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Deep rolling and roller burnishing machines

HEGENSCHEIDT 7797 - Combined coating and rolling of brake discs 

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 7797 is a combined HEGENSCHEIDT brake disc coating and rolling center for the coating and rolling of car and truck brake discs, which contributes significantly to meeting the current European emission standard (EURO 7). The highly specialized center, which is designed to the requirements of the market, provides an economical, energy- and resource-saving process for the cost-effective coating of brake discs and the elimination of harmful residual compressive stresses, thus 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. The HEGENSCHEIDT 7797 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 effciency due to reduced grinding allowance
  • Avoidance of energy-intensive stress-relief heat treatment processes
  • Long-term and leading rolling experience of HEGENSCHEIDT-MFD for almost 100 years
  • Longstanding listed automotive supplier

Function

The 7797 consists of a welded base frame and a rotary table with eight 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 cycle time has been optimized for maximum coating application, with a cycle time of 60 seconds each for priming and coating forward and backward.

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 7797

Machine specification

Machine data
Machine dimensions (L x W ) ~ 5,000 mm x 7,000 mm
General specification
Basic equipment
  • Rotary table with 8 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
  • Dust extraction system
  • Cleaning station for reduced material discharge (cleaning the brake disk and the empty holder)
  • Encapsulation of each station
  • Integrated operating panel
Options
  • Measurement: radial runout, DTV thickness, roughness, layer thickness,
  • Induction heating before rolling
  • Dust filter including exhaust air system
  • Fully automatic handling system
Process data  
Cycle time ~120 s
Machining ~16 min
Internal workpiece change ~7 s
Roughness improvement up to 75 %

 

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Brochure

Here you will find all the contents of the 7797 once again 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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