Turning assisted with deep cold rolling - a cost efficient hybrid process for workpiece surface quality enhancement

The paper reports on a hybrid manufacturing process that performs turning and deep cold rolling simultaneously on the same machine tool. An indexable insert turning tool on which the shank was manufactured to embed a commercially available deep cold rolling system was employed to perform simultaneously the two processes. As the design of the hybrid tool sets the cutting insert ahead of the rolling ball, turning followed by deep cold rolling are performed on the path. Workpiece surface roughness/integrity analysis showed that significant surface quality enhancement could be obtained using the new hybrid manufacturing process. The paramount advantage of 'fusing' turning and deep cold rolling resides in the considerable savings of manufacturing costs and times along with an increased process integration.