Chapter 1: Crankshaft

1. Definition:
A crankshaft is an essential part of the power transmission system. In which, the
reciprocating movement of the piston is converted into the rotating movement by
using the connecting rod.
2. Structure:

A crankshaft consists of:

 Crankpins:
- A crankpin is the part of the crank of a crankshaft to which the
connecting rod is attached.
- Crankpins transfer up-and-down motion between the crankshaft
and connecting rod.
- The big end of the connecting rod is connected to the crankpin of
the crankshaft by way of a bearing.
- Connecting rods typically have two-piece crankpin bearings for
connecting the lower end of the rod to a crankpin of a crankshaft.
 Crank webs (crank arms or cheeks):
- The crank cheek connects the crankpin to the main journal. In some
designs, the cheek extends beyond the journal and carries a
counterweight to balance the crankshaft.
 Balancing weights:
 - The counterweights are a type of weight, that applies opposite
force, which provides balance and stability to the crankshaft. These
are mounted on the crank web.
- The reason for installing counterweights in the crankshaft is, they
can eliminate the reaction caused by rotation. And it is very helpful
for achieving the higher RPM and makes the engine run easily.
 Main journals:
- Journals have attached to the engine block. These bearings hold the
crankshaft and provide it to rotate inside the engine block. This
bearing is such as a plain bearing or journal bearings. The main
bearings vary from engine to engine, often according to the forces
given by the engine.
 Thrust washers:
- At some points, two or more thrust washers are provided to stop
the crankshaft from moving lengthways. These thrust washers
assemble among the machined surfaces in the web and the
crankshaft saddle.
- With the help of thrust washers, it can be easily maintained the gap
and helps to reduce the lateral movement of the crankshaft. In
many engines, these are made as part of the main bearings, usually,
older types, use separate washers.
 Oil Passage and Oil Seals:
- Crankshaft oil passage passes oil from main bearing journals to the
big end journals. Normally the hole is drilled on the crank web.
When the crankpin is in an upward position and combustion forces
push the connecting rod to a downward position, it allows oil to
enter between journal and bearing.
- The crankshaft has some extend beyond the crankcase on both
ends. This causes oil to leak from these ends. So, preventing oil
from these openings, oil seals are provided. There are two main oil
seals are connected at the front end and rear end.
 Flywheel mounting flange:
- In most cases, the crankshaft attaches to the flywheel through the
flanges. The diameter of the crankshaft wheel end is larger than the
other end. This gives a flange face to mount the flywheel.
3. Function:
The crankshaft converts reciprocative motion to rotational motion. It
contains counter weights to smoothen the engine revolutions. There are two
types of crankshaft.
 The monolithic type: used for multi-cylinder engines four-stroke car
engine, outboard marine engines. The type of connecting rods are used is
sssembly type.

 The assembled type fabricated from separate elements: used for Single-
or twin-cylinder four-stroke engine, two-stroke engine. The type
of connecting rods are used is monolithic type.

4. Technical requirement:
The selection of materials and manufacturing methods depend on the type of
engine and the geometry and design of the crankshaft. It is necessary to use
high strength materials to ensure a long operational life. Steel crankshafts are
usually manufactured by forging or die forging or by casting if the material
is cast iron.
 In low and medium speed engines:
Crankshafts are frequently made of low alloy carbon steels such as 1034,
1035, 1038 (UK: 060A35, 080A32, 080A35, 080A5, 080 M36, 1449-
40CS, 40HS, C35; Russia: 35); 1040 and 1042 (UK: 060A40, 080A40,
 080 M40, C40, C40E, CS40; Russia: 40); 1050, 1055 (UK: 060A52,
070 M55, 080 M50, C50E, C55; Russia: 50); 1037 (UK: Gr.A; Germany:
GS20Mn5; Russia: 35Г); 1039, 1041, 1043 (UK: 150 M36; Russia: 40Г);
1045, 1046 (UK: 080 M46, C45, C45E; Russia: 45Г); 1053 (UK:
080 M50, C50E; Russia: 50Г).
 Crankshafts for automobile and tractor engines:
Crankshafts are made of 1044, 1045, 1045H (UK: 060A47, 080 M,
080 M46, 1449-50CS, 1449-50HS, 50HS, C45, C45E; Russia: 45); 1040,
1046 (UK: 080 M46, C45, C45E; Russia: 45Г); 1053 (UK: 080 M50,
C50E; Russia: 50Г) steels and also of 5135, 5140, 5140H, 5140RH (UK:
37Cr4, 41Cr4, 530A36, 530A40, 530H36, 530H40, 530 M40; Russia:
40X); 3135, 3140H (UK: 640 M40; Russia: 40XH); 1144, 1345, 1345H
(Germany: 46Mn27; Russia: 45Г2); 4340 (UK: 817A37, 818 M40;
Russia: 40X2H2MA) steel alloys. Thermal treatment of the steel after
hardening and low temperature tempering provides the martensite
structure of the material.
Steels such as chromium vanadium, chromium-molybdenum, nickel-
chromium and nickel-chromium molybdenum alloys 4130, 4130H (UK:
25CrMo4; Russia: 30XMA); 4340 (UK: 817A37, 818 M40; Russia:
40X2H2MA); 25H2N4WA (Poland) or 25X2H4MA (Russia),
38XH3MA (Russia) or SNC28 (Japan) are used for manufacturing
crankshafts for highspeed, high power diesel engines for various
applications.
 Crankshafts in marine, stationary, locomotive and tractor engines:
Crankshafts are often made by casting modified cast iron, such as 60-40-
18 (UK: EN-GJS-420-12; Russia: BЧ40) with a globular graphite and
pearlite-ferrite structure. Carbon steels and alloy steels may also be used
for this purpose.
Cast iron crankshafts are cheaper and less time consuming to manufacture than
those made from forged steel. Metal may be more economically used in
the casting process when the design of the crankshaft becomes more complex.
The wear resistance of the main and crankpin bearings increases due to the
presence of graphite in cast iron. The reliability of the crankshaft is also
improved due to the high cyclic strength of cast iron. However, it should be
noted that the mechanical strength of cast iron crankshafts is inferior to those
forged from steel and it is more difficult to determine internal casting defects.
When Babbitt bearings or hard alloys such as leaded bronze are used for
manufacturing bearing shells, heat treatment is used to obtain the high levels of
hardness required for increased wear resistance in the crankshaft journals.
Refference:
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