Operating Principle and Process Effect

The FX-45 Deep Rolling Tool is a mechanical single-roller tool designed for plunge deep rolling of external fillets. The spring mechanism inside the tool body enables the rolling force to be generated in a controlled manner. The roller head is connected to the spring-loaded body and elastically adapts to radial or axial force variations that may occur during the process.

The dial gauge included in the standard version indirectly indicates the spring force. This allows the operator to monitor the rolling force during the process. For special applications, force control can also be performed externally using sensor-based measuring systems.

The roller is selected according to the fillet geometry to be processed. With different tool options such as FX-45-10kN and FX-45-20kN, suitable solutions can be configured for different fillet radii and force requirements.

Stronger Transitions on External Fillets, Longer Component Life

In machine components, fatigue cracks often start at section changes, shoulder transitions, and external fillet areas. The FX-45 Deep Rolling Tool has been developed to perform controlled deep rolling on the external fillets of turned components by targeting these critical areas.

FX-45 mechanically strengthens the surface layer without removing material. During the process, the specially profiled roller applies controlled force to the fillet area of the component. As a result of this force, residual compressive stresses are generated beneath the surface, microscopic notch effects are reduced, and the surface layer of the material gains strength through cold forming. This contributes to increased fatigue strength in components exposed to dynamic loads, such as shafts, screws, tie rods, torsion bars, and similar parts.

Targeted Strengthening for Critical Fillets

External fillets are among the areas with the highest stress concentration in many components operating under load. Micro marks that may occur on the surface after conventional machining can create a notch effect and lead to the initiation of fatigue cracks.

FX-45 acts directly on these areas. The roller contacts the component according to the fillet form and rolls the surface layer in a controlled manner. In this way, the fillet area is not only smoothed but also mechanically strengthened beneath the surface.

This feature makes FX-45 a reliable process solution, especially for components exposed to high-cycle fatigue.

Efficient Process in a Single Clamping Setup

FX-45 can be used on CNC or conventional lathes. Since deep rolling can be performed in the same clamping setup after turning, the process can be completed without transferring the component to a second operation.

This structure reduces production time, minimizes clamping errors, and improves process repeatability. Thanks to its compatibility with right-hand and left-hand working directions, its ability to operate in both rotation directions, and its mechanical force monitoring capability, FX-45 offers a reliable and practical solution for serial production conditions.

What Do You Gain with FX-45?

FX-45 is a mechanical deep rolling tool developed for applications requiring increased strength on external fillets. As a result of the process, it helps achieve safer load-bearing behavior in the critical transition area of the component.

With FX-45, you can:

• increase fatigue strength on external fillets,
• reduce the risk of crack initiation,
• generate residual compressive stresses beneath the surface,
• improve surface quality by reducing microscopic notch effects,
• perform additional strengthening in the same clamping setup after turning,
• simplify the production process,
• monitor process quality with a dial gauge or sensor,
• improve the service life of components operating under dynamic loads.

Application Areas

FX-45 can be preferred in many applications where turned external fillets need to be strengthened. It is especially suitable for components operating under variable loads, bending, torsion, vibration, or impact.

Main application areas:

• Shaft and axle fillets
• Screw and bolt transition areas
• Tie rods
• Torsion bars
• Shoulder and section transition fillets
• Engine and power transmission components
• Hydraulic and mechanical connection elements
• Heavy industry, energy, automotive, aerospace, and machine manufacturing components

FX-45 is an effective solution especially for plunge deep rolling applications on narrow and critical fillets.