Bore Burnishing Lance Motion for Shorter Rolling Cycle Time
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing roller burnishing methods require long cycle times for component bore strengthening, especially in high-load applications like fuel injector systems, due to the need for multiple paths and translational movements, which hinder efficiency and increase production costs.
Innovation Solution
A method where the lance is initially immersed non-rotating into the bore, then rotated and radially deflected with burnishing balls during the rolling process, utilizing a single path and controlled process parameters like coolant pressure and flow rate to achieve efficient burnishing, reducing cycle time and enhancing surface quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the lance moves in and out of the bore in a purely translatory manner with multiple paths, then the burnishing process can be completed, but the cycle time becomes excessively long
Solution Approach 1:
The lance transitions from purely translational movement to a dynamic motion combining translation and rotation. The burnishing balls are radially deflected during rotation while the lance translates through the bore, allowing the burnishing action to occur during the forward passage rather than requiring separate forward and return burnishing paths. This dynamic motion pattern reduces the number of required passes and significantly shortens cycle time while maintaining burnishing quality.
Solution Approach 2:
The burnishing balls are radially deflected into their burnishing position before the lance reaches the burnishing zone, and the rotation is initiated in advance. This preliminary preparation ensures that the burnishing action is already in progress when the lance enters the effective burnishing region, eliminating the need for separate positioning and burnishing phases and reducing overall cycle time.
2Productivity
If the burnishing balls are radially deflected and the lance is set in rotation, then burnishing efficiency increases, but the device complexity increases
Solution Approach 1:
The lance serves multiple functions: it acts as both a translational carrier and a rotational element that simultaneously deflects the burnishing balls radially. The same structural component (the lance) performs both the transport function and the burnishing action function, eliminating the need for separate mechanisms and reducing overall device complexity while maintaining high burnishing productivity.
Solution Approach 2:
The translational movement and rotational movement are merged into a single composite motion of the lance. The burnishing balls are integrated into the lance structure itself rather than being separate components, and the radial deflection mechanism is combined with the rotation mechanism. This merging reduces the number of independent components and simplifies the overall device structure while achieving high burnishing speed.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach significantly reduces cycle time, maintains high production quality, and allows for reproducible residual compressive stresses, enabling higher throughput and lower production costs by optimizing the burnishing process with controlled parameters.
Implementation Method 1
roller burnishing bodies, which are distributed in the axial extension and in the circumferential direction of the lance
Implementation Method 2
compress and thus strengthen the inner walls of component bores by roller burnishing, in that internal compressive stresses are introduced into the components
Implementation Method 3
causing the radial deflection and sinking of the burnishing balls of the lance by controlling the coolant pressure and/or coolant flow in the coolant supply channel
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The invention relates to a tool device (10) for rolling a component bore. The tool device (10) has a shaft (11) for coupling to a rotary drive of a machine tool and a lance (12) which has at least one rolling element. The lance (12) has a plurality of balls (18) as rolling elements on the outer circumference of the lance, said rolling elements being distributed in the axial extension and in the circumferential direction of the lance (12) and being arranged in pairs, wherein each pair is mutually spaced in the axial direction, and the balls (18) of each pair are paired approximately diametrically opposite to one another in the circumferential direction of the lance (12).