Fraunhofer Institute for Machine Tools and Forming TechnologyOptimizing process times and avoiding material loss
Cross-rolling with round tools is a partial forming process with rolling kinematics between tool geometry and the emerging workpiece profile. The rotationally symmetric pre-form is clamped between two tips in the axial direction. The gear profile is realized using rolling kinematics by means of a process in which the tool teeth penetrate in radial direction in relation to the diameter. The rolling process is split into the three stages of initial rolling, penetration and calibration. The round rolling processes using two and three profiled tools are industry-oriented.
Improvements to final component characteristics such as load-bearing capacity, tooth root strength, surface quality and minimum quenching distortion result from surface hardness depending on strain hardening and the contour-related fiber orientation. Process-related advantages emerge due to the very short cycle times and the fact that chip disposal is no longer required.