L________

MATERIAL FORMING

Roller Finishing of Cylindrical

Components

BY

Hans J. Naumann

Hegenscheidt Corporation of America

AMERICAN SOCIETY OF TOOL AND MANUFACTURING ENGINEERS

Copyright American Society of Tool
. 20501 FORD ROAD . DEARBORN. MICHIGAN 48128

and Manufacturing Engineers 1967

For presentation a t its

Engineering Conferences
 ROLLER FINISHING OF CYLINDRTCAL COMPONENTS
------

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

Roller finishing requires generally a preparatory

m a c h i n i n g o p e r a t i o n e i t h e r i n t h e form o f t u r n i n g o r g r i n d i n g .
S u r f a c e s , a s f o r e x a m p l e , r e s u l t i n g from a swedging o p e r a t i o n
a s t y p i c a l on gun b a r r e l s h a v e a l s o been v e r y s u c c e s s f u l l y
r o l l e r f i n i s h e d . The c o l d f o r m i n g which t a k e s p l a c e when
r o l l i n g t h e s u r l a c e roughness i s b e s t explained i n t h e follow-
i n g manner:

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 .

111. ROLLING FORCE AND ROLLING STRESS

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.)

SRF = S p e c i f i c R o l l i n g Force (PSI)

This f a c t o r expresses t h e required

specific rolling force i n relation
t o the material strength. ( F i g u r e #5)
L = L e n g t h o f d r o p form between t h e
work p i e c e and t h e work r o l l e r . ( I n . )
D = R e i a t i v e Diameter ( I n . )
The r e l a t i v e d i a m e t e r D i s d e p e n d i n g
upon t h e work r o l l e r d i a m e t e r Dl and
t h e work p i e c e d i a m e t e r D 2 . They a r e
r e l a t e d according t o the following
equation :
1 =-
- 1 +-
1 For E x t e r n a l
D D2 Roller Finishing
1 -
1 =-
- 1
- For I n t e r n a l
D D2 Roller Finishing
A v e r y s i m p l e and p r a c t i c a l means t o d e t e r m i n e t h e
c o n t a c t l e n g t h i s t o make a n i m p r i n t between t h e work r o l l e r
and t h e work p i e c e by u s i n g o n i o n s k i n p a p e r b e t w e e n b o t h
components. The c o n t a c t l e n g t h i s c l e a r l y v i s i b l e and c a n be
measured.
Under known c o n d i t i o n s o f t h e t o o l d i a m e t e r and t h e
c o n t a c t l e n t h , t h e r e q u i r e d r o l l i n g f o r c e s c a n be g r a p h i c a l l y
8
shown i n r e a t i o n t o t h e work p i e c e d i a m e t e r and t h e m a t e r i a l
strength. ( F i g u r e #6)
The h i g h e s t s h e a r s t r e s s and p l a s t i f i c a t i o n a c c o r d i n g
t o t h e s t r e s s d i s t r i b u t i o n t h e o r y from H e r t z and F o e p p l d u r i n g
r o l l i n g i s n o t on b u t r a t h e r u n d e r t h e s u r f a c e o f t h e work
piece. S u b s u r f a c e s h e a r f a i l u r e s c a u s e d when r o l l i n g w i t h
excessive r o l l i n g pressure w i l l , therefore, r e s u l t i n flaking
of t h e s u r f a c e .
The w e l l known c h a r a c t e r i s t i c o f s t e e l t o work h a r d e n
under p l a s t i c deformation e x p l a i n s t h e f a c t t h a t r o l l e r
f i n i s h e d components show a n i n c r e a s e i n s u r f a c e h a r d n e s s . The
g r e a t e s t h a r d n e s s i n c r e a s e i s m e a s u r e d below t h e s u r f a c e on
account of t h e s t r e s s d i s t r i b u t i o n . Actual hardness t e s t s
confirm t h i s condition. (Figure # 7 )
The s u r f a c e h a r d n e s s i n c r e a s e a s a r e s u l t o f c o l d
w o r k i n g c a n be measured o n l y t o a r e l a t i v e l y s h a l l o w p e n e t r a -
t i o n d e p t h . C o n v e n t i o n a l h a r d n e s s t e s t i n g methods a s t h e
Rockwell t e s t o r t h e B r i n e 1 1 t e s t c a n n o t be employed f o r t e s t -
i n g t h e h a r d n e s s i n c r e a s e , b e c a u s e t h e t e s t i n g m e d i i would
b r e a k t h r o u g h t h e h a r d n e s s s c a l e u n d e r t h e p r e l o a d s . Micro
h a r d n e s s t e s t i n g t e c h n i q u e s have t o be employed a s f o r example
t h e Knoop t e s t working w i t h p r e l o a d s o f 5 0 o r 100 gramm. The
h a r d n e s s i n c r e a s e c a n r a n g e from 2 t o 8 Rockwell "C" p o i n t s
whereby t h e l o w e r v a l u e i s e x p e r i e n c e d f o r components a l r e a d y
high i n hardness t o begin with.
IV. TOOLING ARRANGEMENTS
The r e l a t i o n s h i p b e t w e e n t h e mass o f t h e work p i e c e and
t h e mass o f t h e t o o l i n g w i l l d e t e r m i n e g e n e r a l l y w h e t h e r t h e
r o t a t i n g m o t i o n i s g e n e r a t e d by t h e work p i e c e o r t h e t o o l i n g .
I f t h e moment o f i n e r t i a f o r a work p i e c e i s h i g h i n c o m p a r i -
s o n w i t h t h e t o o l i n g , t h e component w i l l be h e l d between
c e n t e r s . R o t a t i o n a l m o t i o n i n t h i s c a s e i s t r a n s m i t t e d from
t h e work p i e c e t o t h e t o o l s . The l a t t e r a r r a n g e m e n t i s m o s t l y
u s e d when r o l l e r f i n i s h i n g l a r g e components w i t h a t w o - r o l l
a t t a c h m e n t . Bending o f t h e work p i e c e o r d e f l e c t i o n s on t h e
r o l l i n g machine a r e e l i m i n a t e d due t o t h e opposed work r o l l e r
arrangement. R o l l e r f i n i s h i n g w i t h a t w o - r o l l attachment can
be p e r f o r m e d a s a p l u n g e o p e r a t i o n o r a s a f e e d o p e r a t i o n w i t h
p a r a l l e l o r i n c l i n e d work r o l l e r a x i s r e s p e c t i v e l y . The f e e d
r a t e h a s t o be g e n e r a t e d by t h e machine s i n c e t h e work p i e c e
i s h e l d between c e n t e r s . ( F i g u r e s #8 and #9)
I f t h e moment o f i n e r t i a o f t h e work p i e c e i s s m a l l ,
t h e c e n t e r l e s s r o l l i n g p r i n c i p l e w i l l b e employed. The
r o t a t i o n a l m o t i o n i s g e n e r a t e d by t h e d r i v e r o l l e r w h i c h , i n
t u r n , under r o l l i n g p r e s s u r e , provides r o t a t i o n a l motion t o
t h e work p i e c e and work r o l l e r s . The t o o l i n g f o r t h e c e n t e r -
l e s s r o l l i n g p r i n c i p l e does permit plunge o r feed r o l l i n g
o p e r a t i o n s . The n e c e s s a r y r o l l e r a x i s i n c l i n a t i o n i s a d j u s t e d
on the tool head. The feed rates are generated by skewing the
axis of the roller head towards the axis of the work piece.
(Figures #10 and #11)
The work rollers must be designed to the smallest
possible size in order to reduce the required rolling force
to a minimum. Optimum conditions are offered by the multiple
work roller attachments. Standard roller heads for centerless
roller finishing machines represent a design compromise with
small floating work rollers backed up by properly supported
back up rollers. Considerations as bearing life for the back
up rollers or the (3) point contact geometry between the work
rollers and the part are the reasons that a roller head can
only be designed for a certain diameter range.
-
ROLLER FINISHING INFLUENCE FACTORS
A. Number of Overrollings
The number of overrollings to which a particular
surface. element is subjected during the roller finishing
process can be an important factor with regard to surface
failure especially for materials with a low ductility. The
number of work rollers used, the length of the drop form and
the feed rate per work piece revolution determine the number
of overrollings. As a general rule, a minimum of three over-
rollings per surface element are desirable, however, very
satisfactory surface finishing results were obtained with only
one overrolling. The maximum number of overrollings for steel
is r
m n +
LI
v ; + ; r o l
I LILal
n r n n r ; g l l ~ r n;+h
bJpbLICCAAJ IIIbIvJI UUJ1116
;nrreqc,nm
hardness. Cast
iron or screw machine materials, however, require to control
the number of overrollings on account of the sensitivity to
subsurface shear failures. These materials are further
sensitive to changes in rolling directions. The micro section
(Figures #12 and #13) show the grain structure, true peak to
valley relationship of a turned sample before and after rolling
and the directional alignment of the grain structure s s a
result of the cold forming.
R. -
Kol.1ing Speed
Extensive tests which were performed to determine the
best suited rolling speed for roller finishing in relation to
various materials showed that speed is o f no consequence with
regard to surface finish. Equally good surface qualities were
experienced with either low or high roller finishing speeds.
Also the tool wear or diameter reduction are not affected by
changes in rolling speed.
Further considerations, as for example the required
floor to floor time, the part piece acceleration, dynamic
behavior of the work piece and heat in the tooling or bearings
limit the rolling speed to a practical value. Best results
were a c h i e v e d w i t h r o l l i n g s p e e d s o f a p p r o x i m a t e l y 2 0 0 f t / m i n
f o r d i a m e t e r s up t o 1%"and 400 f t / m i n f o r d i a m e t e r s o v e r 1%".
Very s m a l l d i a m e t e r s o f 1/16" t o 3/16" s h o u l d b e r o l l e r f i n i s h -
e d below L O O f t l m i n . The r e a s o n b e i n g t h a t t h e p a r t p i e c e
r e v o l u t i o n c o u l d be e x c e s s i v e l y h i g h .

The r o l l i n g t o o l s must a l w a y s c o n t a c t t h e work p r i o r t o

s t a r t o f t h e r o t a t i o n and a c c e l e r a t i o n t o r o l l i n g s p e e d .
E x c e s s i v e s l i p p a g e w i l l c a u s e w i p i n g o f t h e work p i e c e
material. T h i s c o n d i t i o n m i g h t n o t be r e a d i l y a p p a r e n t and
c o u l d c a u s e a n o u t o f r o u n d c o n d i t i o n which p o s s i b l y i s o n l y
recognizable through roundness measurements.

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

L u b r i c a t i o n during t h e r o l l i n g p r o c e s s does not e f f e c t

t h e s u r f a c e q u a l i t y . With r e g a r d t o t h e f e e d r a t e , a l u b r i c a -
t i o n o i l b e t w e e n t h e work p i e c e and t h e t o o l i n g c a n even be
u n d e s i r a b l e b e c a u s e o f s l i p p a g e which w i l l t a k e p l a c e , r e s u l t -
ing i n a feed r a t e reduction. V a r i o u s r e a s o n s , however, make
a l i g h t spindle o i l desirable during the r o l l i n g process. A
c o n t i n u o u s s t r e a m of f i l t e r e d and r e c i r c u l a t e d l u b r i c a t i o n o i l
w i l l f l u s h d i r t and m e t a l p a r t i c l e s o u t o f t h e r e a c h o f t h e
r o l l i n g t o o l s . T h i s c a n be q u i t e d e s i r a b l e when r o l l i n g
c e r t a i n m a t e r i a l s , f o r example s t a i n l e s s s t e e l . S t a i n l e s s h a s
t h e t y p i c a l c h a r a c t e r i s t i c of f l a k i n g minute s u r f a c e p a r t i c l e s
which i s c a u s e d by t h e work h a r d e n i n g c a p a b i l i t y o f t h e
material. S u r f a c e I i n i s h q u a l i t i e s a r e n o t a f f e c t e d by t h i s
phenomenon. A l i g h t s p i n d l e o i l i s o f t e n a l s o u s e d t o l u b r i -
c a t e t h e a n t i - f r i c t i o n b e a r i n g s h o l d i n g t h e work r o l l e r s .

VI. SURFACE F I N I S H AND S I Z E ACCURACY

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.

VII. STRESS BALANCE AND MACRO GEOMETRIC FORM CHANGES

--

-.l n e p i a s t i c deformation t a k i n g place during t h e r o l l z r

f i n i s h i n g p r o c e s s , a s a l r e a d y mentioned above, cause a h a r d -
n e s s i n c r e a s e and c o m p r e s s i v e s t r e s s l a y e r i n t h e s u r f a c e o f
t h e work p i e c e . The c o m p r e s s i v e s t r e s s e s a r e s y m m e t r i c a l t o
t h e work p i e c e a x i s and s h o u l d n o t r e s u l t i n any macro
g e o m e t r y c h a n g e s o f t h e component. P a s t e x p e r i e n c e , h o w e v e r ,
h a s shown t h a t a b e n d i n g o f l o n g components c a n o c c u r . T h i s
c o n d i t i o n was i n i t i a l l y i n t e r p r e t e d a s a n i n s u f f i c i e n c y 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 . More d e t a i l e d i n v e s t i g a t i o n s have
shown t h a t a c y l i n d r i c a l component w i l l o n l y bend i f an u n -
e q u a l s t r e s s p a t t e r n e x i s t s i n t h e component p r i o r t o r o l l i n g .
Preliminary operations a s cold forming, heat t r e a t i n g o r
m a c h i n i n g c o u l d c a u s e t h i s c o n d i t i o n . The u n b a l a n c e d s t r e s s e s
w i l l be r e l i e v e d d u r i n g t h e r o l l i n g p r o c e s s and r e s u l t i n
bending of t h e p a r t .

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.

ness improvement, however, is Increasing with. a greater degree

of chatter or out of round condition. Surface waviness, as
often experienced for tracer turned components, will greatly
be improved provided that the drop form length is longer than
the waviness width,
The surface finish together with the roundness geometry
improvement will result quite favorably in noise level re-
duction predominant-ly for armature shafts running in sinter-
metal sleeve bearings providing only a microscopically thin
oil film with no cushioning effect.
The surface hardness increase, as already mentioned,
is in favor of an increased wear resistance. This effect,
together with the obtainable surface area contact of over 95%,
will permit to eliminate in many cases the required surface
hardening process. The roller finished surface character
reduces greatly notch sensitivity which, together with the
compressive stress layer, results in an increased fatigue life
of the component.
Direct cost savings are provided through roller finish-
ing by eliminating and replacing conventional surface finish-
i n g p r o c e s s e s s u c h a s g r i n d i n g , polishing, l a p p ~ n go r h o n r t i c ~
The m a n u f a c t u r i n g c o s t s a v i n g s t o p r o d u c e a 4 IWS i u r Fnc-
f i n i s h i n r e l a t i o n t o v a r i o u s a c c u r a c j e s i'; w e l I d e m o n s - t r a i c- J
i n F i g u r e # 1 6 . A n o t h e r s u b s t a n t i a l a r e a oP d r u e c t c o s i
s a v i n g s p r o v i d e s t h e p o s s i b i l i t y t o e l i m l n a t e h e a t i r e , 3 t an:;
o p e r a t i o n s , f o r example i n d u c t i o n h a r d e n i n g , l n d l r c c c co
s a v i n g s a r e a c h i e v e d by r e d u c e d t o o l c o s t s , p o s s ~ b l emai c r r d i
c h a n g e s t o l o w e r g r a d e s , o r s a v i n g s on g r i n d l n g wheel c o , i . ; ,
F u r t h e r c o s t s a v i n g s a r e p o s s i b l e by r e l a x i n g t h e r e q u s r e d
quality control.

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.

IX. ROLLER FINTSHIbJG EQUIPMENT AND RPPLTCATIONS

The d i a m e t e r o f t h e component t o be r o l L c r Cinislleci

d e t e r m i n e s g e n e r a l l y t h e equipment o r r o l l i n g procedure ~ i c ; c i i
for roller finishing.

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 . )

1/16 to 4 Roller finish- 200 -

ing machines 10 000
and Internal
Rolling Attach-
ments.

4 to 25 (2) Roller Piston rods, tie 200 -

Attachments rods, turbine 18 000
and Internal shafts, rolls for
Rolling Attach- paper and plastic
ments (16" dia. industry.
only
Above 25 Single Roll Rolls and Roll 1500 -
Attachment Bearings 4 000

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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hlX"E?aL
- - TLWb' - -
ATTER XOL.LiNC

ROLLER SUPE;iPiI\'ISfiiNGWILl. "illPXO',W YL'T XOT ,C!?XCT ::ICCE:J::C \i\~'fn:;~~

--

F i g u r e 15, s h e e t 8 ,

Figure 16, sheet l o ? line 4