Crankshaft Turning - Machining - Grinding

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Great way to crankshaft machining with CNC machine. 

Excellent CNC factory machine performance

Channel: CAD/CAM SOLUTION, 60.4K subscribers

2020

https://www.youtube.com/watch?v=OthJkUfW54c

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2021

Video: 6 cylinder crankshaft factory | Manual Machining 6 Cylinders engine Crankshaft |

30 Sept 2021

https://www.youtube.com/watch?v=NIPX1m1nvuY

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Video: Production of Crankshafts in Factory Complete Process || Manual Machining 3 Cylinder Engine Crankshaft

21 Sep 2021

https://www.youtube.com/watch?v=-inYCr-fV3Q

Suggestions on the above process - I posted in Linkedin, and FaceBook

On Linkedin

Michel Baudin

Takt Times Group

It's wonderful of you to post this example. It's clearly a target-rich environment and great to use in classes.

It's wonderful of you to post this example. It's clearly a target-rich environment and great to use in classes.

More context would be helpful. From the video, we can infer quite a bit but it may not be correct. In particular, we don't know the company's pain points. Is it struggling with productivity, quality, delivery? Does it have many injuries? How is the employee turnover? Are they able to retain employees?

In terms of process technology, work methods, layout, flow, safety, etc., this shop looks 50 to 100 years behind the times. It also does not look like a company that can invest in state-of-the-art CNC lathes or would know how to use them.

On the other hand, they most likely could afford safety glasses, go/no-go gauges, posted work instructions, chucking that doesn't require manually tightening bolts, and powered positioning to replace cranks... And they could have a one-piece flow cell at least through the lathes and drill press.

Also, the video looks to be in fast motion. It's good to visualize the entire process but not for time studies.

The key question after that is where to start improving.

Comments On the video

yarrdayarrdayarrda

Seemingly primitive fixtures to drill the oil passages, and yet he hit the middle of the main journal, nice!

Jeff Yates

Saw the castings were Perkins, the way we do them in the States at Caterpillar and how they do it there shows how far we’ve come.  I am surprised Caterpillar has their subsidiary still do like Henry Ford did it in the 20’s

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Crank Shaft Design Issues

http://www.epi-eng.com/piston_engine_technology/crankshaft_design_issues.htm


Operations in Crank Shaft Machining

Machining           Description of machining                   CTQ characteristic pertaining
Operation no.      operation                                             to the machining operation


10                       Facing and centering     Center to center distance
                                         Diameter and chamfer angle of
                                         locating hole
20                        Milling of crankshaft web Flatness of web
30                        CNC Rough turning of journals Diameter of journal

40                        Whirling of pins    Phase-out of pins
                                    Throw of pins
                                    Pin diameter after whirling
                                    Journal diameter after whirling
50                        Finish turning of journals       Journal diameter after finish
turning
60                       Gun drilling of oil hole                Diameter of oil hole
70                       Finish turning of flange end   Diameter of flange
                                              Circularity of flange
80                      Drilling and tapping of bolt    Pitch circle diameter of bolt holes
                          holes over the PCD                Thread pitch of bolt holes
                                           
                                           
90                      Stub end boring and                Stub-end-hole diameter
                          chamfering using a                  Chamfer angle
                           combination boring-cum
                          chamfering  inserts tool bar
                                             
                                             
100                    Grinding of journals                       Finish diameter of journals
                                                                          Circularity of journals
110                     Grinding of pins              Finish diameter of pins
                                                                   Circularity of pins
120                    Detection of magnetic cracks         Check for internal cracks
130                    Sursulfing                           Hardeness of journals and pins
                                          after sursulfing operation
140                    Pins and journals lapping    Surface roughness of journals
                                           and pins after lapping
150                    Final inspection quality  check


2012
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WFL M60 MillTurn Complete Crankshaft Machining - MARTECH Machinery, NJ - USA
26 Jul 2012
https://www.youtube.com/watch?v=81UjjSH2iFw
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04 July 2011 / Categories: Archive, crankshafts
Modern crankshaft machining methods
https://www.highpowermedia.com/Archive/category/crankshafts/modern-crankshaft-machining-methods


Crank Shaft Grinder
12 May 2016
https://www.youtube.com/watch?v=zZyvxUERx8w

Amc Schou K-1200 CNC Crankshaft Grinder
30 Jan 2018
https://www.youtube.com/watch?v=esOa9DqcgJk

Details of the machine from manufacturer
http://amc-schou.dk/baixu/product/358.html

More videos

http://www.youtube.com/watch?v=7ngNipoENTs&feature=related

http://www.youtube.com/watch?v=taMV8CcszbE

How to Machining Crankshaft on Lathe (tips from MAXNOVO Machine)

Published on February 25, 2021

https://www.linkedin.com/pulse/a17-how-machining-crankshaft-lathe-tips-from-maxnovo-machine-gu/

Thesis chapter on grinding
http://shodhganga.inflibnet.ac.in/jspui/bitstream/10603/194947/11/11_chapter%205.pdf



Rough- and finish-grinding of a crankshaft in one set-up
Abstract
Method of grinding a concentrically clamped crankshaft, a crankshaft grinding machine for carrying out the method, and a crankshaft of high-alloy steel or cast material. The method provides for pin journals and main journals of the crankshaft to be ground in one set-up such that first, at least the main journals are rough-ground and then the pin journals are finish-ground and after that the main journals are finish-ground. The crankshaft grinding machine forms a machining center by means of which corresponding rough-grinding and finish-grinding is possible in a single set-up.

B24B5/42 Single-purpose machines or devices for grinding crankshafts or crankpins

Application US09/980,764 events: 1999-04-30
Application filed by Erwin Junker Maschinenfabrik GmbH: 2000-04-20
Assigned to ERWIN JUNKER MASCHINENFABRIK GMBH: 2004-02-20
Application granted: 2005-04-12
Publication of US6878043B1: 2020-02-29
Application status is Active: 2020-04-20

https://patents.google.com/patent/US6878043B1/en

Junker Products for Crankshaft Grinding

https://www.junker-group.com/junker-group/erwin-junker-maschinenfabrik-gmbh/crankshaft-grinding/

https://www.junker-group.com/grinding-machines/products/jucrank/

The JUNKER Group drives forward with digitalization

Process-optimized production with the digital twin

09/06/2019
Combining real and virtual machines results in an intelligent system able to predict characteristics and operating behavior from the production planning stage and throughout the product lifecycle. The digital twin for JUNKER grinding machines is a virtual representation of the real system, enabling comprehensive digital exchange between the virtual and real world.
https://www.junker-group.com/news/detail/news/process-optimized-production-with-the-digital-twin/


Reference machines for worldwide production
The Renault Group opts for JUNKER machines for hybrid project
07/29/2019
Prototype production takes place at the French main plant Cléon, where Renault have opted for the ZEMA NUMERIKA G 1500 Plus and the JUCRANK 6S 10-10. These two machines supply reference data for series production worldwide. The results then form the basis for global production at the Renault Group’s other sites. This means that the JUNKER reference machines set the standard for efficient production throughout the entire Group. The ZEMA NUMERIKA cylindrical grinding machine grinds flanges and journals for crankshafts in a single clamping set-up using corundum grinding wheels, while the JUCRANK non-cylindrical grinding machine machines the main and pin bearing in a single work step using CBN grinding wheels.
https://www.junker-group.com/news/detail/news/the-renault-group-opts-for-junker-machines-for-hybrid-project/


Hyundai Compact Line Center for Crankshaft Machining WH40RS
Video in the page demonstrates the working of the machine.
(See the video WFL M60 MillTurn Complete Crankshaft Machining - MARTECH Machinery, NJ - USA, 26 Jul 2012   https://www.youtube.com/watch?v=81UjjSH2iFw  also)

https://machine.hyundai-wia.com/eude/fa/product_detail.asp?PRODUCT_SEQ=33329&PRODUCT_CODE=D01008

Virtual machining in engine crankshaft machining

Lili Zhao, Lulu Yuan and Meng Wang
Published under licence by IOP Publishing Ltd
Journal of Physics: Conference Series, Volume 1176, Issue 5
https://iopscience.iop.org/article/10.1088/1742-6596/1176/5/052077/meta

Machines for Crankshaft Machining

Special -Purpose Machine for Crankshaft both end MBE
Special-Purpose Machine for Crankshaft Oil Holes MOH
Fixture for Crankshaft Oil Holes Machining CRANKMASTER Series
https://www.horkos.co.jp/english/products/mc/spm.php

2008 Developed the CNC crankshaft rough milling machine
2009 Developed the Crankshaft pin turner

HNK Machine Tools, Korea

http://www.hnkkorea.com/english/menu/company/sub3_1.htm

Updated on 14.2.2022,  25 Sep 2021,  29 Feb 2020, 3 February 2020.