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What is “Superoll” processing?

What are “Superoll” roller burnishing tools?

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"Superoll" roller burnishing tools are used to provide a mirror finish by smoothing metal surfaces with rollers. It simultaneously achieves high productivity, precision finishing, and surface quality improvement (improved wear resistance and fatigue strength) so as to perform plastic deformation only on the metal surface by the burnishing process (plastic deformation process) using rollers.
Because it easily achieves super precision finishing for parts and at low cost, it is used in various industrial sectors, including the automotive industry, precision instruments, chemistry, and electronic appliances, with great results.

Principles of roller burnishing

 

Roller burnishing is a plastic processing method that allows hard and smooth rollers to contact the metal surface with compressed revolutions, and it finishes the surface layer by giving the surface layer a partial micro plastic deformation.

As the surface roughness is improved during a short time period, the surface hardens and produces the finished surface with increased durability because residual compressive stress is generated.

 SUPEROLL-principleFigure 1. Principles of roller burnishing

Figure 1 is a schematic showing this process method.
At transference area (A), the roller gradually pressurizes while contacting the cutting side of the surface, and when the contact pressure exceeds the yielding point of the material at transference area (B), a partial plastic deformation occurs.
After the maximum load is reached directly below the roller, elastic restoration starts at the smooth area (C), and the roller gradually separates from the processed surface.

During actual superoll processing, the series of movements explained above is repeated with multiple rollers, smoothing the processed surface.

 

Characteristics of superoll processing

 Shortening of processing time

Processing time is reduced to 1/5 to 1/20 that of the polishing process. It can be finalized with a lathe or the machining center, thereby enabling a summary of the progress of the work.
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High-speed mirror finishing

In one pass, mirror finishing of Rz 0.1 to 0.8µm can be obtained. The finished surface without protrusions is suitable for the sliding or sealing surfaces.

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Wear resistance improvement (increased hardness)

  Wear resistance is improved by increasing the hardness of the surface by polishing the protrusions away and making the metal surface dense.

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Roller burnishing Q&A related page

  • What is “Superoll” processing?
  • Processing conditions for "Superoll" roller burnishing tools
  • Method of tool diameter adjustment of "Superoll" roller burnishing tools
  • Changes in the diameter of material used in the “Superoll” roller burnishing tool process
  • Effect of processing with “Superoll” roller burnishing tools
  • Replacement of consumable parts for "Superoll" roller burnishing tools