discount 70% in 2018-09-19 to 2018-09-21
price: USD$ 1540.00
freight :USD$7.00,(Postal parcel)
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High quality:To realize the mirror machining of Ra0.05-0.1 m, the hardness of metal surface can be increased and the wear resistance and fatigue strength of parts can be improved only once.
High efficiency:The machining time is only 1/10-1/20 of the grinding process
Economics：The finish of mirror surface can be clamped on any rotation and feeding equipment
Energy saving and environmental protection:Low energy consumption, no chips, no need to deal with industrial waste
1. rolling tools can only be used for metal material processing, and the material hardness is below HRC40 degrees
2. the rolling tool must be clamped on the rotary feeding machine. Such as drilling machines, lathes, milling machines, boring machines, machining centers and so on
3. when working, clean low viscosity oil working fluid or low viscosity lubricating oil should be chosenThe steel parts are made of oil and diesel oil, aluminum parts are mixed with oil and kerosene, the ratio is 3:7, and the sewing machine oil or transformer oil can also be used）
4. the shape of the handle of the rolling tool is selected according to the machine tool
Machining principle of 1. rolling tool
The machining principle of the rolling tool like roller uneven road pressed flat, this tool is very smooth with roller rolling processing metal surface, the workpiece high convex part to lower part of extrusion, so that the surface to smooth as a mirror effect, is a kind of plastic processing. The surface of machined workpiece not only rises from Ry1.6-3.2um to Ry0.1-0.2um, but also improves the hardness, wear resistance, corrosion resistance and sealing of the machined surface. It can eliminate the early wear, which has the advantages that the cutting process can not replace. The tool has fine tuning device, each small adjustment coefficient is 0.0025mm, the total adjustment range is 0.3mm-0.4mm, so the size of the machining accuracy is also increased accordingly.
2. machining size and surface roughness
We know that the rolling tool processing principle is the use of rollers extrusion workpiece surface, so before processing size, roughness, material and processing requirements have a great relationship, need comprehensive consideration. As part of the concavity and convexity of processing, with the number of machining allowance through rolling can increase completely buried sag, achieve a smooth surface, different material, hardness, diameter is different, so that a variety of products at first 2-3 test and obtained the best processing parameters. Rolling processing allowance can be less, rolling processing is a high requirement of finishing, the general state of the better before processing, the effect is better after processing, and the less wear of rolling tools. General steel parts remain rolling allowance 0.02-0.04mm, copper and aluminum parts remain rolling margin 0.03-0.07mm, roughness is above Ry3.2um.
3. the wall thickness of machining parts
The use of rolling tool machining, the machining department is required to have sufficient thickness (diameter of the aperture is above 20%), or if the thin-walled part machining thin-walled, deformation may occur or reduce the roundness, encounter this problem can be solved by the following methods: 1, reduce the amount of 2, rolling; use fixture support peripheral; in 3, before the implementation of machining processing; maximum hardness of workpiece rolling tool machining value is HRC30, if you encounter high hardness materials processing tools due to withstand pressure, tool life will be shortened
|4, speed and feed|
Inner diameter series SH/SB
Processing diameter (mm) speed (min-1 feed mm/rev)
Outer diameter series SA
Machining diameter(mm)speed(min-1Feed ratemm/rev
15-24 400-650 0.3-0.8
5. tool diameter adjustment method
1. Use micrometer to measure tool diameter.
2. The diameter of the tool can be adjusted by pushing the adjusting sleeve at the same time to the left and right sides of the handle,The left side is reduced and the right is enlargedEvery moment, of a value of 0.0025mm.
3, after adjusting the diameter, open the aluminum shell will automatically lock the diameter.
4, processing blind hole, ladder hole, the bottom of about 0.5mm-1.0mm can not be processed. The needle roller can touch the bottom of the hole gently.
(bottom taper, R shape not mixed work, should be placed at the bottom of the pad block, to prevent tool stuck).
6. processing equipment
This tool is suitable for general drilling, vehicle, boring and other machine tools and machining centers. The clamping forms of the tools are mainly two kinds of straight handle and Morse taper handle, which can also be made according to the needs of customers.
|7. Lubrication and cleaning|
In rolling process, when the roller rolls the metal surface, it will produce very fine metal dust. Metal dust will not only affect the quality of the processing surface, but also accelerate the loss of the rolling head, so it is necessary to inject a large amount of clean working fluid to remove dust. According to the different properties of the workpiece, different clean and low viscosity cooling lubricants should be adopted, and the rolling head must be cleaned regularly to improve the service life of the tool and achieve the desired demand. Recommended: (steel parts with oil and diesel, aluminum parts with oil and kerosene, the ratio of 3 to 7).
Rolling process is a kind of machining without chip
Rolling process is a kind of machining without chip. A certain form of rolling tool is applied to the surface of the workpiece to exert certain pressure. At the normal temperature, the micro deformation of the workpiece surface is rolled by using the plastic deformation of the metal so as to change the surface structure, mechanical characteristics, shape and size. Therefore, this method can achieve two purposes of finishing and strengthening simultaneously.
After the surface rolling process of metal workpiece, the surface layer is strengthened, the ultimate strength and yield point are increased, and the service performance, fatigue resistance, wear resistance and corrosion resistance of the workpiece are obviously improved. After rolling, the hardness can be improved15～30%And the wear resistance is improved15%。
Rolling process can make the surface roughness come from the surface roughnessRa6.3Raise toRa2.4～Ra0.2. And there is a high production efficiency, some of the workpiece can be completed in minutes or seconds.
Rolling process can solve some key problems which are difficult to be realized. For example, the machining of oversize cylinder block. At the same time it is also applicable to special hole finishing or some special material finishing.
Rolling processing is widely used, and can be used in large, medium and small factories. Rolling processing is an excellent processing method, whether in terms of processing quality, production efficiency, production cost and so on. In some respects, it can completely replace finishing finishing such as fine grinding, grinding and honing.
At present, the processing method according to the external force transfer to the rolling tool can be divided into mechanical, rolling and spring three categories.
According to the processing nature, it can be divided into two categories: finish machining and strengthening machining.
Experiments with different materials
（1Whether the rolling pressure is correct or not affects the surface roughness, size and accuracy after rolling. Generally, with the increase of rolling pressure, the surface roughness increases. But the roll pressure increases to a certain extent, and the surface roughness is no longer improved. If the surface continues to increase, the rolling surface begins to deteriorate and even cracks appear.
（2To improve the surface roughness of workpiece, the rolling effect is the best. In the pre processing roughness reachesRa1.6As long as the interference amount is appropriate, the roughness can reachRa0.2Above。 But when the pretreatment roughness is onlyRa6.4～Ra3.2When the surface of the machined surface is vibrating, the deeper knife pattern can not be rolled and rolled, which only increases the amount of interference and rolls again. If the ellipticity and taper of the hole are too large, the defects still exist after rolling, and the roughness is large. Therefore, the machined surface is preferably smaller than that of the machined surfaceRa3.2The geometric accuracy is more than one or two, and small roughness can be obtained with ideal accuracy.
（3The material is soft, plastic and easy to be rolled. With the decrease of plasticity and the increase of hardness, the amount of permanent deformation decreases. Generally, the rolling effect of steel and copper is better, but the effect of cast iron is poor. Malleable iron, ductile cast iron is better than the rolling effect of grey cast iron. Rolling iron parts, when uneven casting material hardness, rolling surface defect (porosity, sand etc.) will soon emerge. Therefore, the rolling process should not be adopted when the surface of castings is hidden and the quality is poor.
（4The magnitude of roll interference has a great influence on the surface roughness and geometric accuracy. Through the test, it is known that the reasonable rolling interference amount is0.027～0.036mmThe surface roughness is minimum at this time. The maximum interference is affected by many factors, so the determination of the optimum interference amount should be determined according to the specific conditions and repeated tests.
（5The rolling speed has little effect on the surface roughness, so we can increase the rolling speed to improve the production efficiency.
（6The number of rolling should not be too much. The effect of single rolling is the most significant, which can reduce the roughness2～3Class. Two or three times.
（7The amount of feed shall be determined by the diameter of the ball. The smaller the feed rate is, the smaller the surface roughness is. The optimum feed rate should be determined by experiments.
（8Rolling tools usually have ball, cylindrical roller, conical roller, roller and so on. But using ball as deformation component can reduce the cost of the whole rolling tool. The ball and the high precision, high hardness, and the workpiece contact surface is small, with the rolling pressure is small, the pressure of small amount of interference can get higher, the smaller the roughness. Moreover, the ball has a long service life, is not easy to wear, cheap and easy to replace.
Analysis of boring and rolling process for cylinder machining
The cylinder as the cylinder, single pillar mining, hydraulic support, guns and other products of the main components, the processing quality directly affects the entire product life and reliability. The cylinder has high machining requirements, and its inner surface roughness is requiredRa0.4～0.8?mThe requirements of coaxiality and wear resistance are strict. The basic feature of cylinder is deep hole machining, and its processing has been bothering processing personnel.
Because of the surface residual compressive stress on the surface layer, the rolling process can help to seal the tiny cracks on the surface and hinder the expansion of the erosion. Thus, the surface corrosion resistance can be improved, and the fatigue crack can be delayed or enlarged, so as to improve the cylinder fatigue strength. Through rolling, rolling surface to form a layer of cold hardening layer, reduces the grinding contact surface of the elastic and plastic deformation, thus improving the wear resistance of the inner wall of the cylinder, while avoiding grinding burns caused by. After rolling, the decrease of surface roughness can improve the matching property.1Design of rolling tool
Designed by us?160mmCutter design and process of combined boring hob.
As shown in the structure, the protective cap1Reference position of tool setting instrument for protecting mandrel head. bearing pad4Support pin6The function is to protect the cage(ZQSn6-6-3)Fracturing without axial pressure on rollers. Support sleeve11Material forGCr15Requirements and mandrel15The interference fit, assembly and grinding.
Roller material isGCr15High speed steelW18Cr4V，62～65HRC. Roller plays a roll and guide role in boring hob. The reason is it is with roller rolling ball rolling work contact area, can withstand the pressure roll, can choose a large amount of feed, thereby improving productivity. For the thin wall and low rigidity workpiece, the roller with smaller diameter and longer length should be selected. The smaller the diameter of the roller, the smaller the surface roughness value?13mmRoller. Roller fillet radiusrEffect of surface roughness in a certain range, reducing the radius, a corresponding increase in the unit stress, can reduce the surface roughness and improve the surface hardness of cold. Roller quantityzThe increase of rolling roughness can reduce the value of rolling roughness, but the required rolling pressure increases. commonlyztake5～10Let's take it6. Increase roller roll back angleaThe surface roughness value can be reduced, but the surface roughness value can be reducedaToo large to form too cold state, destroy the surface layer, generally takea≤1°. In the direction of the roller diameter, the surface of the roller is jammed, vibrating and pulled out for a long time, so the difference between the diameters is not greater than that of the roller0.03mm。
Technical requirements of boring and rolling process for cylinder machining