Single-Crystal Diamond Rolling Tool Working Principle
Under microscopic examination, cutting tools often leave behind step-like feed marks on workpiece surfaces.
The single-crystal diamond rolling tool addresses this issue by applying a controlled spring force to slide the diamond over the metal surface.
This action exceeds the material’s yield point, inducing plastic deformation that smoothens the surface by redistributing material from peaks into valleys. The result is a mirror-like finish. Additionally, the process induces work hardening through plastic deformation, significantly enhancing the fatigue strength of the component.
The diamond burnishing process then applies a highly polished diamond tip to roll and compress the surface, resulting in a superior finish.
This process significantly improves surface integrity by reducing roughness to a range of Ra 0.2–0.05 and introducing compressive residual stresses, which enhance the component’s fatigue life and wear resistance.
The diagram illustrates key zones during burnishing:
- A. Subject to Rolling Area: The region awaiting processing.
- B. Plastic Deformation Zone: Where material undergoes permanent deformation under pressure.
- C. Smooth Region: The finished surface with reduced roughness.
- D. Compressive Residual Stresses: The layer benefits from improved mechanical properties.
Tool Types and Processing Parameters
Our diamond burnishing tools are available in both square and round shank types, with dimensions such as:
- Square shank: 12/16/25/32 mm
- Round shank: D25/32/50 mm
The diamond tip radius (R) options include 1.0, 1.5, and 2.0 mm.
The tool can be adjusted within a ±90° rolling angle and is designed for both left- and right-hand operation.
Key processing parameters include:
- Feed rate: 0.05–0.2 mm/r or 0.005–0.02 mm (depending on application)
- Interference amount: 0.01–0.5 mm
This technology offers a reliable solution for achieving high-quality surface finishes in precision machining applications.
Features of the Diamond Rolling Tool
- Reversible diamond tip design allows both left- and right-hand operation.
- The tool head rotates up to ±90° for flexible rolling at various angles.
- Achieves surface roughness as low as Ra 0.08 (depending on prior machining conditions).
- Extended service life: the diamond can be rotated to utilize multiple contact points.
- Capable of processing materials with hardness up to HRC 60.
What Is Rolling Processing?
Rolling is a chipless plastic forming method. Using an ultra-hard roller, the tool applies pressure to the metal surface, inducing plastic flow that fills surface asperities and reduces roughness. This cold-working process refines the grain structure, creates a dense fibrous layer, and introduces beneficial residual stresses. As a result, the surface hardness, strength, wear and corrosion resistance, and fatigue strength are substantially improved.
The main components of our single-crystal diamond rolling tool are manufactured from internationally sourced imported materials.
Designed for use on lathes, this tool efficiently performs rolling operations on external cylindrical surfaces, end faces, and internal holes (above a certain diameter). With broad applicability across various diameters—except for internal bore limitations—it offers exceptional versatility in precision machining.
