How the crankshaft is manufactured. 1) By Forging 2) By Machining.

2. MANUFACTURING OF
CRANKSHAFT
PRESENTED BY: 16ME44
16ME134

3. INTRODUCTION
The crankshaft is located in the engine of a vehicle and
converts the force created by the engine's pistons moving up
and down into a force that moves the wheels in a circular
motion so the car can go forward. Located inside the car's
engine, it is connected to all the pistons in the engine and to the
flywheel. To understand this shaft, it is important to understand
how the pistons and the flywheel work.

4. MAIN PARTS OF CRANKSHAFT

5. Web:
The portion of a crank between the crankpin and the shaft or between adjacent
crankpins called also crank arm, crank throw.
Counter Weight:
Crankshaft counter weights are needed to statically and dynamically balance the
crankshaft. Without them, the vibrations caused will destroy it. If this is not done, the
engine will experience vibrations that will eventually tear up the main bearings and
cause damage.
Crank journals:
In a reciprocating engine, the crankpins, also known as crank journals are the journals
of the big end bearings, at the ends of the connecting rods opposite to the piston.
MAIN PARTS OF CRANKSHAFT

6. CRANK JOURNAL PIN:
The oil passes through the ammonium crank with holes and passes the oil
inside the tube into the column to the spike and the connecting column. The
oil reaches the crankshaft through a pump located inside the oil filter.
Fly wheel:
Flywheel is bolted and fixed connected to crankshaft. And we cannot
differentiate on macroscopic time scale the power stroke or suction stroke or
in which stroke the flywheel is storing the excessive energy. Flywheel just
stores the excessive energy in form of kinetic energy and immediately after
power stroke crankshaft uses it in other power deficient strokes. Flywheel
rotates with same speed as crankshaft.
MAIN PARTS OF CRANKSHAFT

7. TYPES OF CRANKSHAFTS
 Single Throw Crankshaft
 Double Throw Crankshaft
 Four throw Crankshaft
(Used in car Engines)
 Six throw Crankshaft
(Used in car Engines)

8. MATERIAL SELECTION
Based on the stress imposed on the component during the operation, and operating
temperature, the material to be selected for this component should has the following
characteristics;
The material should be strong in bending.
It must have excellent fatigue resistance.
It must have less coefficient of thermal expansion so that the component
can retain its original dimension at varying temperatures.
The material should be easily machinable so that it can take complex
shape (as required for the geometry of crankshaft) easily.

9. MATERIAL SELECTION
After carrying out an extensive research of materials, following materials
were listed for crankshaft;
 Aluminum
 Copper
 Steel

10. MANUFACTURING
PROCESSES

11. FORGING PROCESSES
PRE-FORMING
TRIMMING
TWISTING
COINING

12. PRE-FORMING:
The material is pressed between two forging dies to get a rough shape of the
crankshaft.
TRIMMING:
In this process it cuts the flash which is produced and appears as flat unformed
metal around the edge of the component.
TWISTING:
Twisting for 2nd and 4th Main journal.
COINING:
The exact shape of the forged crankshaft is obtained in the coining process where
the final blows of the hammer force the stock to completely fill every part of the
finishing impression.
FORGING PROCESSES

13. MACHINING PROCESSES
FACING AND CENTERING
CAM TURNING
DRILLING
GRINDING
BALANCING OF CRANCKSHAFT
WASHING
INSPECTION
HEAT TREATMENT

14. FACING AND CENTERING:
The facing process is a machining operation that is a form of turning in which the work
piece rotation to produce flat surface. Centering refers to the component according to
the final dimensions
CAM TURNING:
CAM turning is the process used to produce cylindrical components, typically on a
lathe. A cylindrical piece of stock is rotated and a cutting tool is traversed along axes of
motion to produce precise diameters and depths.
DRILLING:
In the drilling operation, all inner diameters are drilled in the crankshaft geometry. The
drilling mainly consists of oil holes.
MACHINING PROCESSES

15. GRINDING:
The final grinding of diameters sets the cylinder diameters to their final acceptable
tolerance. This is followed by grinding of other sections such as grooves using CAM.
BALANCING THE CRANKSHAFT:
The last step in the machining process is balancing the crankshaft. In this process the
crankshaft is mounted on two bearings in a device, and the dynamic balance of the
component is checked. Mass and location of material removal is specified. Drilling
holes in the counter weights will balance the crankshaft dynamically. The balance of
the crankshaft is checked once more on the device.
WASHING:
Final washing of the component and preparation for final inspection.
MACHINING PROCESSES

16. INSPECTION:
The final inspection consists of checking diameter of cylinders, radius of
crankshaft and distance of faces.
HEAT TREATMENT:
Heat treatment is the next step to obtain the desired mechanical properties for
the material.
MACHINING PROCESSES