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Burnishing Tools

 
 
 
WHAT IS BURNISHING?

Roller Burnishing is a Super finishing process. It is a Cold Working process which produces a fine surface finish by the planetary rotation of hardened rollers over a bored or turned metal surface. Since all machined surfaces consist of a series of peaks and valleys of irregular height and spacing, the plastic deformation created by roller burnishing is a displacement of the material in the peaks which cold flows under pressure into the valleys. The result is a mirror-like finish with a tough, work hardened, wear and corrosion resistant surface. 

ADVANTAGES OF ROLLER BURNISHING 

Mirror Finish in One Pass Accurate Sizing, Close Tolerances Improved Metallurgical Properties - Work Hardened Surface Increase in fatigue strength No Additional Machine Investment- attachable to any Standard Machine Tool Already Present in the Shop Long Tool Life No Operator Skill Required Low Torque & Power Requirements Maximum Parts Interchangeability.
 

Overview

Roller Burnished surface are smoother and more wear-resistant than abraded surfaces. Abrasive finishing processes remove metal by cutting or tearing it away. Roller burnishing processes displaces metal rather than removing it thereby creating a smoother surface than an abraded surface. Roller burnished surfaces last longer under working conditions than abraded surfaces
.... Cost-Effective ! 

Roller Burnishing tools can be used on lathes, drill press machining centers or any rotating spindles with either tool or part rotating. Any ductile or malleable material like cast iron, Aluminum Steel, Stainless, Alloy, Copper, Brass, Bronze, virtually any material (hardness <40 Rc) can be sized obtaining surface finish as high as 0.2 Ra with 5% to 10% or more increase in tube surface hardness and improving the fatigue life as much as 300% or better in One Single Pass
...Cost-Effective !

Tristar Roller Burnishing tools are already burnishing internal / external diameter & taper/flat faces. These tools are used in the manufacture of components for automobiles, piston & oil engines, textile machinery, material handling equipments, gears, motors & pumps, pneumatic & hydraulic Cylinders, valves, fluid control equipments, precision components etc.

Single roller multi-purpose tools to burnish external diameters & grooves are also manufactured.

 

Benefits

Benefits of Tristar Roller Burnishing Process

    • Process improvement and low production cost.

    • Accurate size, close tolerance in taper and ovality. 

    • Mirror finish surface in one single pass. 

    • Hardening of the finished surface increases by 5% to 10% 

    • Attachable to lathes / boring / drill CNC / NC machines etc. 

    • No skilled operator required. 

    • Very easy interchangeable parts. ( e.g. rollers, mandrel, cage) 

    • Avoids honing, lapping & other costly finishing operations

ADVANTAGES OF TRISTAR ROLLER BURNISHING TOOLS

ACCURATE SIZE 
Tristar roller burnishing tools consists of a built - in calibrated micrometer adjustable in size controlling extremely small increment to cover the tolerance range of any part. Parts produced by roller burnishing, with control in size to micron, levels with high constituency and repeatability.

MIRROR FINISH 
A very smooth surface finish as high as 0.2 Ra can be achieved by Tristar roller burnishing tools in seconds. It eliminates extra parts handling, additional machines and can also replace grinding, honing, lapping and other expensive secondary operations.

SURFACE HARDEN
The Tristar roller burnishing tools increases the surface hardness of the piece-part by 5% to 10% or more, thereby improving the fatigue life 
as much as 300% or better.

SAVES TIME AND LABOUR
Using the built - in micrometer adjustment, set-up of Tristar roller burnishing tool takes less then a minute. Also an unskilled labour can operate unlike in other operations where labour skill plays a more important role in finishing. Thus less labour cost and high productivity saves much of production cost. 

INTERCHANGEABLE WEAR PARTS
Wear parts such as rollers, guide rollers (cage), bearings, mandrels etc., can be easily replaced in Tristar burnishing tools because most parts in a series are standard. Thus convertibility features can save up to 50% of the cost of new tool for each new size needed.

Roller Burnishing Process

Roller burnishing is cold working the surface of the work piece to improve surface structure. It produces a fine surface finish by the planetary rotation of harden rollers over a bored or turned metal surface. The roller burnishing operation compresses the "projection" (peaks) into the "indentations" (valleys) thus forming a smooth mirror finished surface.
In the burnishing process at the point of  contact, the pressure generated by the rollers exceeds.

the yield point of the piece-part material, the surface is plastically deformed by cold flowing of subsurface material. The result is a mirror-like finish and tough, hardened surface.
        
The pressure required for roller burnishing depends on various factors like tensile strength of the material, surface toughness before and after roller burnishing, ductility, shape of the rolls and diameters.

CONSTRUCTION & WORKING PRINCIPLE NON SELF-FEED DESIGN

Roller burnishing tools generally consists of a series of tapered and highly polished precision rollers made of high speed steel polished in slots with a retaining cage. When a tool engages the work piece a hardened mandrel, inversely to the taper of the rollers. forces them against the surface of the work piece.

The tool is constructed with the rollers axis parallel to the axis of the mandrel, when a non-feeding tool is required such as in close approaches to shoulders or in full bottoming. Due to this construction the tool depends on the machine feed to advance along the work piece.

CONSTANT DIAMETER  QUICK AUTOMATIC TOOL RELEASE

In the burnishing process the pressure is developed when the mandrel tends to overtake the rollers as the tool feeds along the work piece. This tendency is restricted by a step on the mandrel. Thus the uniform diameter during the complete pass is maintained because the tool-mandrel relationship is constant.

The self-releasing feature of the tool is provided by the inverse tapers of the rollers and mandrel. The rollers continue to feed in helical path when the advance of the tool in to the work piece is stopped. In this process the rollers move forward on the mandrel to a point where its diameter is smaller and the burnishing pressure is released. Only a small movement is required for the tool to release and at that point it can be easily withdrawn from the work piece.
 

SELF - FEED DESIGN

The self-feeding characteristic in the tool is  established by setting the rollers axis at a slight helix angle to the mandrel and work piece.

Parts & Surface Processed



GM / Bronze Bushes Master Cylinder
Bearing Bushes Brake Cylinder
Bearing Housing Connecting Rod
Motor end cover Piston Rod        
End Shields Valve Rod
Rotor Stamping (ID) Valve Guide
Fan rotor Shaft Rocker Arm
Mixie / Fan Shaft Pipes
Hydraulic Cylinder Long Holes, etc
Pneumatic Cylinder Piston
Chart
 

Work Piece
Size
Range
mm

Internal Surface

External Surface

Stock 
Allowance mm

Surface Finished pm Ra (R1)

Stock 
Allowance mm

Surface Finished pm Ra (R1)

Machined 

 Roller Burnished 

Machined 

Roller Burnished 

3-12 0.010
0.017
2.0 (8)
3.1 (12)
0.2 (1)
0.2 (1)
0.010
0.015
2.0 (8)
2.5 (10)
0.2 (1)
0.2 (1)
12-25 0.017
0.040
1.5 (6)
3.1 (12)
0.2 (1)
0.2 (1)
0.012
0.025
2.0 (8)
4.5 (18)
0.2 (1)
0.2 (1)
25-50 0.025
0.050
1.5 (6)
3.1 (12)
0.2 (1)
0.2 (1)
0.017
0.025
2.5 (10)
4.5 (18)
0.2 (1)
0.2 (1)
50-165 0.040
0.075
1.5 (6)
5.0 (20)
0.2 (1)
0.2 (1)
0.025
0.050
3.1 (12)
10.1 (40)
0.2 (1)
0.2 (1)
3-12 0.010
0.017
2.0 (8)
2.5 (10)
 0.4 (2)
0.4 (2)
0.008
0.012
1.5 (6)
2.3 (9)
 0.4 (2)
0.4 (2)
12-25 0.017
0.025
2.2 (9)
3.1 (12)
0.4 (2)
0.4 (2)
0.012
0.018
2.5 (10)
0.4 (14)
0.4 (2)
0.4 (2)
25-50 0.025
0.040
3.1 (12)
4.5 (18)
0.4 (2)
0.4 (2)
0.012
0.025
0.4 (10)
0.4 (18)
0.4 (2)
0.4 (2)
50-165 0.040
0.050
3.0 (12)
5.0 (20)
0.4 (2)
0.6 (3)
0.020
0.035
0.4 (12)
0.6 (20)
0.4 (2)
0.6 (3)

Burnishing
Diameter
Internal External
* Speed
(rpm)
** Feed
mm/rev
* Speed
(rpm)
** Feed
mm/rev
5 1500 0.12 1000 0.15
12 1000 0.32 700 0.3
40 600 1.3 400 1.0
65 300 1.5 250 1.8
95 250 1.8 200 2.7
165 200 3.4 ----- ------

*  Speed may be increased or decreased by 50% to suit special requirements.
** Feed may be increased or decreased by 30% to suit special requirements. 

0 - 50mm 0-100mm 0-150mm 0-300mm 0-400mm
 
Specification :
 

TYPES

ABBREVIATION

USAGE

RANGE Ø IN mm.

INTERNAL
BURNISHING TOOLS

TTH

  Thru hole   For deep thru hole    5-59

TTB

  Blind hole   For deep blind hole   10-59

TE

  Thru hole   For deep thru hole   60-250

TEB

  Blind hole   For deep blind hole   60-250

TST

  Thru  hole   For short thru hole   5-85

TSB

  Blind hole   For short blind hole   10-85

EXTERNAL
BURNISHING TOOLS

  TPS   Plain Shaft   For plain shaft   2-63
  TSS   Stepped Shaft   For stepped shaft   2-63
       

CUSTOM
BURNISHING TOOLS

  TTP   Taper hole   For internal taper hole   As per   
  Requirement
  TTS   Taper Shaft   For external taper shaft   As per 
  Requirement
  TFT   Face tool   For face burnishing   As per 
  Requirement

REVERSE
BURNISHING TOOLS

  TMRT   Reverse burnishing tools   For SPM's   35-250
 
 
 
 
 
 
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Impact Sockets 1” Square Drive | Impact Sockets 1.1/2” Square Drive | Impact Sockets 2.1/2” Square Drive | Impact Sockets 3.1/2” Square Drive
 
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Automotive Sockets 1/4” Square Drive | Automotive Sockets 3/8” Square Drive | Automotive Sockets 1/2” Square Drive | Automotive Sockets 3/4” Square Drive | Automotive Sockets 1” Square Drive | Automotive Sockets 1.1/2” Square Drive | Automotive Sockets 5” Splined Socket | Bud Wheels Impact Sockets | Bearing Nut Sockets | Lug Nuts Sockets
 
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