Technical details: Type IRG-2-S from Ø 4.9 - 20.8 mm

 

 

Internal roller burnishing tool IRG-2-S

Application blind hole and through hole
Diameter range 4.9 - 20.8 mm
Adjustment range -0.1 up to +0.2 mm
Rolling depth 30, 50, 100 mm
Rollers
Diameter Type Quantity Dimension "X"
4.9 - 6.8 mm S-1680 3 0.5 mm
6.9 - 8.8 mm S-2010 4 0.5 mm
8.9 - 11.8 mm S-2714 4 0.5 mm
11.9-15.8 mm S-3718 4 0.7 mm
15.9-20.8 mm S-4722 4 0.7 mm
Standard fixture cylindrical shank Ø 10 - 20 mm
Morse taper 1 to 4

 

Options

  • Fixture with clamping surface; VDI; HSK etc.
  • Different rolling depth
  • Different number of rollers
  • Tailor made rollers
  • Internal coolant from Ø 8 mm

Application parameters

Please note that this information represents standard values which must be adapted to the individual cases.

Workpiece allowance up to 0.02 mm
Tool preclamping up to 0.05 mm
Rotation direction of tool clockwise (M3)
Return traverse always in rapid traverse (G0)
Lubrication emulsion or oil; filtration of the lubricant (<40 μm) can improve the surface quality and the tool life
Pre-machining of workpiece surface roughness (Rz) up to 15 μm tolerance IT8 or better
Workpiece hardness up to 45 HRC


 

Tip When setting up a tool, the revolution speed can be considerably reduced, however the feed rate per revolution is not to be decreased. When conducting roller burnishing under unfavorable conditions, e.g. when using high-strength materials with insufficient lubrication, it is advisable to reduce the revolution speed.

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Tool assembly and handling

IRG-2-S

 

Internal roller burnishing tool

Type IRG-2-S

  1. Fixture
  2. Sleeve
  3. Cage, bearing assembly
  4. Taper
  5. Rollers
  6. Rolling unit (conversion kit for other diameters including item 3/4/5)
  7. Clamping screw for taper
  8. Clamping screw for sleeve
  9. Locking Ring

 

Adjustment of the tool

Loosen clamping screw (8), then turn the fixture (1) and sleeve (2) against each other accordingto scale. One mark is equivalent to 0.01 mm in the diameter. Retighten clamping screw (8).

Tip When setting up a tool, the revolution speed can be considerably reduced, however the feed rate per rotation is not to be decreased. When conducting roller burnishing under unfavorable conditions, e.g. when using high-strength materials, with insufficient lubrication or very deep holes, it is advisable to reduce the revolution speed.
To carry out a fast basic adjustment of the tool, it is advisable to adjust the tool to the smallest dimension and then to guide it into the pre-machined hole by hand. The tool can then be adjusted in the hole until the rollers are felt to contact the surface. Starting from this setting, the pre-clamping can be increased by 1-2 marks on the scale. This basic adjustment then usually requires only minor corrections dependent on the achieved roller burnishing result.

When setting the tool diameter below the nominalsize of the tool then the taper will overlap the cage. Therefore the dimension “X” (see overleaf) will increase. This increase will be about 0.2 mm per 0.01 mm diameter reduction (= one mark on the tool scale) of the tool setting.

 

Changing components

Rollers

a) Loosen clamping screw (8) and screw the fixture (1) out of the sleeve (2). The rollers (5) become clear. Replace the rollers in sets and remount the components.
Alternative:
b) Remove the locking ring (9) and lift out the cage (3) towards the front until the rollers are clear. Replace the rollers in sets and remount the locking ring.

Tip Coat the roller seats with some grease so that the rollers are held in place by the grease during the assembly.
When replacing the rollers, clean the cage and the taper. Check them for damage, run-in marks, rough spots etc. and replace worn out components. Worn cages or tapers can considerably reduce the service life of the rollers.

 

Taper

Loosen clamping screw (8) and screw the fixture (1) out of the sleeve (2). Unscrew clamping screw (7). Pull the taper (4) out of the fixture. Replace the taper and remount the components.
Please Note: When assembling, ensure the correct position of the countersink in the taper and the clamping screw (7).

Tip When replacing the taper, clean the cage and the rollers. Check them for damage, run-in marks, rough spots etc. and replace worn out components. Worn cages or rollers can considerably reduce the service life of the taper.

 

Cage

Remove the locking ring (9) and lift out the cage (3) towards the front. Replace the cage and remount the components.

Tip When replacing the cage, clean the tool interior and grease it lightly. Dirt particles, in particular chips, reduce the tool life and the quality of the roller burnishing results.

 

What revolution speed and what feed rate …
The graph below shows the revolution speed and the feed rate for the whole diameter range of the IRG-2-S.

 

Machining parameters

 

For your specific application we recommend to use our interactive calculator for machining parameters.

 

interactive calculator for machining parameters

Please remember that these results are only guide values. Different machining conditions (e.g. pre-machining, material, lubrication…) may require different machining parameters.

 

Tip When setting up a tool, the revolution speed can be considerably reduced, however the feed rate per revolution is not to be decreased. When conducting roller burnishing under unfavorable conditions, e.g. when using high-strength materials with insufficient lubrication or very deep holes, it is advisable to reduce the revolution speed.