Crankshaft is a dynamic component that copes with elevated alternating stresses. In order to ensure the service reliability, fillet rolling process is being applied. The state of the art empirical assumptions to consider the effect of fillet rolling process on crankshaft fatigue are conservative. This leads to an over-engineering of the crankshaft. However, calculation of the compressive residual stresses due to surface treatment is a demanding task. The quality of the durability analysis can only be increased by an accurate consideration of the fillet rolling effect. Therefore, Hegenscheidt-MFD, FEV Motorentechnik and Institute for Combustion Engines (VKA) cooperated to enlighten the phenomenon of the fillet rolling process. Process calculations are applied and validated by the measurements and tests. The calculated residual stresses are then superposed with the dynamic loads calculated by FEV Virtual Engine. The calculations are applied based on a state of the art inline four cylinder gasoline engine. The results show that there is an increase in safety factors even more than a factor of 2.5, in case of spheroidal cast iron.
Potentials of Crankshaft Fillet Rolling Process
Sae Int. J. Engines
SAE 2012 World Congress & Exhibition ; 2012
Sae International Journal of Engines ; 5 , 2 ; 622-632
2012-04-16
11 pages
Conference paper
English
Potentials of Crankshaft Fillet Rolling Process
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