Welcome

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bei G. & K. Schön.‚ video_format=“ video_ratio=“ caption_pos=’caption_center‘ custom_title_size=’70‘ av-desktop-font-size-title=“ av-medium-font-size-title=“ av-small-font-size-title=“ av-mini-font-size-title=“ custom_content_size=’38‘ av-desktop-font-size=“ av-medium-font-size=“ av-small-font-size=“ av-mini-font-size=“ font_color=“ custom_title=“ custom_content=“ heading_tag=“ heading_class=“ link_apply=“ link=’lightbox‘ link_target=“ button_label=’GIVE IT A TRY NOW‘ button_color=’light‘ link1=’manually,http://‘ link_target1=“ button_label2=“ button_color2=’light‘ link2=’manually,http://‘ link_target2=“ overlay_enable=’aviaTBaviaTBoverlay_enable‘ overlay_opacity=’0.4′ overlay_color=’#0a0a0a‘ overlay_pattern=“ overlay_custom_pattern=“ av_uid=’av-xqwd6′ sc_version=’1.0′]
Ihr Spezialist für die Fertigung von Glattwalzwerkzeugen und der
Produktion von Einzelteilen und Prototypen.
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[av_heading heading=’Willkommen bei der Firma
G. & K. Schön
Mit Sitz in Korschenbroich‘ tag=’h1′ style=’blockquote modern-quote modern-centered‘ subheading_active=“ show_icon=“ icon=’ue800′ font=’entypo-fontello‘ size=’50‘ av-desktop-font-size-title=“ av-medium-font-size-title=“ av-small-font-size-title=“ av-mini-font-size-title=“ subheading_size=’15‘ av-desktop-font-size=“ av-medium-font-size=“ av-small-font-size=“ av-mini-font-size=“ icon_size=“ av-desktop-font-size-1=“ av-medium-font-size-1=“ av-small-font-size-1=“ av-mini-font-size-1=“ color=“ custom_font=“ subheading_color=“ seperator_color=“ icon_color=“ margin=“ margin_sync=’true‘ av-desktop-margin=“ av-desktop-margin_sync=’true‘ av-medium-margin=“ av-medium-margin_sync=’true‘ av-small-margin=“ av-small-margin_sync=’true‘ av-mini-margin=“ av-mini-margin_sync=’true‘ headline_padding=“ headline_padding_sync=’true‘ av-desktop-headline_padding=“ av-desktop-headline_padding_sync=’true‘ av-medium-headline_padding=“ av-medium-headline_padding_sync=’true‘ av-small-headline_padding=“ av-small-headline_padding_sync=’true‘ av-mini-headline_padding=“ av-mini-headline_padding_sync=’true‘ padding=’20‘ av-desktop-padding=“ av-medium-padding=“ av-small-padding=“ av-mini-padding=“ icon_padding=’10‘ av-desktop-icon_padding=“ av-medium-icon_padding=“ av-small-icon_padding=“ av-mini-icon_padding=“ link=“ link_target=“ id=“ custom_class=“ template_class=“ av_uid=’av-7du4y2′ sc_version=’1.0′ admin_preview_bg=“][/av_heading]

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im Einzugsgebiet von Düsseldorf, wurde das Unternehmen 1984 von Günter und Klaus Dieter Schön gegründet. Die Kernkompetenz ist die Fertigung von hochwertigen Glattwalz- bzw. Rollierwerkzeugen. Auf diesem Gebiet zählt das Familienunternehmen zu den führenden Spezialisten in Deutschland. Darüber hinaus fertigen wir Prototypen für unsere Industriekunden. Dank der steigenden Nachfrage nach Qualitätsglattwalzwerkzeugen konnten wir in vielen Ländern Vertriebspartnerschaften aufbauen. Von Stockholm bis Taipei sind Präzisions-Rollierwerkzeuge von Schön im Einsatz.

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[/av_section][av_section min_height=“ min_height_pc=’25‘ min_height_px=’500px‘ shadow=’no-border-styling‘ bottom_border=’no-border-styling‘ bottom_border_diagonal_color=’#333333′ bottom_border_diagonal_direction=“ bottom_border_style=“ padding=’small‘ custom_margin=’0px‘ custom_margin_sync=’true‘ av-desktop-custom_margin=“ av-desktop-custom_margin_sync=’true‘ av-medium-custom_margin=“ av-medium-custom_margin_sync=’true‘ av-small-custom_margin=“ av-small-custom_margin_sync=’true‘ av-mini-custom_margin=“ av-mini-custom_margin_sync=’true‘ svg_div_top=“ svg_div_top_color=’#333333′ svg_div_top_width=’100′ svg_div_top_height=’50‘ svg_div_top_max_height=’none‘ svg_div_top_opacity=“ svg_div_bottom=“ svg_div_bottom_color=’#333333′ svg_div_bottom_width=’100′ svg_div_bottom_height=’50‘ svg_div_bottom_max_height=’none‘ svg_div_bottom_opacity=“ fold_type=“ fold_height=“ fold_more=’Weiterlesen‘ fold_less=’Read less‘ fold_text_style=“ fold_btn_align=“ color=’header_color‘ background=’bg_color‘ custom_bg=“ background_gradient_direction=’vertical‘ background_gradient_color1=’#000000′ background_gradient_color2=’#ffffff‘ background_gradient_color3=“ src=“ attachment=“ attachment_size=“ attach=’scroll‘ position=’top left‘ repeat=’no-repeat‘ video=“ video_ratio=’16:9′ overlay_opacity=’0.5′ overlay_color=“ overlay_pattern=“ overlay_custom_pattern=“ custom_arrow_bg=“ fold_overlay_color=“ fold_text_color=“ fold_btn_color=’theme-color‘ fold_btn_bg_color=“ fold_btn_font_color=“ size-btn-text=“ av-desktop-font-size-btn-text=“ av-medium-font-size-btn-text=“ av-small-font-size-btn-text=“ av-mini-font-size-btn-text=“ fold_timer=“ z_index_fold=“ css_position_z_index=“ av-desktop-css_position_z_index=“ av-medium-css_position_z_index=“ av-small-css_position_z_index=“ av-mini-css_position_z_index=“ id=“ custom_class=“ template_class=“ aria_label=“ av_element_hidden_in_editor=’0′ av_uid=’av-6bc20y‘ sc_version=’1.0′]
[av_heading heading=’Eine Übersicht unserer Produkte.‚ tag=’h1′ style=’blockquote modern-quote modern-centered‘ subheading_active=“ show_icon=“ icon=’ue800′ font=’entypo-fontello‘ size=’50‘ av-desktop-font-size-title=“ av-medium-font-size-title=“ av-small-font-size-title=“ av-mini-font-size-title=“ subheading_size=’15‘ av-desktop-font-size=“ av-medium-font-size=“ av-small-font-size=“ av-mini-font-size=“ icon_size=“ av-desktop-font-size-1=“ av-medium-font-size-1=“ av-small-font-size-1=“ av-mini-font-size-1=“ color=“ custom_font=“ subheading_color=“ seperator_color=“ icon_color=“ margin=“ margin_sync=’true‘ av-desktop-margin=“ av-desktop-margin_sync=’true‘ av-medium-margin=“ av-medium-margin_sync=’true‘ av-small-margin=“ av-small-margin_sync=’true‘ av-mini-margin=“ av-mini-margin_sync=’true‘ headline_padding=“ headline_padding_sync=’true‘ av-desktop-headline_padding=“ av-desktop-headline_padding_sync=’true‘ av-medium-headline_padding=“ av-medium-headline_padding_sync=’true‘ av-small-headline_padding=“ av-small-headline_padding_sync=’true‘ av-mini-headline_padding=“ av-mini-headline_padding_sync=’true‘ padding=’20‘ av-desktop-padding=“ av-medium-padding=“ av-small-padding=“ av-mini-padding=“ icon_padding=’10‘ av-desktop-icon_padding=“ av-medium-icon_padding=“ av-small-icon_padding=“ av-mini-icon_padding=“ link=“ link_target=“ id=“ custom_class=“ template_class=“ av_uid=’av-65k356′ sc_version=’1.0′ admin_preview_bg=“][/av_heading]
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Prototypenbau

Neben unseren Eigenprodukten helfen wir Ihnen gerne beim Bau ihres Prototypen. Da es hierbei vor Allem um Zeit geht, können sie von unserer hohen Fertigungstiefe und flexiblen Produktion profitieren. Neben der Herstellung und Bearbeitung aller nötigen Einzelteile stimmen wir diese selbstverständlich aufeinander ab, um die optimale Funktionalität des Endproduktes garantieren zu können. Kontaktieren Sie uns gerne und wir werden ein Teil der Lösung sein.
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Endbearbeitung

Bohrungen und Wellen, vor allem bei Gleitpassungen, sind wohl die Bekanntesten Bearbeitungsaufgaben für Glattwalzwerkzeuge. Aus diesem Grund haben wir uns dort breit aufgestellt und bieten eine große Produktpalette an. Neben den verschiedenen Durchmessern beinhaltet unser Katalog Glattwalzwerkzeuge in unterschiedlichen Walzlängen und optional mit Eigenvorschub. Falls bei Ihnen ein Sonderfall vorliegt, helfen wir Ihnen auch gerne dabei.
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Sonderwerkzeuge

Neben den Glattwalzwerkzeugen für Bohrungen und Wellen beinhaltet unsere Produktpalette eine Reihe von Sonderwerkzeugen. für die Bearbeitung von Kegeln, Kugeln, Planflächen oder sogar Mehrstufenbohrungen. Mit den nötigen Informationen können wir ein Werkzeug speziell für Sie konstruieren und fertigen. Wir warten auf ihre Anfrage.
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[av_buttonrow_item label=’GB0 – GB5′ icon_select=’no‘ icon=’4′ font=’entypo-fontello‘ link=’page,929′ link_target=“ size=’small‘ label_display=“ title_attr=“ size-text=“ av-desktop-font-size-text=“ av-medium-font-size-text=“ av-small-font-size-text=“ av-mini-font-size-text=“ btn-padding=“ btn-padding_sync=’true‘ av-desktop-btn-padding=“ av-desktop-btn-padding_sync=’true‘ av-medium-btn-padding=“ av-medium-btn-padding_sync=’true‘ av-small-btn-padding=“ av-small-btn-padding_sync=’true‘ av-mini-btn-padding=“ av-mini-btn-padding_sync=’true‘ color_options=“ color=’theme-color‘ custom_bg=’#444444′ custom_font=’#ffffff‘ btn_color_bg=’theme-color‘ btn_custom_grad_direction=’vertical‘ btn_custom_grad_1=’#000000′ btn_custom_grad_2=’#ffffff‘ btn_custom_grad_3=“ btn_custom_grad_opacity=’0.7′ btn_custom_bg=’#444444′ btn_color_bg_hover=’theme-color-highlight‘ btn_custom_bg_hover=’#444444′ btn_color_font=’theme-color‘ btn_custom_font=’#ffffff‘ btn_color_font_hover=’white‘ btn_custom_font_hover=’#ffffff‘ border=“ border_width=“ border_width_sync=’true‘ border_color=“ border_radius=“ border_radius_sync=’true‘ box_shadow=“ box_shadow_style=’0px,0px,0px,0px‘ box_shadow_color=“ hover_opacity=“ sonar_effect_effect=“ sonar_effect_color=“ sonar_effect_duration=’1′ sonar_effect_scale=“ sonar_effect_opac=’0.5′ av_uid=’av-26ibxu‘ sc_version=’1.0′]
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Unter Glattwalzen versteht man ebenso wie unter Rollieren das Verfestigen und Glätten bestimmter Oberflächen durch Wälzrollen. Das Umformende Verfahren eignet sich insbesondere für die Endbearbeitung von Innen- und Außendurchmessern, Stirnflächen, Kegeln und Kugeln. Unser Spezialgebiet sind mehr-rollige Werkzeuge für eine rotationssymmetrische Bearbeitung.

Beim Rollieren wird das rotierende Werkzeug mit relativem Vorschub zum Werkstück an dessen Profil entlanggeführt. Die Rollen werden von einem axial zum Kegel versstellbaren Käfig geführt und von diesem Verstell-kegel an das Profil gedrückt. Die Rollen wälzen sich am Profil ab und bringen Druckeigenspannungen in das Werkstück ein. Die Randschicht beginnt zu „fließen“ und verformt sich plastisch. Auf diese Weise wird das Rauheitsprofil eingeebnet.

Gegenüber Vergleichenden Verfahren wie Honen, Reiben oder Schleifen überzeugt das Rollieren in nahezu allen Belangen. Mit geringeren Rautiefen, dem Verrunden der Restrauspitzen und einer gesteigerten Verschleißfestigkeit werden höchste Materialanforderungen erfüllt. Außerdem steigert der Einsatz von Rollierwerkzeugen die Wirtschaftlichkeit. Durch einen verringerten Werkzeugverschleiß steigen die Standzeiten und die Bearbeitungszeit lässt sich auf einen Bruchteil reduzieren.

Das notwendige Aufmaß hängt im Wesentlichen von der Vorbearbeitungsrautiefe ab. Der Durchmesser ändert sich in etwa um den Betrag der Ausgangsrautiefe, da die Oberfläche nahezu vollständig eingeebnet wird.
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In Sachen Oberflächenbeschaffenheit punktet das Rollieren als spanloses Verfahren gegenüber Alternativen, welche in der Regel spangebend sind.

Spangebende Verfahren erzeugen durch ihre Schneidgeometrie ein Rauigkeitsprofil. Die Abweichungen der Oberfläche von der Idealgestalt können das Funktionsverhalten entscheidend beeinflussen.

Verbessertes Funktionsverhalten durch Rollieren

Verschleißverhalten
Reibungs- und Gleiteigenschaften
Schmierfähigkeit
Dauerfestigkeit
Passungseigenschaften
Korrosionsverhalten

Mit dem Rollieren lassen sich viele erwünschte Eigenschaften miteinander kombinieren. Entscheidend dabei ist das verbesserte Rauigkeitsprofil, durch die spanlose Bearbeitung beim Rollieren.

Rauigkeit beschreibt die mikroskopische Oberflächengestalt und ist in der Regel das primäre Ziel des Rollierens. Sie ist als Feingestaltabweichung definiert und wird anhand der dynamischen Kenngrößen Ra, Rt und Rmax aus der DIN 4762/ISO 4287 und DIN 4768 charakterisiert. Außerdem wird der Materialanteil Mr herangezogen, um die Oberfläche zu bewerten.

Ra: Mittenrauwert. Beschreibt den mittleren Abstand des Rauigkeitsprofils zur Mittellinie durch das Rauigkeitsprofil

Rt: Differenz aus dem maximalen und dem minimalen Messwert

Rmax: maximale Rautiefe

Angenommen sie planen einen Fertigungsschritt zu optimieren, der bisher durch Feindrehen vollzogen wurde. Durch eine Umstellung auf ein Rollierwerkzeug würden sich sämtliche Oberflächenparameter verbessern. Die dadurch erzeugten Oberflächen sind nicht nur hochwertiger und widerstandsfähiger, sondern werden zeitgleich wirtschaftlicher produziert. Des Weiteren werden durch das rollierende Verfahren die Werkstückeigenschaften verbessert.
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Durch die spanlose Fertigung führt die durch das Werkzeug eingebrachte Energie zum Fließen der Oberflächenrandschicht. Dabei wird die Oberflächen Mikrostruktur in mehrfacher Hinsicht verbessert

Härte
Dauerfestigkeit
Korrosionsbeständigkeit

Dadurch ergeben sich für Rollierwerkzeuge zahlreiche Einsatzmöglichkeiten. Grundsätzlich handelt es sich dabei meist um Oberflächen, die

für besonders hohe thermische oder kinetische Belastungen vorgesehen sind
die mit sehr niedrigen Fertigungstoleranzen versehen sind und dementsprechend mit höchster Präzision zu fertigen sind
ein möglichst ebenes/glattes Oberflächen Profil benötigen, beispielsweise für enge Passungen

In jedem Falle sollten zu jedem Fertigungsschritt optionale Verfahren verglichen werden.
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Das Rollieren ist als Feinbearbeitungsverfahren bekannt für optimale Oberflächeneigenschaften wie geringste Rauigkeit, Erhöhung des Materialtraganteils und Verfestigung der Oberflächen Mikrostruktur. Daneben existieren viele Verfahren, die ebenso auf die Oberflächenveredelung abzielen. Vergleichbare Verfahren sind:

Feindrehen
Feinbohren
Reiben
Honen
Läppen
Schwingschleifen
Rundschleifen
Kugelverfestigungsstrahlen

All diese Verfahren sind spangebend und erzeugen bei einem wesentlich höheren Zeitaufwand ein Profil mit bleibenden Rauigkeitsspitzen und einem geringerem Materialtraganteil.

Wesentliche Vorteile des Rollierens

Reduzierung der Rautiefe auf weniger als 1 um
Verrunden der Restrauspitzen
Erhöhung des Traganteils
Steigerung der Mikrohärte in der Oberfläche
Steigerung der Verschleißfestigkeit
Reduzierung der Korrosionsanfälligkeit
Umweltfreundlich, da kein Materialabtrag stattfindet und wenig Energieintensiv
Kurze Prozesszeiten
Geringe Investitionskosten und kurze Amortisationszeit
Lange Standzeit und hohe Prozesssicherheit
Auf sehr vielen Maschinen einsetzbar

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Für optimale Ergebnisse sind einige Voraussetzungen erforderlich.

Anhaftende Späne von der Vorbearbeitung müssen entfernt sein
Die Oberfläche muss vor dem Rollieren eine Restrautiefe haben (ca. Rt = 10-25 um)
Eine Maximale Werkstoffhärte von ca. 50HRC
Einsatz von KSS (Emulsion, Öl, MMS)

Die Werkzeuge werden relativ zum Werkstück rotiert und lassen sich daher auf Ständerbohrmaschinen, Drehmaschinen, Mehrspindeldrehautomaten, Baz, Fräsmaschinen und Sondermaschinen einsetzen.

Es lassen sich alle plastisch verformbaren (duktilen) Werkstoffe wie Stahl, rostfreier Stahl, Nichteisen-Metalle und Gusswerkstoffe glattwalzen/rollieren. Die Maximale Werkstoffhärte von 50HRC entspricht etwa 1400N/mm² nach der Vorbearbeitung. Das Notwendige Aufmaß entspricht der Rautiefe und kann im Bereich von Rz 5 bis Rz 50 liegen. Da die Toleranz der Vorbearbeitung auch die Fertigteiltoleranz beeinflusst, sollte auf eine genügend feine Vorbearbeitung geachtet werden.

An Seine Grenzen stoßen die Werkzeuge bei Bohrungsdurchmessern kleiner Ø4, Wellen mit Passfedernuten und Profilen mit unterbrochenem Rundlauf.

Mögliche Bauteile zum Rollieren/Glattwalzen sind:

Ankerwellen
Buchsen
Ventilschafte
Kolbenstangen
Laufräder
Zylindergehäuse
Zylinderrohre
Achsen
Kugelzapfen
Antriebselemente
Dichtsitze an Kurbelwellen

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Die Walzgeschwindigkeiten liegen zwischen 60 und 150m/min. Da Walzgeschwindigkeit und Vorschub in einem festen Verhältnis zueinanderstehen, lassen sich so die Prozesszeiten ändern. Der Vorschub pro Rolle liegt abhängig von den Walzbedingungen zwischen 0,5 – 1,5mm/pro Rolle und Umdrehung. Bei mehr-rolligen Werkzeugen kommt man meistens auf 2-7mm/Umdrehung Eine weitere Berechnungsformel für Vorschübe: f = 0,025 x D.

Eine Schmierung Mit Emulsion, Dünnflüssigem Öl etc. wird das Walzergebnis positiv beeinflussen. Bei Sachgemäßen Umgang beschränkt sich der Verschleiß auf den Walzkopf, bestehend aus den Rollen, dem Käfig und dem Verstell-Kegel.

Nachfolgend sollen ein paar gängige Probleme bei der Anwendung von Glattwalzwerkzeugen erläutert werden

Oberfläche ist nach dem Rollieren unzureichend geglättet: Zu grobe Vorbearbeitung oder zu geringer Vorschub

Schuppige Oberfläche oder Abblätterung: Zustellung des Werkzeugs zum Werkzeug zu groß

Starke Verformung der Bohrungskanten: Mittenversatz zwischen Bohrung und Werkzeug oder zu große Zustellung

Gleichförmiges Muster auf der Oberfläche: Beschädigte Rollen

Ungleichmäßiges Muster auf der Oberfläche: Schmutz/Späne auf der Oberfläche oder ein unsauberes Kühlmittel

Welligkeit in der gewalzten Oberfläche: Vorschub zu groß oder Vorbearbeitungsfehler

Bohrung zu eng, Werkzeugzustellung bringt keine Durchmesseränderung: Oberfläche bereits voll ausgewalzt. Das Aufmaß sollte erhöht werden.
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