Lion DVD AFA I CHAPTER: Crankshafts

Crankshafts

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Lion DVD AFA I CHAPTER: Crankshafts

In This Presentation
• Nomenclature
• Function
• Materials
• Manufacturing
• Operation
• Normal Appearance
• Failure Analysis

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Lion DVD AFA I CHAPTER: Crankshafts

Nomenclature

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Lion DVD AFA I CHAPTER: Crankshafts

Crankshaft Functions
• Convert Reciprocating to Rotary Motion
• Carry Heavy Bending, Torsional & Thrust Loads
• Deliver Pressurized Oil to Main & Rod Bearings
• Provide Bearing with Hard Wear Resistant
Surface
• Deliver Power to Gears & Flywheel
• Provide Sealing Surface for Oil Seals

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Lion DVD AFA I CHAPTER: Crankshafts

Materials Forged High/Medium Carbon Steel

Natural metal flow lines

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Lion DVD AFA I CHAPTER: Crankshafts

Hardening Process Medium Carbon Steel

Furnace Heated and water quenched

• Hardness Rockwell C 48
• Deep 2.5mm

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Lion DVD AFA I CHAPTER: Crankshafts

Hardening Process High Carbon Steel

Induction Hardened and water quenched

Shot peened fillet radius

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Lion DVD AFA I CHAPTER: Crankshafts

Hardening Process Medium Carbon Steel

Rockwell C 40
Ground and Polished to final finish

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Lion DVD AFA I CHAPTER: Crankshafts

Crankshaft Forces

• Bending - Fillets
• Torsion - Journals
• Thrust - Sidewalls

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Lion DVD AFA I CHAPTER: Crankshafts

Bending Loads Combustion Stroke

High tensile stresses rod fillets

Compressive stresses in main fillets
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Lion DVD AFA I CHAPTER: Crankshafts

Bending Loads End of Combustion Stroke

Low tensile stresses in main fillets

compressive stresses in rod fillets

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Lion DVD AFA I CHAPTER: Crankshafts

Torsional Loads

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Lion DVD AFA I CHAPTER: Crankshafts

Thrust Load
Carried by one main journal

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Lion DVD AFA I CHAPTER: Crankshafts

Eight Steps of Applied Failure Analysis

1. State Problem Clearly & Concisely

2. Organize Fact Gathering
3. Observe & Record Facts
4. Think Logically with the Facts
5. Identify Most Probable Root Cause
6. Communicate with Responsible Party
7. Make Repair as Directed
8. Follow-Up with Customer

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Lion DVD AFA I CHAPTER: Crankshafts

Inspect All Surfaces

• Inspect Bearings
• Inspect Fillets
• Inspect Fractures

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Lion DVD AFA I CHAPTER: Crankshafts

Crankshaft Failures

• Bending Fatigues
- Main Fillets
- Rod Fillet
• Torsional Fatigue
- Main Journals
- Rod Journals

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Bending Fatigue

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Lion DVD AFA I CHAPTER: Crankshafts

Bending Fatigue

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Lion DVD AFA I CHAPTER: Crankshafts

Bending Fatigue Reverse Bending

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Lion DVD AFA I CHAPTER: Crankshafts

Torsional Fatigue

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Lion DVD AFA I CHAPTER: Crankshafts

Torsional Fatigue

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Lion DVD AFA I CHAPTER: Crankshafts

Fracture Causes

• Material Flaws
• Process Errors

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Material Flaws

• Inclusions
• Seams
• Pipe
• Flake
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Material Flaws (Inclusion)

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Material Flaws (Inclusion)

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Lion DVD AFA I CHAPTER: Crankshafts

Material Flaws (Inclusion)

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Lion DVD AFA I CHAPTER: Crankshafts

Material Flaws (Inclusion)

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Lion DVD AFA I CHAPTER: Crankshafts

Material Flaws (Inclusion)

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Lion DVD AFA I CHAPTER: Crankshafts

Material Flaws (Hydrogen Flake)

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Processing Errors

• Forging
• Heat Treating
• Straightening
• Grinding
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Lion DVD AFA I CHAPTER: Crankshafts

Processing Errors (Forging Burns)

Failed after 80 hours of service

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Lion DVD AFA I CHAPTER: Crankshafts

Processing Errors (Forging Burns)

Subsurface originating fatigue

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Lion DVD AFA I CHAPTER: Crankshafts

Processing Errors (Heat Treating)

Quench Crack

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Lion DVD AFA I CHAPTER: Crankshafts

Processing Errors (Heat Treating)

Straightening Crack

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Lion DVD AFA I CHAPTER: Crankshafts

Reconditioned Crankshafts

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Lion DVD AFA I CHAPTER: Crankshafts

What do you see ?

Beach Marks, subsurface

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Lion DVD AFA I CHAPTER: Crankshafts

What do you see ?

Straightening crack

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Lion DVD AFA I CHAPTER: Crankshafts

What do you see ?

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Lion DVD AFA I CHAPTER: Crankshafts

What do you see ?

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Lion DVD AFA I CHAPTER: Crankshafts

What do you see ?

Re- welded Thrust face ?!!!!

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Lion DVD AFA I

Grinder Burns

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