The roller burnishing tool consists of a cage, which retains a series of precision hardened and polished tapered rolls rotating around, and bearing on, an inversely tapered mandrel. These parts will produce thousands of bores in normal use and are generally the only inventory required.
Components are normally pre-turned, bored or reamed before burnishing and provided the pre-finish is uniform and tear-free, with no deep gouges, a consistent burnished finish will be achieved.
Three factors that affect the finish achieved by burnishing are the feed pattern, cutting tool geometry and stock allowance.
A smooth bore is NOT necessary as sufficient peak and valley height is required for successful burnishing. The better the pre-machined finish, and the lower the ductility of the material, the less material can be displaced. Any deep gouges and tear marks are likely to remain visible after burnishing.
Prepare the part so a 2µm to 3µm (80 – 120 CLA) uniform and tear free surface is generated. An insert with a 0.8mm (0.032”) radius is ideal for most materials although on less ductile materials a larger radius may be required.
Refer to the stock allowance chart for guidance on pre-sizing of the component.