Machining with a lathe has unique challenges.


Inconsistencies in surface roughness

Shortened life for cutting tips

Adding a grinding process with another machine


Superoll™ is the answer.


ROLLER BURNISHING

What is Superoll?

Superoll is a full line of roller burnishing tools that create smoother finishes through compressing the surface - without removing material.

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Explore example case studies


See Example Cases
Circle

Quality and Precision

These hardened and highly polished tools integrate into machining centers to eliminate secondary processes such as grinding and honing, without removing any material.  
Rhombus

A Mirror-Like Finish

Ideal for processing with shorter cycle times to improve productivity and reduce costs.

What is Surface Roughness? How is it Calculated?


Surface Roughness Image Sugino

Surface roughness is the geometrical fine irregularities on the surface of an object. In turning, it refers to the height of the peaks and valleys formed by transferring the tip shape of the cutting.

How to calculate theoretical surface roughness [Rz]

Calculate Surface Roughness

F: Feed amount per rotation (mm/rev)
R: Nose R size of cutting tip (mm)

sugino inspection art

However, does the actual surface roughness match the theoretical roughness in your production site?

Let's explore reasons why they may not match

Why the actual surface roughness does not match the theoretical roughness: 

REASON 1: Build-up edge deteriorates the surface roughness.


Machining under inappropriate conditions causes built-up edges at the tip of the cutting tip.

As a result, the machined surface does not have a regular shape, and deviates from the theoretical shape.


Image

Surface property measurement data — machined by
a cutting tip with build-up edge.


Image

"Build-up edge" is the phenomena in which a tiny part of the work piece adheres to the cutting tip edge during cutting, and changes the shape of cutting edge. The slower the feed rate, the better the surface roughness, but the more likely it is that adhesion will occur. Thus, machining with high speed rotation will be required.

Why the actual surface roughness does not match the theoretical roughness: 

REASON 1: Build-up edge deteriorates the surface roughness.


Machining Conditions and Build Up Edge of Cutting Tool
Machining Conditions

Work piece:           Φ30 SCM440

Cutting tip:            Carbide / Nose R 0.4

Coolant:                  Not used

Peripheral speed: 50 -250m/min

Feed:                       0.05 - 0.3mm/rev

Cutting amount:    0.4mm *Fixed

Why the actual surface roughness does not match the theoretical roughness: 

REASON 2: Wear of the cutting tip.


Surface roughness gradually gets worse due to the wear of cutting tip.

Surface Roughness After Machining Data Chart

Therefore, when aiming for Rz 3.2 in mass production — assuming that it will gradually deteriorate — appropriate feed rate will be 0.07 mm/rev, and then required peripheral speed will be 450 mm/min (4,775 rpm).

However, if the cutting speed (peripheral speed) is faster, the tool life will be shortened significantly due to the increase in cutting temperature. In addition, slowing the feed rate increases flank wear, which leads to a shorter tool life.

    Challenges and Solutions

    Explore real-world examples of how Superoll can simplify and improve your process.


    Case Example One:

    Automate Unstable Works

    unstable workpiece

    Problem

    The workpiece is too long for high-speed machining.  The vibrations at high speed resulted in an uneven finish and surface roughness.

    Conventional Way

    Achieved dimensional accuracy only by machining at a low speed.  But sandpaper hand-finishing was required to meet surface roughness specifications, and uniformity is lacking as hand-finishing varies by worker.

     

    With Superoll

    No hazardous waste. The process is fully automated which results in a uniform finish every time. Stable surface roughness. Reduced cycle time.

    Case Example Two:

    Reduction of cutting tip replacement frequency
    Image

    Problem

    Problem:  The cutting tip life was significantly short due to surface roughness

    Conventional Way

    The cutting tip needed to be replaced frequently due to the rough surface texture.

     

    With Superoll

    Because the Superoll uses compression instead of cutting, the tool life is extended up to four times longer than conventional cutting tips.  This saves time and money. 

    Case Example Three:

    Optimizing the Machining Conditions for Crankshafts

    Image of Superoll Machining Burnishing Crank Shaft

    Problem

    A low rotation speed is needed to maintain balance during the machining process.

    Conventional Way

    The necessary low rotation speed required a separate grinding step and the purchase of an expensive secondary machine.

    With Superoll

    Surface stability is achieved without the use of a secondary machine.

    Case Example Four:

    Integrate the Machining and Grinding Process Together


    deep scratch from surface finishing

    Problem

    Low speed machining leads to edge buildup. Edge buildup leads to scratches. 

    Conventional Way

    Required visual inspection for all parts.

    With Superoll

    Allows the machining to be done at high peripheral speed with a fast feed.  This creates no edge buildup.  No edge buildup = no scratches = no need for inspection.  Saving time and labor costs.

      Comparing Conventional Methods with Using Superoll in your Lathe

      Rough Machining + Dimensional Finish + Surface Finish

      Lathe Machining the Conventional Way


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      Description of conventional machining with lathe and separate grinding

      Lathe Machining with Superoll


      Using Superoll makes you achieve the precise dimensional accuracy and surface roughness at the same time ONLY with attaching your lathe!

      Visual example of using Superoll from Sugino to achieve surface finish in lathe machining

      We're ready to help you find the right Superoll™ solution


      Frequently
      Asked
      Questions




      Single Roller Type - Product Lineup


      SR5A
      For shaft end surface

      Image

      SR16M
      For shaft end surface, taper, R surface

      Sugino SR16M roller burnishing tool for shaft taper, R surface

      SR5C
      For inner

      Image

      SR16C
      For inner

      Image

      SR3Z
      For outer groove side

      Image

      SR3ZH
      For inner groove side

      Image

      SR24MW
      For outer groove bottom

      Image

      CEZF
      For end groove surface

      Image

      CEZH
      For inner groove bottom

      Image

      Materials

      Acceptable Materials

      Iron and non-ferrous material, including:

      • Stainless
      • SCM
      • S45C
      • FC
      • ADC
      • Copper
      • Brass

      Not For

      • Titan
      • Magnesium
      • Wood
      • Glass
      • Ceramic
      • Plastic
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      Surface Roughness Calculator [Rz]: How to find the theoretical value

      F(mm/rev)

      Nose R(mm)

      Rz 

      You should be able to obtain the target surface roughness under the processing conditions that match the theoretical values.