Deep rolling and roller burnishing machines

HEGENSCHEIDT 7796 - Reduction of the surface roughness of brake discs by up to 75%

Deep rolling and roller burnishing of surfaces and highly stressed components for smoothing, hardening and tempering improves the surface quality, reduces roughness and micro-irregularities and extends the service life. HEGENSCHEIDT is a pioneer in these technologies and offers customized solutions with application-specific machine types that give you the decisive advantage for your economical and resource-saving component production.

Application and Use

The 7796 is the latest generation of HEGENSCHEIDT brake disc rolling machines for the rolling of coated brake discs for cars and trucks, which make a significant contribution to meeting the current European emission standard (EURO 7). The highly specialized machine, which is designed to the requirements of the market, provides an economical, energy- and resource-saving process for eliminating harmful residual compressive stresses and improving the surface quality and properties of cast iron brake discs. Plastic deformation produces a smoothing effect and reduces surface roughness by up to 75 percent. In addition, the shielding of cast iron disc brakes is reduced. The HEGENSCHEIDT 7796 is designed for brake discs up to 460 mm in diameter.

Added value

Reduction of flaws
Reduction in the risk of corrosion
Increased surface crack resistance
Enhanced adhesion of base material and coating through neutralization of residual tensile stresses
Cost, time, and environmental efficiency due to reduced grinding allowance
Avoidance of energy-intensive stress-relief heat treatment processes
Long-term and leading rolling experience of HEGENSCHEIDT for almost 100 years
Longstanding listed automotive supplier

Function

The 7796 consists of a welded base frame and a four station rotary table with four stations including trays for brake discs up to 460 mm in diameter. The machine is fully covered, including dust removal, pneumatic pre-cleaning station, and complete electrical equipment with all drives, controls, and displays for the automatic machining process. The operating panel is integrated and has various data interfaces.

The force-controlled rolling process is synchronized on both sides, including real-time monitoring with archiving of process data. Both fully automatic operation and manual loading are possible. Loading and unloading takes place in parallel with the machining process. The rolling unit has two exchangeable cassettes in pliers principle and sensors for monitoring the rolling forces. The force is hydraulically controlled. A pick-up spindle lifts the discs out of the tray.

Results of the 7796

Base layer unrolled

Rolled base layer

Friction layer unrolled

Rolled friction layer

Machine specification

Machine data
Machine dimensions (L x W )	~ 2,500 mm x 3,000 mm
General specification
Basic equipment	Rotary table with 4 stations including trays for discs up to Ø 460 mm Rolling unit with two exchangeable cassettes in pliers principle Hydraulically controlled force Quick-change rolling heads Sensors for monitoring the rolling forces Quick-change clamping inserts in the spindle Pickup spindle lifting discs out of the tray Pneumatic, simple pre-cleaning station Extraction system for dust (can be omitted for non-coated components) Integrated operating panel
Options	Measurement: radial runout, DTV thickness, roughness, coating thickness, Induction heating before rolling Dust filter including exhaust air system Fully automatic handling system
Process data
Cycle time	~35s
Machining	~30s
Internal workpiece change	~5s
Roughness improvement	up to 75

Brochure

Here you will find all the contents of the 7796 as a download

DOWNLOAD | PDF 2.18 MB

Our Services

We adhere to the principles of competence, speed, and professionalism in order to provide you with the best possible support for your daily work. As a reliable and globally positioned partner, we support your company and your machine throughout their entire life cycle. We are committed to ensuring your productivity, coupled with the fastest response times and maximum machine availability. This is why HEGENSCHEIDT machines and services are perfectly matched. We provide uncomplicated and fast support for necessary repairs, replacement parts, services, or technical questions. Our range of services and support at the highest technical level is clearly structured and comprehensive.

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