TY - GEN

T1 - Increasing the lifetime of roller bearings by using precision deep rolling

AU - Denkena, Berend

AU - Grove, Thilo

AU - Maiß, Oliver

AU - Neubauer, Timo

AU - Poll, Gerhard

AU - Dreier, Steven

PY - 2015/1/1

Y1 - 2015/1/1

N2 - It is a well-known fact that residual stresses can improve the lifetime of machined parts. Especially the lifetime of roller bearings is mainly affected by the residual stress state. Conventional machining processes like grinding and honing do not induce high compressive residual stresses in depth of 150 μm to 200 μm to affect the lifetime of roller bearings. Using a defined cutting edge in a hard turning process and applying a subsequent deep rolling procedure, the residual stresses can be shifted to a highly compressive state in great depth. However, due to grinding and honing roller bearings can be machined in a high quality of surface roughness, shape and geometry. In hard turning experiments it could be shown that a comparable part quality to grinding can be reached, if a suitable clamping technique is applied. Within the literature there is no knowledge about the part quality after deep rolling. According to the theory, deep rolling does not affect the shape of the machined parts. It smooths the surface, increases the hardness and induces compressive residual stresses. In deep rolling of roller bearings of the type NU206 C3 high compressive stresses in the subsurface region cause unacceptable shape changes. Within this paper, the shape deviation due to residual stresses is investigated and the main effects on residual stress state and shape deviation are identified. A procedure is introduced how to identify the optimal deep rolling process with respect to the roller bearings lifetime and the surface roughness-, shape- and geometry quality.

AB - It is a well-known fact that residual stresses can improve the lifetime of machined parts. Especially the lifetime of roller bearings is mainly affected by the residual stress state. Conventional machining processes like grinding and honing do not induce high compressive residual stresses in depth of 150 μm to 200 μm to affect the lifetime of roller bearings. Using a defined cutting edge in a hard turning process and applying a subsequent deep rolling procedure, the residual stresses can be shifted to a highly compressive state in great depth. However, due to grinding and honing roller bearings can be machined in a high quality of surface roughness, shape and geometry. In hard turning experiments it could be shown that a comparable part quality to grinding can be reached, if a suitable clamping technique is applied. Within the literature there is no knowledge about the part quality after deep rolling. According to the theory, deep rolling does not affect the shape of the machined parts. It smooths the surface, increases the hardness and induces compressive residual stresses. In deep rolling of roller bearings of the type NU206 C3 high compressive stresses in the subsurface region cause unacceptable shape changes. Within this paper, the shape deviation due to residual stresses is investigated and the main effects on residual stress state and shape deviation are identified. A procedure is introduced how to identify the optimal deep rolling process with respect to the roller bearings lifetime and the surface roughness-, shape- and geometry quality.

KW - Deep rolling

KW - Distortion

KW - Residual stresses

UR - http://www.scopus.com/inward/record.url?scp=84936087475&partnerID=8YFLogxK

M3 - Conference contribution

AN - SCOPUS:84936087475

T3 - Proceedings of the 15th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2015

SP - 373

EP - 374

BT - Proceedings of the 15th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2015

A2 - Leach, R.

T2 - 15th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2015

Y2 - 1 June 2015 through 5 June 2015

ER -