What Is Rolling?

Rolling on our ROLLOTRONIC® systems is a chipless manufacturing process for forming rotationally symmetrical hollow bodies, such as thin-walled deep-drawn parts or tube sections. By means of controlled radial infeed of the internal and/or external forming tools (“rollers”) and their continuous rolling action on the workpiece, circumferential beads or bulges are produced. With the appropriate tool geometry, continuous threads can also be formed, or interrupted form features such as knurls or perforations can be produced. With the appropriate tool geometry, continuous threads can also be formed, or interrupted form features such as knurls or perforations can be produced.

Unlike the seemingly similar process of metal spinning, where roller tools act on the workpiece primarily from one side, the ROLLOTRONIC® process uses localized, simultaneous engagement of opposing forming tools from the inside and outside The workpiece rolls between the continuously advancing tools and conforms precisely to their contour. The forming forces act exclusively in the immediate tool engagement zone. This prevents deflection of the component axis and unwanted deformation of the tube cross-section, which can occur in conventional spinning processes as a result of one-sided loading, particularly with thin-walled cross-sections. Compared with machining processes, forming the tube wall without material removal enables minimal material input and therefore exceptionally resource- and energy-efficient lightweight construction. This reduces material consumption, energy demand and CO₂ emissions.

Rolling is particularly suitable for the economical production of high-quality rotationally symmetrical components for the automotive, measurement technology, sanitary products, consumer goods and packaging industries, as well as numerous other sectors. Simple deep-drawn parts or tubular components are frequently used as starting blanks. Applications range from the series production of simple cosmetic cream jars to safety-critical shock absorber components for the automotive industry. Simultaneous forming from the inside and outside using contour discs or contour rollers achieves high precision and excellent repeatability. In addition to conventional steels, stainless steels and non-ferrous metals such as copper, aluminium and their alloys can also be processed. Furthermore, where required, local preheating of the workpiece can expand the range of processable wall thicknesses and increase the achievable complexity of the rolling contours.