mold

Solutions for tool and mold construction

Industries / Applications

Industry-specific areas of application:

Punch and forming technology | Injection molding | Die casting | Die-forging technology

Requirements for workpieces:

Surface quality / roughness | Hardness | Wear resistance | Fatigue strength

Applications

Cutting tool Body panel Car body shell

Forming arbor Preform PET bottle

More areas of application

Mold segment Reflector White goods Interior

Operating principle of hydrostatic tools
A major cost factor in die and mold construction is surface finishing. In many cases finishing is performed manually
and the result depends highly on the experience and skill of the operator. ECOROLL offers a solution specifically for
surface finishing using hydrostatic roller burnishing tools. Thereby the manual process is substituted by CNC machi-
ning or finishing with the aid of a robot.

Hub

Following system 3D rolling of free-form surfaces Influence on the surface layer

An essential characteristic of hydrostatic tools is the self-aligning following system with a hydrostatically loaded
ball in a rolling element. The tool is mounted in the machine spindle of a machining center and activated through the
supply of high pressure coolant-lubricant or compressed air. For burnishing free-form surfaces the tool moves line by
line over the workpiece surface controlled by CNC, which achieves a roughness lower than Rz = 1 µm or Ra = 0.1 µm.
The tool following system ensures automatic adaptation to the workpiece surface at a constant rolling force. This

system is applicable for material hardness up to 65 HRC, requiring coolant-lubricant pressure up to 250 bar.

External pressure supply

with hydraulic unit HGP6.5

For activating the tool by high pressure either an externally connected hydraulic unit or an internal high pressure

pump can be used. For operating with MQL (minimum quantity lubrication) a solution using compressed air is avai-

lable. Depending on workpiece geometry various combinations of ball inserts and following systems are available,

enabling to reach not only large workpiece sections but also smaller sectors and radii.

SK | HSK | Capto | KM

HG system, modularly combinable with

burnishing elements of varying size

Cost savings potential in tool and mold construction by
substituting polishing

Polishing is time and money consuming – Solution > Reduce polishing

n Develop reproducible process strategies

n Reduce polishing time

Success Story

Task

Improving the surface quality of a cutting tool for aluminum/

steel sheets

Workpiece: ............ Cutting tool (car body)

Material: ................ 1.2358

Tensile strength: .... 1.000 N/mm2

Hardness: . . . . . . . . . . . . . . 56 HRC

Solution

Process: ................. machining the surface line by line

(with stationary machine spindle)

Machine: ................ 5-axis machining center

Tool: ....................... Hydrostatic tool HG6-19

Speed: .................... 10 m/min (rapid traverse of the machine)

Line offset: ............. 0.05 mm

Rolling force: .......... 375-500 N (150-200 bar)

Customer benefit

n Substituting manual polishing

Process time

n Significant reduction of process time by 95%

- 95%
n Reproducibility by using a deep rolling tool

n Surface quality: Rz 1,4 µm

n Less flakes and burrs
n Polishing n Deep Rolling
ECOROLL AG Werkzeugtechnik

ECOROLL AG Werkzeugtechnik is the leading supplier of tools and machines for mechanically improving the surfaces of
metal components. In close cooperation with our customers, demand-oriented tools and machines for burnishing and
deep rolling as well as processing cylinders are designed, manufactured and marketed throughout the world.

Roller Burnishing
The economic alternative for producing high-quality component surfaces
Reducing the initial roughness by up to factor 20
n Produces mirror-finish or pre-defined surfaces
n Can be used with any conventional or CNC-controlled machines
n Complete processing in one setting
n Short cycle time and elimination of set-up and auxiliary processing time
n Increased surface hardness
n Increased wear resistance

Schematic diagram of Roller Burnishing

n Can be used with minimum quantity lubrication

Deep Rolling
Smoothing, cold work and induction of residual compressive stresses
in a single process
Increasing the service life by up to factor 5
n Complete processing in one setting
n Can be used with any conventional or CNC-controlled machines
n For a wide range of work pieces
n Prevents or hinders stress corrosion crack formation or growth
n Significantly increases service life and fatigue strength
Schematic diagram of Deep Rolling n Extraordinary increase of fatigue strength

Processing Cylinders
Fast and efficient internal machining
Reducing process time by up to 90%
n Produces surfaces with very low residual surface roughness,
reduced friction and less wear
n Notably decreases irregularities in circular form
n Suitable for cold drawn or hot rolled tubes
n For diameter range 28 to 800 mm
n Possible processes: Combined boring – skiving – roller burnishing,
skiving on lathes
ECOROLL AG Update

compact
Designed for the
smallest workspaces

As technology leader in roller burnishing and deep rolling ECOROLL AG Werkzeugtechnik expands their portfolio with
the new product range . ECOROLL keeps pace with component miniaturization and launches a
product line adjusted to the requirements for smaller workpieces. Ideal applications for tools are
especially on machine types as automatic long-turning lathes, Swiss lathes or automatic rotary indexing machines,
which offer a limited workspace.

ECOROLL AG MechKon App Solutions | Catalogue | Applications

Tool Box with sample videos
Contact with integrated snapshot-function
Calculator | 10-X CostSaver

Android iOS

ECOROLL AG Werkzeugtechnik
Hans-Heinrich-Warnke-Str. 8 | D-29227 Celle
Phone: +49 5141 98650 | Fax: +49 5141 881440
Mail: [email protected] | www.ecoroll.com