StudentShare
Contact Us
Sign In / Sign Up for FREE
Search
Go to advanced search...
Free

Service Requirements for an Automotive Crankshaft - Term Paper Example

Cite this document
Summary
The author of this term paper "Service Requirements for an Automotive Crankshaft" points out that the crankshaft is the part of a car engine that converts the up and down movements of the pistons into the horizontal rotation. The shaft is a single piece that is made of cast iron or forged steel…
Download full paper File format: .doc, available for editing
GRAB THE BEST PAPER91.5% of users find it useful
Service Requirements for an Automotive Crankshaft
Read Text Preview

Extract of sample "Service Requirements for an Automotive Crankshaft"

Materials and Manufacturing Selection Analysis Materials and Manufacturing Selection Analysis Automotive Crankshaft Section 1: Functions and Service Requirements of an Automotive Crankshaft Functions of an automotive crankshaft The crankshaft is the part of a car engine that converts the up and down movements of the pistons into horizontal rotation. The shaft is a single piece that is made of cast iron or forged steel. Oil passages are cast or drilled into the crankshaft to distribute lubricant to the main end rod journals. The crankshaft is a link between the piston and the drive wheels that is located in the bottom end of the engine. It holds the huge forces produced by the explosions in the combustion chamber. The snout which is the front end of the crankshaft turns the turning gear to drive the camshaft. This turns the drive pulley that runs a belt that is connected to the flywheel that allows the starter motor to rotate the crankshaft. The resulting forces caused by the ignition of the spark plugs force the pistons to move downward with a huge force. The crankshaft changes this up and down motion of the pistons into a rotating motion. This is made possible when the connecting rods attached to the pistons connect to the crankshaft so that they go up and down their angle changes (Crankshaft Forming, 2005). Service Requirements for an Automotive Crankshaft An automotive crankshaft goes through a large number of load cycles during its service life in a car engine, fatigue performance and durability is a key consideration in its manufacture. It is important to manufacture a less expensive crankshaft with the least weight possible and the right fatigue strength. This will result in a lighter and smaller engine with better fuel efficiency and higher power output. The crankshaft must have enormous strength and made of material that are hard. The crankshaft will be made of medium-carbon steel alloys and alloying elements combinations. Specific service requirements must be in the mixture used and include surface and core hardness, nitridability, hardenability, ultimate tensile strength, temper-embrittlement resistance, corrosion resistance, impact resistance, yield strength, ductility and endurance limit. Titanium, aluminum, vanadium, cobalt, silicon, nickel, molybdenum, chromium and manganese are the alloying elements capable of producing these properties. The carbon content in these elements determines the hardness and the ultimate strength, and is used in making the crankshaft (Fatemi & Williams, 2007). Crankshaft Section 2: Material Requirements and Selection Material Requirements The crankshaft is made of steel alloys whose combination of properties will ensure ultra strength and hardness of the crankshaft. Iron and a little percentage of carbon, about 0.45%, are found in the medium-carbon steel alloys. This is combined with other alloying elements that produce a mixture that produce a specific alloy that is suitable to the manufacture of the crankshaft. The mixture needs to have enormous tensile strength, hardenability, corrosion resistance, impact resistance, ductility and an endurance limit or what is called fatigue strength. The alloying elements that can produce this type of mixture are titanium, aluminum, vanadium, cobalt, silicon, nickel, molybdenum, chromium and manganese. Specific properties will be added by each to the required material. The main determinant of the hardness and ultimate strength is the carbon content, which helps in heat treating the alloy (Fatemi & Williams, 2007). High strength steels are refined to remove undesirable impurities such as sulfur, phosphorous to increase the tolerance of the material. Other steels that are ultra-high-strength are known as “maraging” steels can be refined to remove as much carbon as possible in order to develop fatigue properties and extreme strengths. A high performance crankshaft will require a nickel-chrome-molly alloy which is used due to its good ductility, fatigue and high strength properties and good impact resistance. A nominal 40 points mainly of carbon is contained in it, and is often described as the standard for ultra strength alloys (Fatemi & Williams, 2007). A crankshaft is made of cast iron or forged steel. The difference between iron and steel is in the percentage of carbon contained. Those containing less than 2% carbon are known as steels and those with more than 2% are known as pig iron. The iron is processed further to reduce the carbon content to obtain steel. The properties of iron are that it is ductile, malleable, has a very high tensile strength and is very workable. This means it can easily be used to come up with a desired shape and thickness. It is one of the three naturally occurring elements. CES Material Selection The material selection for the manufacture of the automotive crankshaft will be done using the CES selector using a CES software. The selector is used to achieve reduction in costs of the components, enhances product performance and ensures high quality designs of the automotive crankshaft. Section 3: Manufacturing Route Selection Manufacturing Route Selection Carbon steel alloys that are medium are required for the manufacture of the crankshaft. Primary manufacturing processes fall into four categories. This include, machining, casting, forging and joining. The factors considered in choosing the manufacturing route are;- Quality. The crankshaft must meet certain specifications. The flexibility of the process required to produce the crankshaft in terms of shape, the materials and the finish. Costs of capital equipment and labor. The manufacturing route that will be used for the crankshaft is the forging process. Shaping or forming of bulk metal in between dies of the crankshaft is part of the forging process. There are normally two types of dies; open die for general or large numbers and a closed die that is for small and specific orders. A billet of a suitable size is heated using the appropriate temperature which is then pressed or pounded to come up with the desired shape of the crankshaft. The dies have the concave opposite shape form of the desired crankshaft. Crankshafts for motorsports vehicles are manufactured from a billet. These are fully machined from the billet of the selected medium steel alloys. This process provides the flexibility of the design required and allows for alterations to achieve the optimal service requirements (Kinaan, 2002). CES Process Selection Exercise This requires the results from the use of the CES software. Section 4: Manufacturing Route Manufacturing Route The manufacturing route that will be used for the crankshaft is the forging process. As earlier explained, shaping or forming of bulk metal in between dies of the crankshaft is part of the forging process. A billet crank is one of the strongest crankshafts manufactured. The manufacture process starts with a big heavy chunk of steel that goes through the manufacturing process. The billet crank will require more work than a forged crank due to the strength attained in the finished product. This is composed of iron and carbon, about 0.45%. This is in combination with other alloying metals such as manganese, chromium and nickel. The high strength steel is refined in order to remove any impurities such as sulfur, calcium and phosphorous that may reduce the strength of the metal. Highest quality steels are also used and these require a certain level of purity. The vacuum processing methods used are VIM (Vacuum Induction Melting) and VAR (Vacuum Arc Remelting). A billet of a suitable size is heated using the appropriate temperature which is then pressed or pounded into the most desired shape. The dies have the concave opposite shape form of the desired crankshaft. The main crankshafts are usually in most cases, fully machined from the billet of the selected medium steel alloys. This process provides the flexibility of the design required and allows for alterations to achieve the optimal service requirements. Manufacturing Process and Material Microstructure Crankshafts are manufactured using the forging process. The crankshafts are forged from a steel bas through roll forging or casting in ductile steel. The forging process is preferred due to the light weight and the capability of achieving more compact dimensions and better inherent dampening. Crankshafts that are cast are used for low output whereas forged crankshafts are normally used for more expensive outputs. The casting process is also used to manufacture crankshafts, however the forged method is preferred due to the poor mechanical and fatigue strength of a cast crankshaft. The solution to this the cast crankshaft has to be machined to get the desired accuracy, tolerance and finishing. High strength, ductility and fatigue strength are critical properties required from the crankshaft material and manufacturing process. The process selected has to ensure that these standards are achieved. Forged steel has significantly higher strength than ductile cast iron. The forged steel also has more ductility than the ductile cast iron. It is therefore the forging method is better then the casting method for the manufacture of the automotive crankshaft. References Crankshaft Forming, 2005. Metal Forming Virtual Simulation Lab. New York: John Wiley. Fatemi, A., & Williams, J., 2007. Fatigue Performance Evaluation of Forged Steel versus Ductile Cast Iron Crankshaft: A Comparative Study. New York: FIERF and American Iron and Steel Institute. Fatemi, A., & Williams, J., 2007. Fatigue Performance of Forged Steel and Ductile Cast Iron Crankshafts. SAE Technical Paper 2007-01-1001, SAE World Congress. Fatemi, A., & Williams, J., 2007. Dynamic Load and Stress Analysis of a Crankshaft. SAE Technical Paper 2007-01-0258, SAE World Congress. Kinaan, R., 2002. Inside the making of a SCAT crankshaft. NMRA. Read More
Cite this document
  • APA
  • MLA
  • CHICAGO
(Service Requirements for an Automotive Crankshaft Term Paper, n.d.)
Service Requirements for an Automotive Crankshaft Term Paper. Retrieved from https://studentshare.org/engineering-and-construction/1612386-materials-manufacturing-selection-analysis
(Service Requirements for an Automotive Crankshaft Term Paper)
Service Requirements for an Automotive Crankshaft Term Paper. https://studentshare.org/engineering-and-construction/1612386-materials-manufacturing-selection-analysis.
“Service Requirements for an Automotive Crankshaft Term Paper”, n.d. https://studentshare.org/engineering-and-construction/1612386-materials-manufacturing-selection-analysis.
  • Cited: 0 times

CHECK THESE SAMPLES OF Service Requirements for an Automotive Crankshaft

The Future of Automotive Design

automotive design is based on the consideration of the artistic and visual aspects of an automobile.... hellip; automotive design takes various things into consideration, for example, branding, security, usability, engineering, sustainability, and the like. "automotive design is really complex.... As strange as it sounds, having to have four wheels on a car really makes it difficult: it demands a complex shape, and so form must follow function" (Lewin and Borroff 26). Sana Osman English 14 April 2009 The Future of automotive Design automotive design is based on the consideration of the artistic and visual aspects of an automobile....
2 Pages (500 words) Essay

Engine Crankshaft System

Firing interval refers to the regulation of the angle turned by the crankshaft between the power strokes of a multi cylinder engine.... In Inline 3-cylinder engines the engine fires once every 240 degrees crankshaft angle.... Regardless of how the crankshaft rotates, the combined center of gravity of the 3 pistons and con-rods remains at the same location hence eliminating the generation of vibrations.... In reality, the forces actually act on three different points on the crankshaft resulting in the crankshaft vibrating end to end rather than the cancellation of the forces....
4 Pages (1000 words) Essay

Automotive Cruise Control System

automotive cruise control system is an adaptive cruise control unit that allows vehicles cruise control system to adapt the vehicles speed in a traffic environment.... automotive device controls became more popular in USA in the year 1973 after the historical oil crisis which led to tremendous rise in fuel price.... automotive cruise control uses the mechanism of transmission whereby a sensor system is mounted to the vehicle front....
4 Pages (1000 words) Essay

Describe how a torque wrench relates to automotive physics

This force… In an automotive engine the combustion gas in the cylinder creates pressure against the piston which in turn creates a force which pushes it down.... The relationship between engine power and horse power is:In an automotive engine the combustion gas in the cylinder creates pressure against the piston which in turn creates a force which pushes it down.... The force is transmitted from the piston to the connecting rod and from the rod to the crankshaft....
1 Pages (250 words) Essay

Automotive Repairs and After-Sales Service Company for Women

It is a common observation that automotive repairs and after-sales services are regular activities of individuals who are associated with automobile maintenance.... The writer of this paper analyzes automotive repairs and after-sales service company for women in Australia.... This research will try to unveil the extent to which social bias is reflected in the quality of automotive repairs and after sales services received by them.... hellip; Car dealers are generally equipped with a service section that provides an array of automobile care services....
6 Pages (1500 words) Research Paper

Materials: Nodular Iron Casting Crankshaft

The paper is an account of the heat-treating process for the nodular iron crankshaft.... A crankshaft translates the linear motion of pistons into rotational motion in an engine.... The crankshaft may undergo extreme conditions of pressure, heat, torsional forces, and vibrational forces that necessitate careful planning when designing these parts and choosing the materials with which they will be constructed.... The crankshaft has since the steam engine, which often used only a single piston and commonly appears in four-stroke and six-cylinder engines used in contemporary automotive design....
8 Pages (2000 words) Term Paper

Automotive Suspension

an automotive suspension spring or the leaf spring is one of the suspension system components.... This work called "automotive Suspension" describes a system in the automobile's design that is used to make a connection of the vehicle parts to its wheel system and in isolation and management of vibrations as well as vibrations.... Generally, automotive suspension springs are classified by the amount of deflection exhibited under a specific load....
9 Pages (2250 words) Coursework

Manufacturing of Automotive Piston

The piston, together with the combustion chamber, cylinder head, and the piston rings seal the combustion gas and after ignition, transfers the combustion pressure to the rotating crankshaft through the connecting rod and the piston pin.... The paper "Manufacturing of automotive Piston" describes that quality control is important because this is what will ensure that the end product meets specific chemical composition, has the right mechanical properties, and possesses the correct microstructure as had been intended....
7 Pages (1750 words) Essay
sponsored ads
We use cookies to create the best experience for you. Keep on browsing if you are OK with that, or find out how to manage cookies.
Contact Us