Rolling tools
Rolling tools utilize the principle of plastic deformation of metal materials to process the surface of workpieces. The squeezing action between the rolling head and the workpiece surface causes plastic flow of the metal, thereby improving surface roughness, hardness, and fatigue strength. Rolling is a non-cutting process. Compared with traditional cutting, it offers advantages such as high efficiency, low cost, and excellent surface quality. It is widely used in industries such as machinery manufacturing, automotive parts, and hydraulic components.
The structure of a rolling tool usually consists of a rolling head, a tool holder, an adjustment device, and other parts. The rolling head is the core component of the rolling tool, and rolling elements are installed inside it. Common rolling elements include balls, rollers, and wheels. Different types of rolling elements are suitable for different processing scenarios. Ball-type rolling heads are suitable for processing surfaces with complex shapes such as curved and spherical surfaces. Since the balls can rotate flexibly, they can better adapt to the contour changes of the workpiece surface. Roller-type rolling heads are suitable for processing regular surfaces such as planes and cylindrical surfaces. The contact between the roller and the workpiece surface is line contact, which can apply a large rolling force and has high processing efficiency.
Rolling tools come in a variety of types, classified according to the workpiece being machined. These tools can be categorized as internal, external, and flat rolling tools. Internal rolling tools are primarily used to machine the inner surfaces of various pipes and sleeves, such as hydraulic cylinder barrels and bearing housings. By adjusting the diameter of the rolling head, they can accommodate various bore diameters. External rolling tools are used to machine the outer surfaces of shafts and discs, such as automotive axles and motor shafts. During CNC machining, the workpiece rotates while the rolling head advances axially, rapidly improving the surface quality of the workpiece’s outer diameter.
The selection of rolling tools requires consideration of multiple factors, including the workpiece material, the shape and size of the machined surface, and the required surface quality. For materials with good plasticity, such as low-carbon steel and aluminum alloys, rolling is effective and can achieve a lower surface roughness. For materials with high hardness and brittleness, such as hardened steel and cast iron, a harder rolling head material, such as cemented carbide, is required, and the rolling force should be appropriately reduced to avoid cracks on the workpiece surface. Furthermore, parameters such as the rolling force, feed rate, and rolling speed of the rolling tool also need to be adjusted according to the specific situation. Whether the parameter settings are reasonable or not directly affects the processing effect.
With the continuous development of the manufacturing industry, rolling tools are also undergoing continuous innovation and improvement. New rolling tools utilize more advanced materials and structural designs. For example, the use of ceramic materials for the rolling elements improves the wear resistance and service life of the rolling head. The addition of pressure sensors and automatic adjustment devices enables intelligent control of the rolling process, enabling real-time monitoring of changes in rolling force and automatic adjustment of parameters to ensure consistent processing quality. The development of rolling tools has not only improved processing efficiency and quality but also expanded the application range of rolling processes, providing strong support for the advancement of the machinery manufacturing industry.
