Enginematerialscamshaftcrankshaft 130123030835 Phpapp01

Material and technology
for Automotive engine:

brief overview
o The camshaft
o The crankshaft
Materials and technology for automotive
engine
Catania, 06/07/2012, A.Manicone
The camshaft

engine
The camshaft -
The valve operating

mechanism transforms
rotation of the
crankshaft into reciprocating
motion in the valves.
The valves protrude into
the combustion chamber and
are pushed back by the
reactive force of the valve
spring.
camshaft= crankshaft/2
- camshaft high: contact pressure is reduced by the inertia of the valve lifter (oil is
providing hydrodynamic lubrication);
- camshaft low: contact pressure is highest and lubrication most challenging.
engine
The camshaft Machining, dimension

accuracy, clearance,
roughness
Lubricating oil
condition
Flaking
Pitting
Friction condition
1. Lubrication
2. Contact
3. Foreign object
Wear of sliding portion

1. Rugged surface due to
wear
2. Adhesive wear
3. Fatigue wear
4. Corrosive wear
(scagliatura)
(corrosione per vaiolatura)
It is very important to choose an appropriate combination of materials.

The torque from the crankshaft drives the camshaft: it must have high
torsional rigidity.
engine
The camshaft -
Chill hardening cannot be used where the gap between the cam lobes is
narrow because of the difficulty in using the chiller, so forged camshafts
are used.
Tough martensite
microstructure.
is
more
resistant
to
pitting
than
the
chill

engine
The camshaft Finishing boring and grinding
ASSEMBLING
E.g.: Hydroforming

engine
The crankshaft

engine
The crankshaft The crankshaft converts reciprocative motion to rotational

motion.
Two types:
the monolithic type
the assembled type

engine
The crankshaft Note:

Included lead or MnS
particles significantly
function as a chip
breaker and a solid
lubricant and increase
machinability.
Carbon steel
Alloyed
steel
Micro Alloyed steel
Typical materials
nodular cast iron: for high-volume,

low-load production.
forged steel: for fuel-efficient

engines requiring a high power-todisplacement ratio.
less expensive
lower rigidity: abnormal vibrations (resonance)
increases in rigidity of more than 10%

reduces noise levels and harshness
makes possible a careful design
more expensive

engine
The crankshaft STRESS on

Crankshaft
Static: combustion pressure, inertial

forces of the piston and con-rod,
bearing load and drive torque.
Dynamic: The vibration causes

dynamic stress. If it occurs at the
resonating
frequency,
the
deformation will be very high and
will instantly rupture the crankshaft.
Fatigue fracture of a carbon steel

S50C crankshaft
HIGH STATIC AND DYNAMIC RIGIDITY:

- increasing the crankpin diameter (increasing weight)
- using forged steel
- Surface-hardening methods
engine
Fatigue
survey
behaviour:
principles
Principi (macro)
Whler [1860]
Ampiezza
tensione
applicata
Vita finita
*
Leghe di
alluminio
104
Tipo di materiale
* Legge di Basquin:
a = f (2Nf)b
Tipici
Curva
tipica
acciai
per
acciai
Dipende da:
and
105
106
Vita infinita
107
Cicli alla rottura,

Nf
Concentrazione di
tensioni
Trattamento termico
superficiale
Contenuto di inclusioni e
impurezze
Tensione media e
tipo di sollecitazione

engine
The crankshaft HOT FORGING PROCESS (for a four-stroke crankshaft)
The coarse structure is broke down and is

replaced, as recrystallisation proceeds, by
one which is of relatively fine grain
Impuritires are redistribuited in a fibrous

form
Introduction of compressive residual stresses

engine
The crankshaft SURFACE HARDENING

(carburizing, nitring, carbonitring and nitrocarburizing):
CARBURIZING
O: origins
S: a few beachmarks
B: arrest lines
R: ratchet marks
Pitting observed at a crankpin surface

engine

CARBURIZING
Compressive residual stress

generated by carburizing

engine
The crankshaft Modern carburizing technology: Acetylene Vacuum Carburizing- AvaC
Steel
Fe
Cr
Mn
Acetile
ne
C
Siti di
adsorbimento
H
2
A. Manicone

engine
The crankshaft Avac - Adsorbimento

(T>Taustenitizzazione)
Steel
Fe
Cr
Mn
Acetile
ne
C
Siti di
adsorbimento
H
2
A. Manicone

engine
The crankshaft Avac - Decomposizione in

radicali
Steel
Fe
Cr
Mn
Acetile
ne
C
Siti di
adsorbimento
H
2
A. Manicone

engine
The crankshaft Avac - Inizio cementazione

Steel
Fe
Cr
Mn
Acetile
ne
C
Siti di
adsorbimento
H
2
A. Manicone

engine

Steel
Fe
Cr
Mn
Acetile
ne
C
Siti di
adsorbimento
H
2
A. Manicone

engine

Steel
Fe
Cr
Mn
Acetile
ne
C
Siti di
adsorbimento
H
2
A. Manicone

engine
The crankshaft Diffusione nellacciaio

Steel
Fe
Cr
Mn
Acetile
ne
C
Siti di
adsorbimento
H
2
A. Manicone

engine
The crankshaft Saturazione
Steel
Fe
Cr
Mn
Acetile
ne
C
Siti di
adsorbimento
H
2
A. Manicone

engine

NITRING: NH3
decomposes at the steel surface to catalytically generate elemental nitrogen,
which diffuses into the material. The nitrogen expands the iron lattice and also
forms hard compounds (the nitrides Fe4N and Fe3N) with iron atoms.
Nitridable steel reaches the necessary hardness by forming stable nitrides (Al, Cr,
V)
NITROCARBURIZING, CARBONITRURING
higher hardness surface,

but lower toughness
INDUCTION HARDENING

engine
The crankshaft RECENT TRENDS: Micro alloyed steel, via plasma ion nitring
Precipitation hardening is the main method for increasing strength at the
cooling stage after hot forging.
Micro-alloyed steel contains a small amount of V, which dissolves in the
matrix during hot forging above 1,200 C. During air cooling, the
dissolved V combines with carbon and nitrogen to precipitate as
vanadium carbide and nitride at around 900 C.
the vanadium
carbide and nitride will
be more finely
dispersed.

engine
The crankshaft Manufacturing process
Trade-off:
machinabilityfatigue resistance
Surface roughness
For low and medium loaded bearings: Ra = 15

microinch max. Rz = 60 microinch max.
For highly loaded bearings: Ra = 10 microinch
max. Rz = 30 microinch max.

engine
The crankshaft Conclusions: Methods to strengthen crankshafts

engine
Material and technology

for Automotive engine:
brief overview
Thanks for
attention
engine

Enginematerialscamshaftcrankshaft 130123030835 Phpapp01

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Formate disponibile

Material and technology

for Automotive engine:

Materials and technology for automotive

The valve operating

The camshaft Machining, dimension

Wear of sliding portion

(corrosione per vaiolatura)

It is very important to choose an appropriate combination of materials.

Materials and technology for automotive

The camshaft Finishing boring and grinding

Materials and technology for automotive

Materials and technology for automotive

The crankshaft The crankshaft converts reciprocative motion to rotational

Materials and technology for automotive

The crankshaft Note:

nodular cast iron: for high-volume,

forged steel: for fuel-efficient

lower rigidity: abnormal vibrations (resonance)

increases in rigidity of more than 10%

Materials and technology for automotive

The crankshaft STRESS on

Static: combustion pressure, inertial

Dynamic: The vibration causes

Fatigue fracture of a carbon steel

HIGH STATIC AND DYNAMIC RIGIDITY:

Cicli alla rottura,

Materials and technology for automotive

The crankshaft HOT FORGING PROCESS (for a four-stroke crankshaft)

The coarse structure is broke down and is

Impuritires are redistribuited in a fibrous

Introduction of compressive residual stresses

Materials and technology for automotive

The crankshaft SURFACE HARDENING

Materials and technology for automotive

The crankshaft SURFACE HARDENING

Compressive residual stress

Materials and technology for automotive

The crankshaft Modern carburizing technology: Acetylene Vacuum Carburizing- AvaC

Materials and technology for automotive

The crankshaft Avac - Adsorbimento

Materials and technology for automotive

The crankshaft Avac - Decomposizione in

Materials and technology for automotive

The crankshaft Avac - Inizio cementazione

Materials and technology for automotive

The crankshaft Avac - Inizio cementazione

Materials and technology for automotive

The crankshaft Avac - Inizio cementazione

Materials and technology for automotive

The crankshaft Diffusione nellacciaio

Materials and technology for automotive

The crankshaft Saturazione

Materials and technology for automotive

The crankshaft SURFACE HARDENING

higher hardness surface,

Materials and technology for automotive

Materials and technology for automotive

The crankshaft Manufacturing process

For low and medium loaded bearings: Ra = 15

Materials and technology for automotive

The crankshaft Conclusions: Methods to strengthen crankshafts

Materials and technology for automotive