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 stringent European emission and durability standards (EURO 7). The specialized machine, which is designed to the requirements of the market, provides an economical, energy- and resourcesaving process for eliminating harmful residual compressive stresses and cracking and improving the surface quality and part lifespan of cast iron brake discs. Precise cold-forming roller burnishing produces a smoothing effect, reduces surface roughness by up to 75 percent and corrects laser cladding warping. 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

Technlogical - Superior Performance, Prove Results

Improved crack resistance and longer component life under thermal and mechanical stress
Lower corrosion risk for both coated and uncoated brake discs
Stronger coating adhension through elimination of residual tensile stress
Up to 40% lower grinding and energy costs by reducing post-machining effort
No need for stress relief heat treatment, resulting in lower energy consumption and faster production
Backed by 100 years of precision rolling expertis from HEGENSCHEIDT
Trusted Tier - 1 automotive supplier for OEMs globally

Economic - Boost Efficiency, Lower Costs

Minimize grinding effort thanks to reduced deformation
and improved flatness
Lower scrap rates through precise correction of bolt mounting and friction surfaces
Short cycle time (~35 sec per disc) supports high volume production
Low energy consumption due to elimination of heat-based stress relief
Fast, cost-effective process with minimal setup changes
Long tool life reduces maintenance costs and downtime

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.

Parallel loading and machining for uninterrupted operation and higher throughput
Simultaneous, force-controlled rolling on both disc sides for perfect symmetry and reduced handling time
Real-time process monitoring and data logging for full traceability and quality assurance
Fast cycle time of ~35 seconds (30s machining + 5s handling) to maximize output
Quick-change tool design for minimal downtime during part changeover

Results of the 7796

Total flatness of inner friction surface after coating

Total flatness of inner friction surface after rolling

Inner tension after coating

Inner tension after rolling

System Options

7796 - Standalone full-covered system

Compact footprint: ~2.5m x 3m
4-station turntable enables continuous operation and high productivity
Supports both manual and automatic loading for flexible deployment
Optional add-ons (measuring, cleaning, marking stations)
Quick-change tooling for trays and clamps minimizes downtime
Fully enclosed design ensures safe operation and easy maintenance access

7796 - Integration module

Core machine footprint: 1.5m x 0.9m
Auxiliary equipment: ~2m x 2m
Engineered for seamless integration into existing production lines/cells

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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