller 6. Instead of the drive by the smooth rolling roller 6 with the largest diameter, the drive can also be initiated by one or both of the smooth rolling rollers 7 or 8, each of which has a smaller diameter than the smooth rolling roller 6, as can be seen from FIGS. 1 and 2.
Der Glattwalzzyklus beträgt nur wenige Überrollungen des To s 4. Die Glattwalzkraft 14 hängt ab von der Grosse und dem Werkstoff der Festwalzrolle 1 und wird zuvor experimentell ermittelt.The smooth rolling cycle is only a few overruns of the To s 4. The smooth rolling force 14 depends on the size and the material of the deep rolling roller 1 and is previously determined experimentally.
Nach dem Glattwalzen wird die Festwalzrolle 1 durch Verschieben von mindestens einer der Glattwalzrollen 6, 7 oder 8 in eine Öffnungsstellung entnommen. Danach wird eine weitere Festwalzrolle 1 zwischen diese Glattwalzrollen 6, 7 und 8 eingebracht und die zuvor geöffnete Glattwalzrolle 6, 7 oder 8 wieder in die Arbeitsstellung zurückgeführt, wie sie in der Fig. 1 dargestellt ist. Der Vorgang des Ein- und Ausspannens einer Festwalzrolle 1 kann automatisch erfolgen.After the smooth rolling, the deep rolling roller 1 is removed by moving at least one of the smooth rolling rollers 6, 7 or 8 into an open position. A further deep-rolling roller 1 is then introduced between these smooth-rolling rollers 6, 7 and 8 and the previously opened smooth-rolling roller 6, 7 or 8 is returned to the working position, as shown in FIG. 1. The process of clamping and unclamping a deep rolling roller 1 can take place automatically.
Die glattgewalzte Festwalzrolle 1 wird sodann gehärtet. Die glattgewalzte und gehärtete Festwalzrolle 1 wird abschliessend dem letzten Verfahrensschritt des Polierens zugeführt. Bei diesem Schritt wird die gesamte Oberfläche der Festwalzrolle 1 auf an sich bekannte Weise vergütet. Abmessungen und Form der Festwalzrolle 1 werden durch das Polieren nicht mehr verändert.The smooth-rolled deep-rolling roller 1 is then hardened. The smooth-rolled and hardened deep-rolling roller 1 is finally fed to the last process step of polishing. In this step, the entire surface of the deep rolling roller 1 is tempered in a manner known per se. The dimensions and shape of the deep rolling roller 1 are no longer changed by the polishing.
Analog zu der beschriebenen Behandlung von Festwalzrollen 1 können auch die Führungsrollen von Festwalzwerkzeugen behandelt werden. Hierfür wird man, anstelle von mit Umfangsrillen 13 versehenen Glattwalzrollen 6, 7 und 8, solche Glattwalzrollen einsetzen, die einen vorspringenden Aussenumfang haben, ohne dass es dazu einer gesonderten Beschreibung bedarf. Analogous to the treatment of deep rolling rollers 1 described, the guide rollers of deep rolling tools can also be treated. For this purpose, instead of smooth rolling rollers 6, 7 and 8 provided with circumferential grooves 13, such smooth rolling rollers will be used which have a projecting outer circumference without the need for a separate description.
Ziffernverzeichnisdigits directory
1 Festwalzrolle1 deep rolling roller
2 Bereich des grössten Aussenumfangs2 Area of the largest outer circumference
3 Abrundungsradius3 rounding radius
4 Toms4 toms
5 Kegelstumpf5 truncated cone
6 Glattwalzrolle6 smooth rolling roll
7 Glattwalzrolle7 smooth rolling roll
8 Glattwalzrolle8 smooth rolling roll
9 Längsachse9 longitudinal axis
10 Längsachse10 longitudinal axis
11 Längsachse11 longitudinal axis
12 Drehsinn12 direction of rotation
13 Umfangsrille13 circumferential groove
14 Glattwalzkraft14 smooth rolling force
15 grösster Durchmesser 15 largest diameter

Claims

Patentansprüche claims
1. Verfahren zum Herstellen von Festwalzrollen (1 ) gekennzeichnet durch die folgenden Verfahrensschritte: a) Vorformen des Körpers einer Festwalzrolle (1) durch Drehen am Ende einer zylindrischen Stange aus Werkzeugstahl, b) Abstechen der vorgeformten Festwalzrolle (1 ) vom Ende der Stange, c) Glattwalzen der Festwalzrolle (1 ) im Bereich (2) ihres grössten Umfangs, d) Härten der glattgewalzten Festwalzrolle (1 ) und e) Polieren der gehärteten Festwalzrolle (1).1. A method for producing deep-rolling rollers (1) characterized by the following process steps: a) preforming the body of a deep-rolling roller (1) by turning at the end of a cylindrical rod made of tool steel, b) parting the pre-shaped deep-rolling roller (1) from the end of the rod, c) smooth rolling the deep-rolling roller (1) in the area (2) of its largest circumference, d) hardening the smooth-rolled deep-rolling roller (1) and e) polishing the hardened deep-rolling roller (1).
2. Verfahren nach Anspruch 1 , dadurch gekennzeichnet, dass man durch das Glattwalzen der Festwalzrolle (1 ) den Krümmungsradius (3) im Bereich (2) ihres grössten Umfangs festlegt.2. The method according to claim 1, characterized in that the radius of curvature (3) in the region (2) of its greatest extent is determined by the smooth rolling of the deep rolling roller (1).
3. Verfahren nach Anspruch 2, dadurch gekennzeichnet, dass man durch Masswalzen im Rahmen des Glattwalzens den grössten Durchmesser (15) der Festwalzrolle (1) festlegt.3. The method according to claim 2, characterized in that the largest diameter (15) of the deep rolling roller (1) is determined by mass rolling in the course of smooth rolling.
4. Verfahren nach Anspruch 1 oder 2, dadurch gekennzeichnet, dass man die Festwalzrolle (1 ) durch Wärmebehandlung auf Härtegrade zwischen 60 und 70 Rockwell C härtet.4. The method according to claim 1 or 2, characterized in that one hardens the deep rolling roller (1) by heat treatment to degrees of hardness between 60 and 70 Rockwell C.
5. Verfahren nach Anspruch 1 oder 2, dadurch gekennzeichnet, dass man die Festwalzrolle (1 ) spitzenlos zwischen drei Glattwalzrollen (6, 7 und 8) glattwalzt.5. The method according to claim 1 or 2, characterized in that the deep rolling roller (1) smoothly rolled between three smooth rolling rollers (6, 7 and 8).
6. Festwalzrolle (1) für ein Festwalzwerkzeug zum Festwalzen von Radien oder Einstichen an den Haupt - oder Pleuellagem von Kurbelwellen von Kraftfahrzeugen mit einem annähernd kegelstumpfförmigen Körper, der durch spanabhebende Formgebung am Ende einer zylindrischen Stange aus Werkzeugstahl erzeugt wurde sowie gehärtet und poliert ist, dadurch gekennzeichnet, dass6. Deep rolling roller (1) for a deep rolling tool for deep rolling radii or recesses on the main or connecting rod bearings of crankshafts Motor vehicles with an approximately frustoconical body, which was produced by machining at the end of a cylindrical rod made of tool steel and hardened and polished, characterized in that
- der Körper der Festwalzrolle (1 ) ein Drehteil und- The body of the deep rolling roller (1) a turned part and
- im Bereich (2) seines grössten äusseren Umfangs glattgewalzt ist.- Is smooth-rolled in the area (2) of its largest outer circumference.
7. Festwalzrolle nach Anspruch 6, dadurch gekennzeichnet, dass sie aus pulvermetallurgisch hergestelltem Werkzeugstahl besteht.7. deep rolling roller according to claim 6, characterized in that it consists of powder-metallurgically produced tool steel.
8. Festwalzrolle nach einem der Ansprüche 6 oder 7, dadurch gekennzeichnet, dass sie Härtegrade zwischen 60 und 70 Rockwell C aufweist. 8. deep rolling roller according to one of claims 6 or 7, characterized in that it has degrees of hardness between 60 and 70 Rockwell C.
EP02727379A 2001-03-31 2002-03-08 Method for producing a deep rolling roller, and deep rolling roller Withdrawn EP1372903A1 (en)

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DE10116174 2001-03-31
DE10116174 2001-03-31
PCT/EP2002/002569 WO2002078897A1 (en) 2001-03-31 2002-03-08 Method for producing a deep rolling roller, and deep rolling roller

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FI105584B (en) * 1999-03-30 2000-09-15 Valmet Corp Method for making a roll of a paper or board machine and a roll of a paper or board machine
CN100464937C (en) * 2004-06-28 2009-03-04 周柏森 Rolling press treating method for surface protruding on metal material
JP5752351B2 (en) * 2009-12-02 2015-07-22 Ntn株式会社 Processing method and bearing
CN102231348A (en) * 2011-06-23 2011-11-02 江苏省如高高压电器有限公司 Method for improving surface roughness of silver coating layer of cylindrical contact terminal of breaker

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GB1504774A (en) * 1976-08-04 1978-03-22 British Steel Corp Steelplant rolls
US5806184A (en) * 1996-08-21 1998-09-15 Lonero Engineering Company, Inc. Process to manufacture upper work roll products

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