Crankshafts.ppt

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This document discusses crankshafts, including their function of converting reciprocating motion to rotational motion, materials used such as forged steel, manufacturing processes like hardening, common failure modes from bending and torsional fatigue, and potential material flaws or processing errors that can lead to failures. Key points covered are the crankshaft's role in an engine, how forces like bending and torsion act on it, common failure analysis methods, and factors that contribute to crankshaft damage.

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Crankshafts

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In This Presentation
• Nomenclature
• Function
• Materials
• Manufacturing
• Operation
• Normal Appearance
• Failure Analysis
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Nomenclature
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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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Materials Forged High/Medium Carbon Steel
Natural metal flow lines
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Hardening Process Medium Carbon Steel
Furnace Heated and water quenched
• Hardness Rockwell C 48
• Deep 2.5mm
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Hardening Process High Carbon Steel
Induction Hardened and water quenched
Shot peened fillet radius
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Hardening Process Medium Carbon Steel
Rockwell C 40
Ground and Polished to final finish
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Crankshaft Forces
• Bending - Fillets
• Torsion - Journals
• Thrust - Sidewalls
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Bending Loads Combustion Stroke
High tensile stresses rod fillets
Compressive stresses in main fillets
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Bending Loads End of Combustion Stroke
Low tensile stresses in main fillets
compressive stresses in rod fillets
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Torsional Loads
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Thrust Load
Carried by one main journal
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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
Eight Steps of Applied Failure Analysis
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Inspect All Surfaces
• Inspect Bearings
• Inspect Fillets
• Inspect Fractures
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Crankshaft Failures
• Bending Fatigues
- Main Fillets
- Rod Fillet
• Torsional Fatigue
- Main Journals
- Rod Journals
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Bending Fatigue
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Bending Fatigue
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Bending Fatigue Reverse Bending
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Torsional Fatigue
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Torsional Fatigue
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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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Material Flaws (Inclusion)
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Material Flaws (Inclusion)
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Material Flaws (Inclusion)
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Material Flaws (Hydrogen Flake)
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Processing Errors
• Forging
• Heat Treating
• Straightening
• Grinding
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Processing Errors (Forging Burns)
Failed after 80 hours of service
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Processing Errors (Forging Burns)
Subsurface originating fatigue
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Processing Errors (Heat Treating)
Quench Crack
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Processing Errors (Heat Treating)
Straightening Crack
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Reconditioned Crankshafts
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What do you see ?
Beach Marks, subsurface
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What do you see ?
Straightening crack
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What do you see ?
CHAPTER: Crankshafts

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What do you see ?
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What do you see ?
Re- welded Thrust face ?!!!!
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Grinder Burns

Couplings are used in countless different applications, but sometimes an application requires a little outside-of-the-box thinking to get things working properly. This webinar will present three unique coupling applications with unusual problems and how they were resolved. This webinar will look at: – How a coupling can handle an overload problem in a pumping application – How a coupling can correct RPM droop in an automotive testing application – How couplings can hold up to high temperature applications

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In today’s fast-changing business environment, it’s extremely important to be able to respond to client needs in the most effective and timely manner. If your customers wish to see your business online and have instant access to your products or services. Online Grocery Store is an e-commerce website, which retails various grocery products. This project allows viewing various products available enables registered users to purchase desired products instantly using Paytm, UPI payment processor (Instant Pay) and also can place order by using Cash on Delivery (Pay Later) option. This project provides an easy access to Administrators and Managers to view orders placed using Pay Later and Instant Pay options. In order to develop an e-commerce website, a number of Technologies must be studied and understood. These include multi-tiered architecture, server and client-side scripting techniques, implementation technologies, programming language (such as PHP, HTML, CSS, JavaScript) and MySQL relational databases. This is a project with the objective to develop a basic website where a consumer is provided with a shopping cart website and also to know about the technologies used to develop such a website. This document will discuss each of the underlying technologies to create and implement an e- commerce website.

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Crankshafts.ppt

1. 1 Service Training Malaga AFA I www.dvd4arab.com CHAPTER: Crankshafts Crankshafts

2. 2 Service Training Malaga AFA I www.dvd4arab.com In This Presentation • Nomenclature • Function • Materials • Manufacturing • Operation • Normal Appearance • Failure Analysis CHAPTER: Crankshafts

3. 3 Service Training Malaga AFA I www.dvd4arab.com Nomenclature CHAPTER: Crankshafts

4. 4 Service Training Malaga AFA I www.dvd4arab.com 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

5. 5 Service Training Malaga AFA I www.dvd4arab.com Materials Forged High/Medium Carbon Steel Natural metal flow lines CHAPTER: Crankshafts

6. 6 Service Training Malaga AFA I www.dvd4arab.com Hardening Process Medium Carbon Steel Furnace Heated and water quenched • Hardness Rockwell C 48 • Deep 2.5mm CHAPTER: Crankshafts

7. 7 Service Training Malaga AFA I www.dvd4arab.com Hardening Process High Carbon Steel Induction Hardened and water quenched Shot peened fillet radius CHAPTER: Crankshafts

8. 8 Service Training Malaga AFA I www.dvd4arab.com Hardening Process Medium Carbon Steel Rockwell C 40 Ground and Polished to final finish CHAPTER: Crankshafts

9. 9 Service Training Malaga AFA I www.dvd4arab.com Crankshaft Forces • Bending - Fillets • Torsion - Journals • Thrust - Sidewalls CHAPTER: Crankshafts

10. 10 Service Training Malaga AFA I www.dvd4arab.com Bending Loads Combustion Stroke High tensile stresses rod fillets Compressive stresses in main fillets CHAPTER: Crankshafts

11. 11 Service Training Malaga AFA I www.dvd4arab.com Bending Loads End of Combustion Stroke Low tensile stresses in main fillets compressive stresses in rod fillets CHAPTER: Crankshafts

12. 12 Service Training Malaga AFA I www.dvd4arab.com Torsional Loads CHAPTER: Crankshafts

13. 13 Service Training Malaga AFA I www.dvd4arab.com Thrust Load Carried by one main journal CHAPTER: Crankshafts

14. 14 Service Training Malaga AFA I www.dvd4arab.com 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 Eight Steps of Applied Failure Analysis CHAPTER: Crankshafts

15. 15 Service Training Malaga AFA I www.dvd4arab.com Inspect All Surfaces • Inspect Bearings • Inspect Fillets • Inspect Fractures CHAPTER: Crankshafts

16. 16 Service Training Malaga AFA I www.dvd4arab.com Crankshaft Failures • Bending Fatigues - Main Fillets - Rod Fillet • Torsional Fatigue - Main Journals - Rod Journals CHAPTER: Crankshafts

17. 17 Service Training Malaga AFA I www.dvd4arab.com Bending Fatigue CHAPTER: Crankshafts

18. 18 Service Training Malaga AFA I www.dvd4arab.com Bending Fatigue CHAPTER: Crankshafts

19. 19 Service Training Malaga AFA I www.dvd4arab.com Bending Fatigue Reverse Bending CHAPTER: Crankshafts

20. 20 Service Training Malaga AFA I www.dvd4arab.com Torsional Fatigue CHAPTER: Crankshafts

21. 21 Service Training Malaga AFA I www.dvd4arab.com Torsional Fatigue CHAPTER: Crankshafts

22. 22 Service Training Malaga AFA I www.dvd4arab.com Fracture Causes • Material Flaws • Process Errors CHAPTER: Crankshafts

23. 23 Service Training Malaga AFA I www.dvd4arab.com Material Flaws • Inclusions • Seams • Pipe • Flake CHAPTER: Crankshafts

24. 24 Service Training Malaga AFA I www.dvd4arab.com Material Flaws (Inclusion) CHAPTER: Crankshafts

25. 25 Service Training Malaga AFA I www.dvd4arab.com Material Flaws (Inclusion) CHAPTER: Crankshafts

26. 26 Service Training Malaga AFA I www.dvd4arab.com Material Flaws (Inclusion) CHAPTER: Crankshafts

27. 27 Service Training Malaga AFA I www.dvd4arab.com Material Flaws (Inclusion) CHAPTER: Crankshafts

28. 28 Service Training Malaga AFA I www.dvd4arab.com Material Flaws (Inclusion) CHAPTER: Crankshafts

29. 29 Service Training Malaga AFA I www.dvd4arab.com Material Flaws (Hydrogen Flake) CHAPTER: Crankshafts

30. 30 Service Training Malaga AFA I www.dvd4arab.com Processing Errors • Forging • Heat Treating • Straightening • Grinding CHAPTER: Crankshafts

31. 31 Service Training Malaga AFA I www.dvd4arab.com Processing Errors (Forging Burns) Failed after 80 hours of service CHAPTER: Crankshafts

32. 32 Service Training Malaga AFA I www.dvd4arab.com Processing Errors (Forging Burns) Subsurface originating fatigue CHAPTER: Crankshafts

33. 33 Service Training Malaga AFA I www.dvd4arab.com Processing Errors (Heat Treating) Quench Crack CHAPTER: Crankshafts

34. 34 Service Training Malaga AFA I www.dvd4arab.com Processing Errors (Heat Treating) Straightening Crack CHAPTER: Crankshafts

35. 35 Service Training Malaga AFA I www.dvd4arab.com Reconditioned Crankshafts CHAPTER: Crankshafts

36. 36 Service Training Malaga AFA I www.dvd4arab.com What do you see ? Beach Marks, subsurface CHAPTER: Crankshafts

37. 37 Service Training Malaga AFA I www.dvd4arab.com What do you see ? Straightening crack CHAPTER: Crankshafts

38. 38 Service Training Malaga AFA I www.dvd4arab.com What do you see ? CHAPTER: Crankshafts

39. 39 Service Training Malaga AFA I www.dvd4arab.com What do you see ? CHAPTER: Crankshafts

40. 40 Service Training Malaga AFA I www.dvd4arab.com What do you see ? Re- welded Thrust face ?!!!! CHAPTER: Crankshafts

41. 41 Service Training Malaga AFA I www.dvd4arab.com Grinder Burns

Crankshafts.ppt

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