FATIGUE LIFE PREDICTION OF CRANKSHAFT MADE OF MATERIAL 48MnV BASED ON FATIGUE TESTS,DYNAMIC SIMULATION AND FEA

S-N curve and fatigue parameters of 48MnV are obtained using small sample tests and staircase or up and down method, which paves the way for predicting fatigue life of crankshaft made of 48MnV. The fatigue life of the crankshaft of a six-cylinder engine is calculated using different damage models such as S-N method, normal strain approach, Smoth-Watson-Topper （SWT）Bannantine approach, shear strain approach, and Fatemi-Socie method based on dynamic simulation and finite element analysis （FEA） of crankshaft. The results indicate that the traditional calculation is conservative and the residual fatigue life of crankshaft is sufficient to maintain next life cycle if the crankshaft is remanufactured after its end of life.

Identification of Axial Vibration Excitation Source in Vehicle Engine Crankshafts Using an Auto-regressive and Moving Average Model

Violent axial vibration of a vehicle engine crankshaft might lead to multiple defects to the engine.Much research on mechanism and control measures has been done on engines,such as using the dynamic stiffness matrix method,rayleigh differential method,and system matrix method.But the source of axial vibration has not been identified clearly because there are many excitation factors for the axial vibration of a crankshaft,such as coupled torsional-axial vibration and coupled bending-axial vibration,etc.In order to improve the calculation reliability and identify the excitation source of axial vibration of in vehicle engine crankshafts,this paper presents a method to identify the axial vibration excitation source of crankshafts for high speed diesel engines based on an auto-regressive and moving average（ARMA） model.Through determining initial moving average variables and measuring axial /bending/torsional vibrations of a crankshaft at the free-end of a 4-cylinder diesel engine,autoregressive spectrum analysis is applied to the measured vibration signal.The results show that the axial vibration of the crankshaft is mainly excited by coupled bending vibration at high speed.But at low speed,the axial vibration in some frequencies is excited primarily by torsional excitation.Through investigation of axial vibration source of engine crankshafts,calculation accuracy of vibration can be improved significantly.

Non-linear Torsional Vibration Characteristics of an Internal Combustion Engine Crankshaft Assembly

Crankshaft assembly failure is one of the main factors that affects the reliability and service life of engines.The linear lumped mass method,which has been universally applied to the dynamic modeling of engine crankshaft assembly,reveals obvious simulation errors.The nonlinear dynamic characteristics of a crankshaft assembly are instructionally significant to the improvement of modeling correctness.In this paper,a general expression for the non-constant inertia of a crankshaft assembly is derived based on the instantaneous kinetic energy equivalence method.The nonlinear dynamic equations of a multi-cylinder crankshaft assembly are established using the Lagrange rule considering nonlinear factors such as the non-constant inertia of reciprocating components and the structural damping of shaft segments.The natural frequency and mode shapes of a crankshaft assembly are investigated employing the eigenvector method.The forced vibration response of a diesel engine crankshaft assembly taking into account the non-constant inertia is studied using the numerical integral method.The simulation results are compared with a lumped mass model and a detailed model using the system matrix method.Results of non-linear torsional vibration analysis indicate that the additional excitation torque created by non-constant inertia activates the 2nd order rolling vibration,and the additional damping torque resulting from the non-constant inertia is the main nonlinear factor.The increased torsional angular displacement evoked by the high order excitation torque relates to the non-constant inertia.This research project is aimed at improving nonlinear dynamics theory,and the confirmed nonlinear parameters can be used for the structure design of a crankshaft assembly.

Multi-body dynamic simulation research on the influence of piston engine crankshaft thrust bearings abrasion

Fault diagnosis studying on piston engine,crankshaft and gearbox is focused in this paper. The thrust bearing abrasion caused by axial movement of the crankshaft will affect the force of timing gears and oil pump gears,which will result in the fracture of gears,abnormal ignition,connecting rod cracking and collision of cylinder. Simulation based on CREO software is done to build three-dimensional models of crankshaft and gears of a WP10 diesel engine. The models are imported into ADAMS to complete multi-body dynamics simulations. The force analysis of gears in different kinds of axial movements is finished and variations rules of gear dynamic load is obtained. The presented results show that the crankshaft axial movement can cause overload and vibration on gears. Combined with the realistic case data,the fault feature through simulation research is validated and early warming parameters of gear fault are proposed.

The Applications of Measurement System for Crankshaft

This paper will introduce two types of multi-parameter co-measuring system and their application in the produc- tion.The first is crankshaft bent deformation measuring machine system.The second is the crankshaft pneumatic-electric measur- ing system.They have been used in final inspection procedure of automation line for crankshaft of automobie engine with good re- sults,the structure principle and soft clash technological process of the measurement system are presented.

Residual fatigue strength of 48MnV crankshaft based on safety factor

Residual fatigue strength of 48MnV crankshaft was studied and analyzed based on safety factor. Three different status crankshafts were used to the hop-up tests, which maintain new after 500h hop-up tests and after 1000h hop-up tests. Then, crankshafts were cut into unit cranks. The unit cranks were used to do endurance bending tests to get the residual fatigue strength. Finally, the results were analyzed based on safety factor. The results show that safety factor of crankshaft descends a little with the increase of the running time, and the residual safety factor is still much bigger than the endurable safety factor. Furthermore, after the crankshaft accomplishes a full life cycle, the residual fatigue strength of the crankshaft is enough to remanufacture and fulfill the next life cycle.

Fatigue life prediction of crankshaft repaired by twin arc spraying

This paper used Baumel Jr. and Seeger’s approach estimating fatigue parameters of 48MnV with 3Cr13 coatings. The fatigue life of the crankshaft of a six-cylinder engine, repaired by twin arc spraying 3cr13 deposits, is respectively calculated using different damage model such as S-N method, normal strain approaches, SWT-Bannantine approaches, shear strain approaches, and fatemi-Socie method based on dynamical simulation and FE analysis of crankshaft. The results indicate that the traditional calculation is conservative and that the life of crankshaft repaired by arc spraying is sufficient.

A Simplified Model for Vibration Analysis of Diesel Engine Crankshaft System

A spatial finite element model for vibration analysis of crankshaft system was proposed. The crankshaft body was simplified as spatial rigid frame by using beam elements based on Timoshenko beam theory. The main bearings in system were simplified as linear springs and dashpots. The natural frequencies of the crankshaft system of a four in-line cylinder engine were calculated and compared with the analytical and experimental values available in other publications. In order to simulate the motion of operating crankshaft system, the gas forces, rotating masses and reciprocating masses were considered, the crankshaft and main bearings were coupled in a rotating coordinate system, and a dynamic model for vibration analysis of crankshaft system was established. By applying the dynamic model, the influence of the mass and moment of inertia of front pulley on the behavior of crankshaft vibration was investigated.

Production of 48MnV-C non-heat treatment crankshaft steel by means of converter plus continuous casting and hot-rolling process

48MnV-C non-heat treatment crankshaft steel is specially used for making crankshafts of Cummings C engines.It mainly adopts the technology of V—N micro-alloying,at present,it has been successfully used in making crankshaft of heavy duty truck engines.BX STEEL made trial production by means of converter→secondary metallurgy(RH + LF)→rectangular slab caster→hot rolling process,and studied the T[O],T[N],[H]and non-metal inclusion in 48MnV - C steel under continuous casting process condition,the actual grain size and the slab quality.All the chemical compositions and test results met the needs of Cummings Crankshaft Steel Standard.In order to ensure the mechanical properties of the non-heat treatment steel,a certain amount of nitrogen is added to it,also a small amount of sulfur is added to improve the cutting property of the steel.This process route can make full use of the de-hydrogen function of RH,and during RH treatment,rough adjustment of alloy elements may be made while the adjustment of Nitride Manganese nitrogen pick up and adjusting Mn,as well as Ca treatment and S content adjustment may be done during LF treatment so as to ensure the requirement of high nitrogen,low hydrogen,low oxygen content in 48MnV-C steel.Magnetic marks are defects shown in magnetic powder testing after the steel was used to make finished crankshafts.The 48MnV - C non-heat treatment crankshaft steel produced by means of the above-mentioned process route has not only relatively high robust performance which meets the needs of truck crankshaft safety,but also high qualification rate and basically no "magnetic marks" are found after being made into finished crankshafts,which meets the crankshaft standard.Therefore,this steel has been widely used in domestic crankshaft industry.

Effect of Lightening Hole on Dynamic Characteristics and Fatigue Life of Diesel Engine Crankshaft

As the core components of diesel engine,the structure and dynamic characteristics of the crankshaft has a vital role on engine performance. To Process the lightening hole with properly size in a certain location can reduce the weight of the crankshaft so as to,improve the dynamic characteristics and the connecting rod load of the crankshaft. Using finite element method and using three-dimensional software to model,the structural static and dynamic analysis theory to are gotten the performance and fatigue life analysis of crankshaft which have lightening hole with appropriate size. In this paper,to select the lightening hole for 25 mm size to analyze and compare the results with no hole of crankshaft analysis data can get that lightening hole can improve the crankshaft strength and the fatigue life of some location of the crankshaft.

Engine Multi-Body with Flexible Crankshaft Modeling and Numerical Simulation

A multi-body model of engine system with flexible crankshaft was presented in this paper to analyze the dy- namic behavior of an internal combustion engine. The flexible crankshaft structural dynamics was coupled with the main bearing hydrodynamic lubrication in this model by a system approach. An application of an 14 engine was given to show this sophisticated simulation model and to predict the loads and the orbit plots in the journal bearings by the dy- namic response of the multi-body engine system with flexible crankshaft. The numerical results show the capabilities and significance of the flexible crankshaft in this system. The objective of the research is to provide the scientific guid- ance for design and maintenance of the internal combustion engine.

Coordination control for crankshaft forging hydraulic press

Taking a new type of full-fiber crankshaft forging hydraulic press as the research object,an upsetting-bending stroke coordination control is studied to improve crankshaft forming accuracy.A master-slave proportion integration differentiation(PID)coordination control strategy based on velocity feed-forward is proposed to improve the coordination control accuracy.The structure and working process of the full-fiber crankshaft forging hydraulic press are introduced,and a mathematical model of the upsetting and bending control system are established.The coordination control strategy is verified experimentally.The experimental results show that the maximum tracking error of the coordination control strategy is reduced by 66%compared with the traditional PID controller,and the coordination motion accuracy is improved effectively.

Mechanical properties of vanadium-alloyed austempered ductile iron for crankshaft applications

This study focused on the development of austempered ductile iron(ADI)with desirable combination of mechanical properties for crankshaft applications by the combined effect of vanadium(V)alloying and an optimized heat treatment process.The produced unalloyed GGG60,0.15%V-alloyed GGG60(V-15),and 0.30%V-alloyed GGG60 samples were subjected to austenitizing at 900℃for 1 h and subsequent austempering processes at 250,300,and 350℃for 15,30,60,90,and 180 min.As a result of these austempering processes,different bainitic structures were obtained,which led to the formation of diverse combinations of mechanical properties.The mechanical properties of the austempered samples were tested comprehensively,and the results were correlated with their microstructures and the stability of the retained austenite phases.From the microstructural observations,the V-alloyed samples exhibited a finer microstructure and a more acicular ferrite phase than unalloyed samples.The V addition delayed the coarsening of the acicular ferrite structures and considerably contributed to the improvement of the mechanical properties of GGG60.Moreover,the X-ray diffraction results revealed that the retained austenite volume and the carbon enrichment of austenite phases in ADI samples were remarkably affected by the addition of vanadium.The increase in volume fraction of retained austenite and its carbon content provided favorable ductility and toughness to V-15,as confirmed by the elongation and impact test results.Consequently,the dual-phase ausferrite microstructure of V-15 that was austempered at 300℃for 60 min exhibited high strength with substantial ductility and toughness for crankshaft applications.

曲轴综合测量机几何误差建模及敏感性分析

为提高曲轴综合测量机测量精度,针对其几何误差元素多,逐一进行补偿工作量大、过程繁琐等问题,基于多体系统理论和齐次坐标变换建立曲轴综合测量机的几何误差模型,采用Sobol敏感性分析方法进行分析,识别出对测量精度影响较大的关键几何误差项。通过对曲轴综合测量机随动测板不同位置处的误差元素敏感性系数进行分析计算,从21项几何误差中识别出10项对曲轴综合测量机测量精度影响较大的关键项,为合理经济地提高曲轴综合测量机测量精度提供依据。

遗传算子-蚁群优化在柴油机曲轴振动中的应用

针对船用柴油机振动大,噪声高的特点,考虑柴油机往复运动和旋转分量引起的不平衡力等多个影响因素,建立了柴油机缸体内部活塞二次运动的动力学模型,采用Runge-Kutta(RK)方法对目标函数进行求解,计算内燃机的惯性和活塞拍击在发动机悬置处产生的冲击力和发动机缸体表面的振动位移。以优化曲轴轴系振动幅值为目标,采用蚁群算法,引入遗传算法中的交叉、变异等遗传算子,提出全局搜索与局部搜索相耦合的方法策略。研究结果表明,柴油机曲轴轴系振动在交叉概率0.6和变异概率0.05处产生了最小的收敛;通过和数学模型进行对比分析,进一步验证了该变异蚁群算法的准确性。

Development of remaining life prediction of crankshaft remanufacturing core

This paper reviewed the main research work in the field of remaining life prediction of crankshaft remanufacturing core by Science and Technology on Remanu- facturing Laboratory. Based on the results of finite element analysis, the R angle zone of crankshaft was determined as a major measuring position. A special measuring probe is developed, and bending fatigue bench tests were carried out to collect electromagnetic damage information during fatigue process. A neural network model was established to identify damage degree of crankshaft core, and a damage evaluation equipment for crankshaft core was developed.

Fatigue features study on the crankshaft material of 42CrMo steel using acoustic emission

Crankshaft is regarded as an important component of engines, and it is an important application of remanufacturing because of its high added value. However, the fatigue failure research of remanufactured crankshaft is still in its primary stage. Thus, monitoring and investigating the fatigue failure of the remanufacturing crankshaft is crucial. In this paper, acoustic emission （AE） technology and machine vision are used to monitor the four-point bending fatigue of 42CrMo, which is the material of crankshaft. The specimens are divided into two categories, namely, pre-existing crack and non-pre- existing crack, which simulate the crankshaft and crank- shaft blank, respectively. The analysis methods of para- meter-based AE techniques, wavelet transform （WT） and SEM analysis are combined to identify the stage of fatigue failure. The stage of fatigue failure is the basis of using AE technology in the field of remanufacturing crankshafts. The experiment results show that the fatigue crack propagation style is a transgranular fracture and the fracture is a brittle fracture. The difference mainly depends on the form of crack initiation. Various AE signals are detected by parameter analysis method. Wavelet threshold denoising and WT are combined to extract the spectral features of AE signals at different fatigue failure stages.