Crankshaft Deffect
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1 Service Training Malaga AFA I Lion DVD CHAPTER: Crankshafts Crankshafts
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Crankshaft Deffect
Transcript of Crankshaft Deffect
1Service Training Malaga
AFA ILion DVD CHAPTER: Crankshafts
Crankshafts
2Service Training Malaga
AFA ILion DVD
In This Presentation• Nomenclature• Function• Materials• Manufacturing• Operation• Normal Appearance• Failure Analysis
CHAPTER: Crankshafts
3Service Training Malaga
AFA ILion DVD
NomenclatureCHAPTER: Crankshafts
4Service Training Malaga
AFA ILion DVD
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
CHAPTER: Crankshafts
5Service Training Malaga
AFA ILion DVD
Materials Forged High/Medium Carbon Steel
Natural metal flow lines
CHAPTER: Crankshafts
6Service Training Malaga
AFA ILion DVD
Hardening Process Medium Carbon Steel
Furnace Heated and water quenched• Hardness Rockwell C 48• Deep 2.5mm
CHAPTER: Crankshafts
7Service Training Malaga
AFA ILion DVD
Hardening Process High Carbon Steel
Induction Hardened and water quenchedShot peened fillet radius
CHAPTER: Crankshafts
8Service Training Malaga
AFA ILion DVD
Hardening Process Medium Carbon Steel
Rockwell C 40Ground and Polished to final finish
CHAPTER: Crankshafts
9Service Training Malaga
AFA ILion DVD
Crankshaft Forces
• Bending - Fillets
• Torsion - Journals
• Thrust - Sidewalls
CHAPTER: Crankshafts
10Service Training Malaga
AFA ILion DVD
Bending Loads Combustion Stroke
High tensile stresses rod fillets Compressive stresses in main fillets
CHAPTER: Crankshafts
11Service Training Malaga
AFA ILion DVD
Bending Loads End of Combustion Stroke
Low tensile stresses in main fillets compressive stresses in rod fillets
CHAPTER: Crankshafts
12Service Training Malaga
AFA ILion DVD
Torsional LoadsCHAPTER: Crankshafts
13Service Training Malaga
AFA ILion DVD
Thrust LoadCarried by one main journal
CHAPTER: Crankshafts
14Service Training Malaga
AFA ILion DVD
1. State Problem Clearly & Concisely2. Organize Fact Gathering3. Observe & Record Facts4. Think Logically with the Facts5. Identify Most Probable Root Cause6. Communicate with Responsible Party7. Make Repair as Directed8. Follow-Up with Customer
Eight Steps of Applied Failure AnalysisCHAPTER: Crankshafts
15Service Training Malaga
AFA ILion DVD
Inspect All Surfaces
• Inspect Bearings• Inspect Fillets• Inspect Fractures
CHAPTER: Crankshafts
16Service Training Malaga
AFA ILion DVD
Crankshaft Failures
• Bending Fatigues - Main Fillets - Rod Fillet
• Torsional Fatigue - Main Journals - Rod Journals
CHAPTER: Crankshafts
17Service Training Malaga
AFA ILion DVD
Bending FatigueCHAPTER: Crankshafts
18Service Training Malaga
AFA ILion DVD
Bending FatigueCHAPTER: Crankshafts
19Service Training Malaga
AFA ILion DVD
Bending Fatigue Reverse Bending
CHAPTER: Crankshafts
20Service Training Malaga
AFA ILion DVD
Torsional FatigueCHAPTER: Crankshafts
21Service Training Malaga
AFA ILion DVD
Torsional FatigueCHAPTER: Crankshafts
22Service Training Malaga
AFA ILion DVD
Fracture Causes
• Material Flaws• Process Errors
CHAPTER: Crankshafts
23Service Training Malaga
AFA ILion DVD
Material Flaws
• Inclusions• Seams• Pipe• Flake
CHAPTER: Crankshafts
24Service Training Malaga
AFA ILion DVD
Material Flaws (Inclusion)
CHAPTER: Crankshafts
25Service Training Malaga
AFA ILion DVD
Material Flaws (Inclusion)
CHAPTER: Crankshafts
26Service Training Malaga
AFA ILion DVD
Material Flaws (Inclusion)
CHAPTER: Crankshafts
27Service Training Malaga
AFA ILion DVD
Material Flaws (Inclusion)
CHAPTER: Crankshafts
28Service Training Malaga
AFA ILion DVD
Material Flaws (Inclusion)
CHAPTER: Crankshafts
29Service Training Malaga
AFA ILion DVD
Material Flaws (Hydrogen Flake)
CHAPTER: Crankshafts
30Service Training Malaga
AFA ILion DVD
Processing Errors
• Forging• Heat Treating• Straightening• Grinding
CHAPTER: Crankshafts
31Service Training Malaga
AFA ILion DVD
Processing Errors (Forging Burns)
Failed after 80 hours of service
CHAPTER: Crankshafts
32Service Training Malaga
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Processing Errors (Forging Burns)
Subsurface originating fatigue
CHAPTER: Crankshafts
33Service Training Malaga
AFA ILion DVD
Processing Errors (Heat Treating)
Quench Crack
CHAPTER: Crankshafts
34Service Training Malaga
AFA ILion DVD
Processing Errors (Heat Treating)
Straightening Crack
CHAPTER: Crankshafts
35Service Training Malaga
AFA ILion DVD
Reconditioned CrankshaftsCHAPTER: Crankshafts
36Service Training Malaga
AFA ILion DVD
What do you see ?Beach Marks, subsurface
CHAPTER: Crankshafts
37Service Training Malaga
AFA ILion DVD
What do you see ?Straightening crack
CHAPTER: Crankshafts
38Service Training Malaga
AFA ILion DVD
What do you see ?CHAPTER: Crankshafts
39Service Training Malaga
AFA ILion DVD
What do you see ?CHAPTER: Crankshafts
40Service Training Malaga
AFA ILion DVD
What do you see ?Re- welded Thrust face ?!!!!
CHAPTER: Crankshafts
41Service Training Malaga
AFA ILion DVD
Grinder Burns
