Technical Advices - SUGINO MACHINE

» What is Superoll processing?

» Processing conditions

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» Variations in internal diameter

» Effects of Superoll processing

» Replacing consumable parts


	Superoll processing improves the surface roughness and at the same time provides the following effects.
	» Increases fatigue strength of the work piece » Increases durability and life of any sliding section or contact area of the work piece » Environmental measures » Deleting initial abrasion » Improvement of the sealing performance of the work piece

In Superoll processing, as the surface roughness is improved compressive residual stress appears in the surface layer that in turn leads to improvement of fatigue strength. Figure 1 shows the distribution of residual stress in depth from the surface for SUS304. The comparison is between turning and Superoll processing. The compressive residual stress due to Superoll processing creates a peak at a depth of 0.08-0.10 mm where the shear stress is maximized.

The results of a study on inner pressure fatigue are shown in Figure 2. The circumferential compressive residual stress in the material due to Superoll processing reducing the development of cracks near the fatigue limit and increasing the fatigue strength by 30%.


Fig.1 Distribution of residual stress	Fig.2 Change of SN curves due to residual stress

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	O-rings and packings are sealing materials for hydraulic and pneumatic cylinders; resinous and metal seals are also commonly used. These seal materials slide with the metal body of a cylinder. The sealing material must prevent wearing away while providing its sliding motion and yet closely fit the metal body to maintain high leakage efficiency. Typically cutting operations such as grinding and honing create micro peaks on the material surface that are so sharp that the sealing material is quickly worn away. A Superoll finished surface creates smooth plateaus on micro peaks and the sealing materials subsequently fit smoothly to the surface. Abrasion that makes seals stick is drastically reduced providing better performance in the end product. This technology is used in pneumatic and hydraulic cylinders, brake cylinders of automobiles, valve bodies and shock absorbers.

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	Usually a surface roughness of Ry3.2µm or less is required to reduce the friction of plain bearings. Since most bearing materials are cast iron or similar metal, it is easy to obtain a high quality finished surface if a Superoll tool is utilized. Superoll does not produce factory wastes like grinding and honing (sludge disposal) and it can achieve great results on productivity and environmental measures.

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	Metal parts and shafts with interference fits or holes that bushings and bearings are pressed into are required to have a high-level quality finish as well as dimensional precision tolerances. If parts processed by typical cutting tools are used their surfaces will soon be plastic deformed due to repeated loading and vibration providing short life expectancies. In contrast, parts processed by Superoll tools not only have smoother surfaces with their irregularities evened out but also provide a higher yield point which promises longer and more stable performance.

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	Most valve seats used for water, oil, gas or air have tapered shapes. The surface of the taper must have a precision finish as well as high quality dimensional precision in order to prevent leakage. Superoll provides precision finished surfaces delivering high wear resistance with high fatigue strength and improvement of durability. After roller burnishing, greater leakage efficiency of the sealed surface can be expected.

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