Tool mechanisms for deep rolling machines

A lower work tool having a one-piece open style design with a plurality of openings and an upper work tool having a housing and cover plate each forming a plurality of openings.

FIELD OF THE INVENTION 
This invention broadly relates to deep rolling of fillets of engine 
crankshafts or other annular areas of metallic work pieces subject to high 
stress loads. More specifically, this invention relates to new tool 
mechanisms for deep rolling machines for use in the deep rolling of 
crankshafts or like work pieces. 
BACKGROUND OF THE INVENTION 
The state of the art is indicated by following cited references: 
Gottschalk, U.S. Pat. No. 5,495,738; Gottschalk, et al., U.S. Pat. No. 
5,445,003; Bone, U.S. Pat. No. 5,493,761; Winkens, U.S. Pat. No. 
5,138,859; Betsrein, U.S. Pat. No. 4,561,276; and Ostertag, U.S. Pat. No. 
4,947,668. 
Various machines and methods have been employed to strengthen and finish 
metal work pieces such as camshafts and crankshafts for internal 
combustion engines. In many modern automobiles, engines have been 
downsized for installation into smaller vehicles. Accordingly, with 
downsizing of automotive vehicles and their components for reducing 
weights and improving fuel efficiency, smaller engines and crankshafts are 
needed. 
To improve the fatigue strength and durability of downsized crankshafts, 
deep rolling of fillets and other circular joint areas is increasingly 
important. The fatigue strength and durability of crank pins and main 
bearing journals can be significantly increased by deep rolling 
compressive stresses into the middle of the annular fillets between the 
pin journals and adjacent counterweights or balancing webs. 
During this deep rolling process, the industry has long known to provide a 
full flooding process necessary to lubricate and/or cool the work tools 
and work piece while the work tools are engaging the work piece. A more 
recent process of lubricating and/or cooling includes a limited coolant 
supply in the form of a mist (e.g., lubricant mist). Both of these 
cooling/lubricating methods tend to cause shavings from said work piece 
and any other debris or foreign matter in the work area to adhere to the 
work piece and work tool mechanisms. 
The adherence of debris to the work tools and work pieces create many 
problems for the industry. First, there is considerable wear and tear of 
the tool mechanisms effectively shortening tool life. Second, to increase 
the life and performance of the work tools, many man hours are required to 
disassemble the work tools for cleaning, and to later re-assemble for 
subsequent use of the cleaned tools. Consequently, productivity is greatly 
diminished because the work tools cannot be used in the deep rolling 
process during the cleaning process. Third, debris collecting around the 
work area may work its way between the work tool and work piece during the 
deep rolling process to cause the compressive stresses to be misaligned 
effectively negating the purpose of the deep rolling process. Accordingly, 
those skilled in the art have long sought a solution for keeping the work 
tools and work piece clear of debris and other foreign matter during the 
deep rolling process, particularly where a fluid mist or lubricant mist is 
used in the work tool process. 
One object of the present invention is to provide a novel design of the 
work tool in which disassembly of the work tool for cleaning is 
unnecessary. 
Another object of the present invention is to provide a design of the lower 
work tool that permits easy assembly and disassembly if necessary for the 
cleaning process. 
Still another object of the present invention is to provide a novel design 
of the work tools that can be cleaned in conventional ultrasonic cleaning 
systems without disassembly.

SUMMARY OF THE INVENTION 
According to the present invention, the foregoing and other objects and 
advantages are attained by novel designs for the upper and lower work 
tools used to apply the compressive stresses in the deep rolling process. 
According to the unique design of the tipper and lower work tools, the 
design provides for and includes a plurality of openings to allow foreign 
matter and debris to pass through the tools during the deep rolling 
process. 
While not previously known or used in industry, the designs for each tool 
having a plurality of openings to allow for debris to be swept through the 
openings by the lubricating solution of the deep rolling process. With 
debris prevented from adhering and collecting around the work tool or work 
piece, the necessity to remove the work tool from the deep rolling process 
for cleansing is greatly diminished. 
Accordingly, production is not wasted removing the work tool from a deep 
rolling project to have the tool cleansed. Similarly, man hours are not 
wasted cleaning the work tools since the frequency of cleaning is reduced. 
An added benefit is the cleanliness of the work piece. With the debris 
capable of being swept away from the work piece, a cleaner product results 
and is always welcomed by the customer. Furthermore, debris is less likely 
to be collected around the area where the work tool engages the work piece 
during the deep rolling process. Consequently, a more precise deep rolling 
process results creating the most effective compressive stresses possible 
in the annular fillets. 
When cleaning the work tools is necessary, the plurality of openings allows 
the work tools to be thoroughly cleaned in conventional ultrasonic 
cleaning systems without complete disassembly. 
DESCRIPTION OF THE PREFERRED EMBODIMENTS AND BEST MODE OF CARRYING OUT THE 
INVENTION 
FIG. 1 illustrates an upper work tool 10 in accordance with the present 
invention. 
The tool 10 comprises a rectangular housing 12 having one side forming an 
annular opening 14. Said annular opening 14 is closed by an annular cover 
plate 18 which is secured to the housing 12 by threaded fasteners 16. The 
cover plate 18 forms an annular recess 32 to receive one end of a 
cylindrical hub 28. The combination 30 of just the housing 12 and cover 
plate 18 of the present invention is more fully illustrated in FIG. 2. 
As shown in FIG. 1, the housing 12 has a pair of L-shaped work roller 
retainers 20, 21 adjustably secured by the threaded fasteners 25, 26. Said 
retainers 20, 21 have ends 27, 29 which are recessed to provide cages 15. 
Said cages 15 support work rollers 22 for floating rotation generally 
about upwardly and outwardly so that the working circumference of said 
rollers 22 can engage fillets of crankshaft journals or other similar work 
pieces to deep roll compressive stresses in said work pieces. This design 
for the upper work tool is generally known in the industry as illustrated 
by U.S. Pat. No. 5,445,003 to Gottschalk et al., and referenced herein. 
However, none of the referenced patents teach a cover plate having a 
plurality of openings, nor do the patents teach a housing having a 
plurality of openings. The cover plate 18 of the present invention forms a 
first plurality of openings 24 in the shape of disjoined concentric 
circles radiating outwardly from the center of said cover plate 18. 
Additionally, a side 13 of the housing 12 opposite the annular opening 14 
also forms a second plurality of openings in the shape of disjoined 
concentric circles (not shown) radiating outwardly from the center of said 
side 13, said first plurality of openings 24 aligned with the second. 
FIG. 4 illustrates a side view of a lower work tool 40 of the present 
invention comprising a main body essentially forming an L shape member 
with a longitudinal axis 57 integrally supporting two laterally spaced 
sides allowing for a one-piece open design of the lower work tool as 
illustrated in FIGS.4, 5 and 6. Each side is symmetrically aligned 
relative to the other comprising a pair of spaced ridges 62, 72 and 63, 73 
with each ridge forming an annular race 64, 74, 65, 75. Two hubs 61, 71 
are axially positioned between the sides and supported by oppositely 
aligned races with said hubs secured to said ridges 73, 62 by flat head 
screws (not shown), said screws positioned through tapered openings 42, 44 
respectively. A pair of receiving rollers 51, 53 are rotatably supported 
by needle beatings 55 (as illustrated in FIG. 4 with view of cut away of 
ridge 72) with said needle bearings 55 supported by said hubs 61, 71. 
Since the lower work tool is routinely beneath the work piece during the 
deep rolling process, the bulk of the debris collects around this tool, 
and consequently, may require disassembly for a thorough cleaning. When 
disassembly is required, the one-piece open design permits easy assembly 
and disassembly. Only the hubs 61, 71 and rollers 51, 53 are required to 
be removed and is easily accomplished by simply removing the hubs and 
rollers from the open end of the tool 40. Therefore, when cleaning is 
necessary, only a minimal amount of man hours is needed to clean the tool 
and down time for the tool is greatly diminished increasing productivity 
considerably. 
The longitudinal axis 57 of said lower work tool 40 forms two rectangular 
openings 58, 59, as illustrated in FIG. 6, positioned beneath said hubs 
during the deep rolling process and are large enough to allow a smooth 
flow of lubricating fluid and debris to pass said receiving rollers 51, 
53. Additionally, the ridges 62, 72, 63, 73 form a plurality of openings 
70 leaving just enough structure for each ridge to adequately support said 
hubs 61, 71 during the deep rolling process. With this combination of 
openings, the bulk of debris is able to effectively pass the work tools 
and work piece. 
While it will be apparent that the preferred embodiments of the invention 
disclosed are well calculated to fulfill benefits, objects or advantages 
of the invention, it will be appreciated that the invention is susceptible 
to modification, variation and change without departing from the proper 
scope or fair meaning of the subjoined claims.