Application and Use

The 7796 is the latest generation of HEGENSCHEIDT brake disc rolling machines for the rolling of coated brake discs for cars and trucks, which make a significant contribution to meeting the stringent European emission and durability standards (EURO 7). The specialized machine, which is designed to the requirements of the market, provides an economical, energy- and resourcesaving process for eliminating harmful residual compressive stresses and cracking and improving the surface quality and part lifespan of cast iron brake discs. Precise cold-forming roller burnishing produces a smoothing effect, reduces surface roughness by up to 75 percent and corrects laser cladding warping. In addition, the shielding of cast iron disc brakes is reduced. The HEGENSCHEIDT 7796 is designed for brake discs up to 460 mm in diameter.

Added value

Technlogical - Superior Performance, Prove Results

• Improved crack resistance and longer component life under thermal and mechanical stress
• Lower corrosion risk for both coated and uncoated brake discs
• Stronger coating adhension through elimination of residual tensile stress
• Up to 40% lower grinding and energy costs by reducing post-machining effort
• No need for stress relief heat treatment, resulting in lower energy consumption and faster production
• Backed by 100 years of precision rolling expertis from HEGENSCHEIDT
• Trusted Tier - 1 automotive supplier for OEMs globally

Economic - Boost Efficiency, Lower Costs

• Minimize grinding effort thanks to reduced deformation 
•  and improved flatness
• Lower scrap rates through precise correction of bolt mounting and friction surfaces
• Short cycle time (~35 sec per disc) supports high volume production
• Low energy consumption due to elimination of heat-based stress relief
• Fast, cost-effective process with minimal setup changes
• Long tool life reduces maintenance costs and downtime

Function

The 7796 consists of a welded base frame and a four station rotary table with four stations including trays for brake discs up to 460 mm in diameter. The machine is fully covered, including dust removal, pneumatic pre-cleaning station, and complete electrical equipment with all drives, controls, and displays for the automatic machining process. The operating panel is integrated and has various data interfaces.

• Parallel loading and machining for uninterrupted operation and higher throughput
• Simultaneous, force-controlled rolling on both disc sides for perfect symmetry and reduced handling time
• Real-time process monitoring and data logging for full traceability and quality assurance
• Fast cycle time of ~35 seconds (30s machining + 5s handling) to maximize output
• Quick-change tool design for minimal downtime during part changeover