US20060266492A1 - Method for manufacturing crankshafts - Google Patents
Method for manufacturing crankshafts Download PDFInfo
- Publication number
- US20060266492A1 US20060266492A1 US11/136,414 US13641405A US2006266492A1 US 20060266492 A1 US20060266492 A1 US 20060266492A1 US 13641405 A US13641405 A US 13641405A US 2006266492 A1 US2006266492 A1 US 2006266492A1
- Authority
- US
- United States
- Prior art keywords
- abrasion
- resistant
- cam rings
- crankshaft
- mold set
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 238000000034 method Methods 0.000 title claims abstract description 14
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 11
- 238000005299 abrasion Methods 0.000 claims abstract description 34
- 238000002844 melting Methods 0.000 claims abstract description 12
- 230000008018 melting Effects 0.000 claims abstract description 12
- 239000002184 metal Substances 0.000 claims abstract description 11
- 229910052751 metal Inorganic materials 0.000 claims abstract description 11
- 239000000463 material Substances 0.000 claims abstract description 9
- 229910001018 Cast iron Inorganic materials 0.000 claims abstract description 6
- 229910000851 Alloy steel Inorganic materials 0.000 claims abstract description 5
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims abstract description 5
- 229910001567 cementite Inorganic materials 0.000 claims abstract description 5
- 238000005266 casting Methods 0.000 claims description 13
- 238000003754 machining Methods 0.000 claims description 4
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- 230000002860 competitive effect Effects 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 230000009189 diving Effects 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
Images
Classifications
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01L—CYCLICALLY OPERATING VALVES FOR MACHINES OR ENGINES
- F01L1/00—Valve-gear or valve arrangements, e.g. lift-valve gear
- F01L1/02—Valve drive
- F01L1/04—Valve drive by means of cams, camshafts, cam discs, eccentrics or the like
- F01L1/047—Camshafts
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D19/00—Casting in, on, or around objects which form part of the product
Definitions
- the present invention relates to crankshafts and more particularly to a method for manufacturing crankshafts.
- crankshaft is an important element to output diving power of vehicle engines.
- the conventional method for manufacturing crankshafts generally includes forming a cavity in the shape of a crankshaft in a mold set resistant to high temperature; then pouring a melting metal into the cavity that is cooled and solidified to form a crankshaft; and the cams of the crankshaft are machining by grinding to form the finished crankshaft of the vehicle engine.
- crankshafts for the engines are produced by chill casting or from FCD700 materials.
- the lower shaft made from the FC material by chill casting is easily ruptured when used in heavy loading or severe conditions.
- the FCD700 materials cannot withstand high temperature, and abrasion wearing occurs after used for a period of time. As a result, the engine power diminishes, and noise occurs. Replacement has to be done periodically. It is costly.
- the present invention aims to provide an abrasion-resistant and more permanently durable crankshaft to meet market requirements.
- the primary object of the present invention is to provide a method for manufacturing crankshafts that have a greater abrasion-resistance and precision without increasing cost.
- the method for manufacturing crankshafts of the invention aims to fabricate a crankshaft.
- the crankshaft has a shaft portion and a plurality of abrasion-resistant cam rings.
- the method includes the steps of:
- Each of the abrasion-resistant cam rings has an aperture.
- the mold set which consists of two mold elements coupled together to form a casting orifice.
- the mold set has a housing chamber formed in the shape of the crankshaft communicating with the casting orifice.
- FIG. 1 is a schematic view of the crankshaft of the present invention.
- FIG. 2 is a manufacturing process flow of the present invention.
- FIG. 3 is a schematic view of the abrasion-resistant cam ring of the present invention.
- FIG. 4 is a schematic view of a mold set of the present invention.
- FIG. 5 is a schematic view of placing the abrasion-resistant cam ring in the mold set according to the present invention.
- the method for manufacturing crankshafts according to the invention aims to fabricate a crankshaft 10 .
- the crankshaft 10 includes a shaft portion 20 made from a FCD45 high flexible-resistant casting iron and a plurality of abrasion-resistant cam rings 30 made from a steel alloy of high chrome iron-carbide.
- the manufacturing method includes steps 2 A- 2 E as follow:
- Step 2 A Fabricate the abrasion-resistant cam rings 30 each has an aperture 301 .
- Step 2 B Fabricate a mold set 40 which consists of two mold elements 401 that are coupled together to form a casting orifice 402 .
- the mold set 40 has a housing chamber 403 formed according to the crankshaft 10 .
- the housing chamber 403 communicates with the casting orifice 402 .
- Step 2 C Place the abrasion-resistant cam rings 30 in the housing chamber 403 of the mold set 40 .
- Step 2 D Pour a melting metal (not shown in the drawings) formed by a FCD45 high flexible-resistant cast iron into the mold set 40 through the casting orifice 402 to fill the apertures 301 of the abrasion-resistant cam rings 30 to form the shaft portion 20 .
- Step 2 E Solidify the melting metal and remove the rough blank of the crankshaft 10 from the mold set 40 .
- each of the abrasion-resistant cam rings 30 may have a positioning boss 302 .
- the housing chamber 403 has a plurality of cavities 404 corresponding to the positioning bosses 302 so that the abrasion-resistant cam rings 30 may be placed in the housing chamber 403 of the mold set 40 on precise locations. After the rough blank of the crankshaft 10 is produced, the bosses 302 may be removed by grinding.
- the material used in fabricating the abrasion-resistant cam rings 30 of the invention is a steel alloy such as high chrome iron-carbide that is abrasion-resistant and can withstand the high temperature of the melting metal without lowering the hardness.
- the shaft portion 20 is made by melting FCD45 high flexible-resistant cast iron.
- the crankshaft 10 thus formed is made from two types of materials, in which the material of the abrasion-resistant cam rings 30 (steel alloy of high chrome iron-carbide) can withstand abrasion wearing, and the material of the shaft portion 20 (FCD45 high flexible-resistant cast iron) can facilitate machining with a high flexibility without fracturing.
- the manufacturing method of the invention makes machining easier without increasing the cost, and the cams can be permanently durable without wearing.
- the shaft portion 20 can be used safely even in the heavy duty and severe conditions to maintain the engine in an optimum performance condition. It can save a lot of cost for consumers, and the product is more competitive in the market place.
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Shafts, Cranks, Connecting Bars, And Related Bearings (AREA)
Abstract
A method for manufacturing abrasion-resistant crankshafts including: first, forming a plurality of abrasion-resistant cam rings from an abrasion-resistant material such as a steel alloy of high chrome iron-carbide; placing the abrasion-resistant cam rings in a mold set on desired locations; pouring a melting metal formed by FCD45 high flexible-resistant cast iron into the mold set to form a shaft portion to couple with the abrasion-resistant cam rings; and solidifying the melting metal to become a crankshaft that is abrasion-resistant and flexible-resistant. The crankshaft thus formed can be used in heavy duty and severe conditions without wearing and fracturing.
Description
- The present invention relates to crankshafts and more particularly to a method for manufacturing crankshafts.
- A crankshaft is an important element to output diving power of vehicle engines. The conventional method for manufacturing crankshafts generally includes forming a cavity in the shape of a crankshaft in a mold set resistant to high temperature; then pouring a melting metal into the cavity that is cooled and solidified to form a crankshaft; and the cams of the crankshaft are machining by grinding to form the finished crankshaft of the vehicle engine.
- Most known vehicle manufacturers in the world fabricate the crankshafts for the engines by chill casting or from FCD700 materials. The lower shaft made from the FC material by chill casting is easily ruptured when used in heavy loading or severe conditions. The FCD700 materials cannot withstand high temperature, and abrasion wearing occurs after used for a period of time. As a result, the engine power diminishes, and noise occurs. Replacement has to be done periodically. It is costly. In view of the foregoing concerns, the present invention aims to provide an abrasion-resistant and more permanently durable crankshaft to meet market requirements.
- Therefore the primary object of the present invention is to provide a method for manufacturing crankshafts that have a greater abrasion-resistance and precision without increasing cost.
- The method for manufacturing crankshafts of the invention aims to fabricate a crankshaft. The crankshaft has a shaft portion and a plurality of abrasion-resistant cam rings. The method includes the steps of:
- First, fabricate a plurality of the abrasion-resistant cam rings by casting. Each of the abrasion-resistant cam rings has an aperture.
- Next, fabricate a mold set which consists of two mold elements coupled together to form a casting orifice. The mold set has a housing chamber formed in the shape of the crankshaft communicating with the casting orifice.
- Place the abrasion-resistant cam rings in the housing chamber of the mold set.
- Pour a melting metal formed by a FCD45 high flexible-resistant cast iron into the mold set through the casting orifice to fill the apertures of the abrasion-resistant cam rings to form the shaft portion.
- Finally, solidify the melting metal and remove the rough blank of the crankshaft from the mold set.
- The foregoing, as well as additional objects, features and advantages of the invention will be more readily apparent from the following detailed description, which proceeds with reference to the accompanying drawings.
-
FIG. 1 is a schematic view of the crankshaft of the present invention. -
FIG. 2 is a manufacturing process flow of the present invention. -
FIG. 3 is a schematic view of the abrasion-resistant cam ring of the present invention. -
FIG. 4 is a schematic view of a mold set of the present invention. -
FIG. 5 is a schematic view of placing the abrasion-resistant cam ring in the mold set according to the present invention. - Please referring to
FIGS. 1 through 5 , the method for manufacturing crankshafts according to the invention aims to fabricate acrankshaft 10. Thecrankshaft 10 includes ashaft portion 20 made from a FCD45 high flexible-resistant casting iron and a plurality of abrasion-resistant cam rings 30 made from a steel alloy of high chrome iron-carbide. The manufacturing method includessteps 2A-2E as follow: -
Step 2A: Fabricate the abrasion-resistant cam rings 30 each has anaperture 301. -
Step 2B: Fabricate amold set 40 which consists of twomold elements 401 that are coupled together to form acasting orifice 402. Themold set 40 has ahousing chamber 403 formed according to thecrankshaft 10. Thehousing chamber 403 communicates with thecasting orifice 402. -
Step 2C: Place the abrasion-resistant cam rings 30 in thehousing chamber 403 of the mold set 40. -
Step 2D: Pour a melting metal (not shown in the drawings) formed by a FCD45 high flexible-resistant cast iron into the mold set 40 through thecasting orifice 402 to fill theapertures 301 of the abrasion-resistant cam rings 30 to form theshaft portion 20. -
Step 2E: Solidify the melting metal and remove the rough blank of thecrankshaft 10 from the mold set 40. - In the
crankshaft 10 fabricated according to the method of the invention previously discussed, each of the abrasion-resistant cam rings 30 may have apositioning boss 302. Thehousing chamber 403 has a plurality ofcavities 404 corresponding to thepositioning bosses 302 so that the abrasion-resistant cam rings 30 may be placed in thehousing chamber 403 of the mold set 40 on precise locations. After the rough blank of thecrankshaft 10 is produced, thebosses 302 may be removed by grinding. - The material used in fabricating the abrasion-
resistant cam rings 30 of the invention is a steel alloy such as high chrome iron-carbide that is abrasion-resistant and can withstand the high temperature of the melting metal without lowering the hardness. Theshaft portion 20 is made by melting FCD45 high flexible-resistant cast iron. Thecrankshaft 10 thus formed is made from two types of materials, in which the material of the abrasion-resistant cam rings 30 (steel alloy of high chrome iron-carbide) can withstand abrasion wearing, and the material of the shaft portion 20 (FCD45 high flexible-resistant cast iron) can facilitate machining with a high flexibility without fracturing. The manufacturing method of the invention makes machining easier without increasing the cost, and the cams can be permanently durable without wearing. Theshaft portion 20 can be used safely even in the heavy duty and severe conditions to maintain the engine in an optimum performance condition. It can save a lot of cost for consumers, and the product is more competitive in the market place.
Claims (5)
1. A method for manufacturing crankshafts to fabricate a crankshaft which has a flexible-resistant shaft portion to facilitate machining and a plurality of abrasion-resistant cam rings, the method comprising the steps of:
fabricating the abrasion-resistant cam rings each having an aperture;
fabricating a mold set which consists of two mold elements coupled together to form a casting orifice, the mold set has a housing chamber formed according to the crankshaft that communicates with the casting orifice;
placing the abrasion-resistant cam rings in the housing chamber of the mold set on desired locations;
pouring a melting metal into the mold set through the casting orifice to fill the apertures of the abrasion-resistant cam rings to form the shaft portion; and
solidifying the melting metal and removing the crankshaft from the mold set.
2. The method of claim 1 , wherein each of the abrasion-resistant cam rings has a positioning boss, the housing chamber having a plurality of cavities corresponding to the positioning bosses to allow the abrasion-resistant cam rings to be positioned on desired locations, the positioning bosses being removed by grinding after the crankshaft has been removed from the mold set.
3. The method of claim 1 , wherein the abrasion-resistant cam rings are made from a high abrasion-resistant material.
4. The method of claim 3 , wherein the abrasion-resistant cam rings are made from a steel alloy of a high chrome iron-carbide.
5. The method of claim 1 , wherein the melting metal is FCD45 high flexible-resistant cast iron.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US11/136,414 US20060266492A1 (en) | 2005-05-25 | 2005-05-25 | Method for manufacturing crankshafts |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US11/136,414 US20060266492A1 (en) | 2005-05-25 | 2005-05-25 | Method for manufacturing crankshafts |
Related Parent Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| US10/914,629 Continuation US20060036251A1 (en) | 2004-08-09 | 2004-08-09 | Systems and methods for the fixation or fusion of bone |
Related Child Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| US12/960,857 Continuation-In-Part US8470004B2 (en) | 2004-08-09 | 2010-12-06 | Apparatus, systems, and methods for stabilizing a spondylolisthesis |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| US20060266492A1 true US20060266492A1 (en) | 2006-11-30 |
Family
ID=37461944
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| US11/136,414 Abandoned US20060266492A1 (en) | 2005-05-25 | 2005-05-25 | Method for manufacturing crankshafts |
Country Status (1)
| Country | Link |
|---|---|
| US (1) | US20060266492A1 (en) |
Cited By (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2013001067A1 (en) * | 2011-06-30 | 2013-01-03 | Thyssenkrupp Presta Teccenter Ag | Camshaft with axially movable cam pack |
| US20130042990A1 (en) * | 2008-04-12 | 2013-02-21 | Schaeffler Technologies AG & Co. KG | Shaft with roller bearing |
| CN108273977A (en) * | 2018-01-31 | 2018-07-13 | 新疆金风科技股份有限公司 | Axis with wear ring and its manufacturing method |
| CN109562444A (en) * | 2016-08-23 | 2019-04-02 | 阿伯梅克斯可变动资本额公司 | The manufacturing process of camshaft with the functional component as assembled insert and the camshaft obtained using it |
| CN111531132A (en) * | 2020-05-30 | 2020-08-14 | 张明杰 | Transmission crankshaft forming and casting die |
| CN112901640A (en) * | 2021-01-14 | 2021-06-04 | 溧阳市新力机械铸造有限公司 | Gear alloy shaft and preparation method thereof |
Citations (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US5620042A (en) * | 1993-06-30 | 1997-04-15 | Kelsey-Hayes Company | Method of casting a composite disc brake rotor |
-
2005
- 2005-05-25 US US11/136,414 patent/US20060266492A1/en not_active Abandoned
Patent Citations (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US5620042A (en) * | 1993-06-30 | 1997-04-15 | Kelsey-Hayes Company | Method of casting a composite disc brake rotor |
Cited By (12)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US20130042990A1 (en) * | 2008-04-12 | 2013-02-21 | Schaeffler Technologies AG & Co. KG | Shaft with roller bearing |
| WO2013001067A1 (en) * | 2011-06-30 | 2013-01-03 | Thyssenkrupp Presta Teccenter Ag | Camshaft with axially movable cam pack |
| WO2013001060A1 (en) * | 2011-06-30 | 2013-01-03 | Thyssenkrupp Presta Teccenter Ag | Camshaft with an axially displaceable cam pack |
| CN103688026A (en) * | 2011-06-30 | 2014-03-26 | 蒂森克虏伯普里斯塔科技中心股份公司 | Camshaft with an axially displaceable cam pack |
| CN103764317A (en) * | 2011-06-30 | 2014-04-30 | 蒂森克虏伯普里斯塔科技中心股份公司 | Camshaft with axially movable cam pack |
| US9261177B2 (en) | 2011-06-30 | 2016-02-16 | Thyssenkrupp Presta Teccenter Ag | Camshaft with axially movable cam pack |
| US9273765B2 (en) | 2011-06-30 | 2016-03-01 | Thyssenkrupp Presta Teccenter Ag | Camshaft with an axially displaceable cam pack |
| US9534674B2 (en) | 2011-06-30 | 2017-01-03 | ThyssenKrupp Presta TecCener AG | Camshaft having an axially displaceable cam pack |
| CN109562444A (en) * | 2016-08-23 | 2019-04-02 | 阿伯梅克斯可变动资本额公司 | The manufacturing process of camshaft with the functional component as assembled insert and the camshaft obtained using it |
| CN108273977A (en) * | 2018-01-31 | 2018-07-13 | 新疆金风科技股份有限公司 | Axis with wear ring and its manufacturing method |
| CN111531132A (en) * | 2020-05-30 | 2020-08-14 | 张明杰 | Transmission crankshaft forming and casting die |
| CN112901640A (en) * | 2021-01-14 | 2021-06-04 | 溧阳市新力机械铸造有限公司 | Gear alloy shaft and preparation method thereof |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| AS | Assignment |
Owner name: WORLD WILD ENTERPRISE CO., LTD., TAIWAN Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:WU, KUNG-HU;REEL/FRAME:016606/0955 Effective date: 20050505 |
|
| STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |