PRESENTATION ON CRANKSHAFT

By: 1. 2. 3. Sachin kumar(2010JE0751) Vipin Sharma(2010JE0857) Shashi Ranjan(2010JE0772)

INTRODUCTION TO CRANKSHAFT

Has crank pins which is attached to big end of the connecting rod Typically connects to a flywheel to reduce the pulsation characteristic of the 4-S cycle Sometimes torsional or vibrational damper are connected to the other end to reduce the torsional vibrations Counterweights to improve engine balance

CRANKSHAFT is a part of the engine that translates reciprocating linear piston motion into rotation

PARTS OF A CRANKSHAFT

PISTON MOTION BASICS

COMPONENTS OF ACCELERATION

FORCES IMPOSED ON A CRANKSHAFT

If the gas pressure is assumed to be 200bar and piston diameter of 10cm, the force on crankshaft will be of the order of 16,000kgf. This level of force produces substantial bending and torsional moments and the resulting tensile, compressive and shear stresses. The combined weight of the piston, ring package, wristpin, retainers, small end of connecting rod and a small amount of oil are continuously accelerated from rest to very high velocity and back to rest twice each crankshaft revolution.

Combustion forces and piston acceleration are also the main source of external vibration produced by an engine.
Rotating mass associated with each crankpin, weight of the big end of connecting rod , connecting rod bearing(s), some amount of oil, and the mass of the crankshaft structure comprising the crankpin and cheeks. These rotating forces are counteracted by counterweight masses located in appropriate angular locations opposing the rod journals

TORSIONAL VIBRATION AND MATERIALS USED IN CRANKSHAFT MANUFACTURING

By- Shashi Ranjan 2010JE0772

TORSIONAL VIBRATIONS
Crankshaft has its own torsional resonant frequency as it has mass and its own torsional stiffness Torsional resonant frequency of the crankshaft system is a function of: Crankshaft length Crankshaft torsional stiffness Crankshaft stroke Balance masses Moments of inertia of rotating items attached to or driven by the engine Crankshaft has very little inherent damping as it is made of lump of high-strength steel. Therefore, vibration attenuating device is provided at the free end of engine crankshaft.

CRANKSHAFT TORSIONAL ABSORBERS

Difference between damper and absorber

Damper dissipates energy, mainly in the form of heat

Absorber is a device which is designed to oscillate in direct opposition to a vibration at either a specific frequency or a specific order, depending on the design.

Types of absorber Elastomer absorber Pendulum absorber

PENDULUM-STYLE ORDER-ABSORBERS

MATERIALS USED IN MANUFACTURE OF CRANKSHAFTS

Crankshaft are subjected to shock and fatigue loads. Therefore material should be tough and fatigue resistant. The crankshafts are generally made of carbon steel, special steel or special cast iron. Medium-carbon steel alloys are composed of predominantly the element iron, and contain a small percentage of carbon (0.25% to 0.45%) Several alloying mix are carefully mixed carefully in order to produce specific qualities in target alloy. These qualities are hardenability, nitridability, surface and core hardness, ultimate tensile strength, yield strength, endurance limit (fatigue strength), ductility, impact resistance, and corrosion resistance. Alloying elements typically used are manganese, chromium, molybdenum, nickel, silicon, cobalt, vanadium, and sometimes aluminium and titanium.

In industrial engines, the crankshafts are generally made from carbon steel such as 40C8, 55C8 and 68C4 In transport engines- managanese steel such as 20-Mn-2, 27-Mn-2 and 37-Mn-2 In aero engines- Nickel Chromium steel such as 35-Ni-1-Cr-60 and 40-Ni-2-Cr-1-Mo-28

MANUFACTURING OF CRANK SHAFT

By: Sachin kumar 2010JE0751

MANUFACTURING OPERATIONS
Forging

Crank web milling, Journal milling, Crank pin milling

Drilling of flywheel flange, Drilling of crankpin, Drilling of crossed oil hole Grinding Crack Detection

Nitriding
Dynamic Balancing Lapping and Super finish Journal Grading and Bearing Selection

Raw forging

Billet Crankshaft machining

Drilling of crankpin

Drilling of flywheel flange

Drilling of crossed oil hole

Milling cutter used for journal and crankpin milling

Grinding- Surface grinding is done for main journal and crank pin. Grinding of sidewalls is a critical step Crack detection- For a forged material there is possibility of internal flaws. Hence before sending materials for further operations, cracks are detected by magnaflux method. Nitriding- Higher surface hardness is obtained, extremely resistant to abrasion and high fatigue strength

Lapping and Superfinishing- Crankshaft is super-finished so as to avoid cyclic fatigue failure

Journal Grading and bearing selection

Fully counterweighted V8 crank

Bolt on counterweights