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Processes in the material during roller burnishing
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Carbide or steel rollers are guided over the workpiece with pressure and displace the surface peaks into the boundary layer. The displaced material volume flows from below into the profile valleys rising up. Surface plateaus then result from the surface peaks, and these form the high contact area ratio of roller burnished surfaces.
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This leads to the formation of surfaces smooth as a mirror with a low surface roughness (< 1 µm) and reduced coefficients of sliding friction.
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Roller burnishing compresses the workpiece surface in the affected zone, improving the resistance to wear, the corrosion resistance and the material fatigue limit.
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As no volume change takes place, approximately half of the surface roughness is flattened and the same volume is raised. The achievable final surface roughness is directly proportional to the roughness of the premachined surface.

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