EMAG ELDRo 100

$400,000 - $600,000 Updated 2026-03-17

Key Specifications

Maximum Shaft Diameter

100 mm

Maximum Shaft Length

1,000 mm

Maximum Workpiece Weight

30 kg

Rolling Force Range

Up to 30 kN per rolling head

Force Control

Closed-loop hydraulic, ±1% accuracy

Spindle (Workpiece Rotation) Speed

10–500 rpm

Overview

The EMAG ELDRo 100 is a CNC deep rolling machine designed to induce compressive residual stresses in the surface layer of shaft-type components, dramatically improving fatigue life without adding material or changing component geometry. Deep rolling — also called roller burnishing under high pressure — is a cold-working process in which a hardened roller or ball presses against the workpiece surface under controlled force, plastically deforming the near-surface zone and creating compressive stresses that counteract the tensile stresses responsible for fatigue crack initiation.

The ELDRo 100 targets crankshafts, camshafts, transmission shafts, and similar rotating components where fatigue life is a primary engineering constraint. By processing bearing journal fillets, oil hole edges, and other high-stress regions, the ELDRo can extend component fatigue life by 50–200% depending on geometry, material, and rolling parameters. This improvement is achieved without heat, coatings, or chemical processes — the workpiece emerges dimensionally unchanged (within micrometer-level elastic recovery) with a burnished surface finish as low as Ra 0.1–0.2 µm.

The machine is CNC-controlled and accommodates shafts up to 100 mm in diameter and 1,000 mm in length, with the rolling head traversing programmed paths under closed-loop force control. Force feedback ensures consistent compressive stress depth regardless of workpiece hardness variation within a batch. Multiple rolling heads can be configured for simultaneous processing of several journals, reducing cycle time for high-volume crankshaft lines.

In automotive powertrain manufacturing, the ELDRo 100 is often positioned immediately after turning and grinding operations, before final inspection. Its integration with EMAG conveyor and automation systems allows it to participate as a fully automated station in a crankshaft or camshaft machining line. The process is also used in aerospace and off-highway engine components where fatigue performance is non-negotiable.

Full Specifications

Parameter	Value
Maximum Shaft Diameter	100 mm
Maximum Shaft Length	1,000 mm
Maximum Workpiece Weight	30 kg
Rolling Force Range	Up to 30 kN per rolling head
Force Control	Closed-loop hydraulic, ±1% accuracy
Spindle (Workpiece Rotation) Speed	10–500 rpm
Number Of Rolling Heads (Max)	4 simultaneous
Achievable Surface Finish	Ra 0.1–0.4 µm
Compressive Stress Depth	Up to 2 mm below surface (material dependent)
Control	Siemens SINUMERIK 840D sl
Automation Interface	EMAG standard conveyor / TrackMotion compatible
Nr Crt	NUMAR/SERIE
Pozitiv	96%
Neutru	1%
Negativ	4%

Specifications sourced from emag.com — verified 2026-03-28

Strengths & Limitations

Strengths

Dramatically improves fatigue life (50–200%) of crankshafts and camshafts without changing dimensions
Achieves Ra 0.1–0.4 µm surface finish as a byproduct of the rolling process
Closed-loop force control ensures repeatable compressive stress depth across entire batch
No heat, coatings, or chemicals — clean, dry process with minimal consumables
Integrates directly into EMAG modular machining lines for fully automated shaft production

Limitations

Highly specialized process — investment is only justified for high-volume shaft component production
Rolling tool (ball or roller) wear must be monitored; premature wear affects process consistency
Limited to rotationally symmetric features on shaft-type parts; not applicable to prismatic components

Best For

High-volume automotive crankshaft lines where fatigue life improvement eliminates the need for heavier cross-sections Camshaft and transmission shaft producers needing journal fillet rolling to meet engine durability specs Aerospace engine shaft manufacturers requiring demonstrable fatigue life improvement per engineering specifications Off-highway and heavy truck engine builders processing large crankshafts for extreme-duty cycle applications

Frequently Asked Questions

01 What is deep rolling and how is it different from conventional roller burnishing?

Both processes use a hardened roller or ball pressed against a rotating workpiece surface. The distinction is force level and intent: conventional burnishing targets surface finish improvement at relatively low forces. Deep rolling applies forces in the range of 10–30 kN to induce significant plastic deformation and compressive residual stress to depths of 1–2 mm, with fatigue life improvement as the primary goal rather than just cosmetic surface improvement.

02 How much can deep rolling improve fatigue life on a crankshaft?

Published data for automotive crankshafts typically shows 50–200% improvement in fatigue strength when journal fillets are deep rolled. The exact improvement depends on base material, initial stress state, rolling force, and geometry. For ductile iron crankshafts, improvements at the higher end of this range are common.

03 Does the ELDRo 100 change the workpiece dimensions?

Negligibly. Deep rolling induces plastic deformation, but the bulk dimensional change (diameter reduction at the rolled zone) is typically in the range of a few micrometers due to elastic recovery. Parts are designed to tolerance their pre-rolling dimensions so that post-rolling dimensions remain within specification.

04 What materials are suitable for the ELDRo 100 deep rolling process?

The process is most effective on steels (forged or cast) and ductile iron in the hardness range of 20–55 HRC. Very hard materials (above 58 HRC) may not yield sufficient plastic deformation for meaningful compressive stress induction. Common materials include 42CrMo4, nodular iron grades, and case-hardened steels.

05 How does the ELDRo 100 fit into a crankshaft production line?

The ELDRo 100 is typically placed after finish grinding and before final wash and inspection. Using EMAG's TrackMotion or belt conveyor system, crankshafts arrive automatically, are clamped between centers, processed under CNC force-controlled rolling programs, and transferred out without manual handling.