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AFA I

CHAPTER: Crankshafts

Crankshafts
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AFA I

CHAPTER: Crankshafts

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

CHAPTER: Crankshafts

Nomenclature

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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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AFA I

Materials

CHAPTER: Crankshafts

Forged High/Medium Carbon Steel

Natural metal flow lines

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CHAPTER: Crankshafts

AFA I

Hardening Process

Medium Carbon Steel

Furnace Heated and water quenched

Hardness Rockwell C 48
Deep 2.5mm

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AFA I

Hardening Process

CHAPTER: Crankshafts

High Carbon Steel

Induction Hardened and water quenched

Shot peened fillet radius

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AFA I

Hardening Process

CHAPTER: Crankshafts

Medium Carbon Steel

Rockwell C 40
Ground and Polished to final finish

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AFA I

CHAPTER: Crankshafts

Crankshaft Forces

Bending - Fillets
Torsion - Journals
Thrust

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- Sidewalls

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AFA I

Bending Loads

CHAPTER: Crankshafts

Combustion Stroke

High tensile stresses rod fillets

Compressive stresses in main fillets
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Bending Loads

CHAPTER: Crankshafts

AFA I

End of Combustion Stroke

Low tensile stresses in main fillets

compressive stresses in rod fillets

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CHAPTER: Crankshafts

Torsional Loads

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CHAPTER: Crankshafts

Thrust Load
Carried by one main journal

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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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AFA I

CHAPTER: Crankshafts

Inspect All Surfaces

Inspect Bearings
Inspect Fillets
Inspect Fractures
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CHAPTER: Crankshafts

Crankshaft Failures
Bending Fatigues
- Main Fillets
- Rod Fillet
Torsional Fatigue
- Main Journals
- Rod Journals
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CHAPTER: Crankshafts

Bending Fatigue

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CHAPTER: Crankshafts

Bending Fatigue

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Bending Fatigue

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CHAPTER: Crankshafts

Reverse Bending

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CHAPTER: Crankshafts

Torsional Fatigue

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CHAPTER: Crankshafts

Torsional Fatigue

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CHAPTER: Crankshafts

Fracture Causes

Material Flaws
Process Errors

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CHAPTER: Crankshafts

Material Flaws

Inclusions
Seams
Pipe
Flake
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Material Flaws

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AFA I

CHAPTER: Crankshafts

(Inclusion)

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Material Flaws

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AFA I

CHAPTER: Crankshafts

(Inclusion)

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Material Flaws

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AFA I

CHAPTER: Crankshafts

(Inclusion)

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Material Flaws

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AFA I

CHAPTER: Crankshafts

(Inclusion)

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Material Flaws

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AFA I

CHAPTER: Crankshafts

(Inclusion)

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Material Flaws

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AFA I

CHAPTER: Crankshafts

(Hydrogen Flake)

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Processing Errors

Forging
Heat Treating
Straightening
Grinding
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Processing Errors

CHAPTER: Crankshafts

(Forging Burns)

Failed after 80 hours of service

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Processing Errors

CHAPTER: Crankshafts

(Forging Burns)

Subsurface originating fatigue

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Processing Errors

CHAPTER: Crankshafts

(Heat Treating)

Quench Crack

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Processing Errors

CHAPTER: Crankshafts

(Heat Treating)

Straightening Crack

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CHAPTER: Crankshafts

Reconditioned Crankshafts

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CHAPTER: Crankshafts

What do you see ?

Beach Marks, subsurface

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CHAPTER: Crankshafts

What do you see ?

Straightening crack

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CHAPTER: Crankshafts

What do you see ?

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CHAPTER: Crankshafts

What do you see ?

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CHAPTER: Crankshafts

What do you see ?

Re- welded Thrust face ?!!!!

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Grinder Burns

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