Straight face crankshaft manufacturing technology and special process

The advanced crankshaft processing lines are typically compact in size but highly efficient, with large output and excellent product quality. For example, the crankshaft production line at Ford's engine plant in the United States consists of only 17 processes and occupies an area of 6,967 square meters, yet it can produce 535,000 ductile iron V8 crankshafts annually. The technological advancement is mainly reflected in two aspects: first, a large number of CNC-controlled systems are used to create a flexible production line; second, high-speed, high-efficiency, and flexible machining technologies are applied to simplify the process, improve processing quality, and reduce single-piece processing time. Additionally, to meet cost-reduction demands, many crankshaft manufacturers have started to implement more advanced techniques. In contrast, most production lines in China still lag behind.  Advanced machining technology and equipment play a crucial role in improving the precision and efficiency of crankshaft manufacturing. One key aspect is the drilling quality and center hole technology. Crankshafts are slender parts, and the main positioning reference during machining is the center hole at both ends. There are two types of center holes: geometric center holes, which are based on the geometric center, and mass center holes, which are determined by the actual mass distribution. While Chinese production lines often use geometric center holes, foreign countries prefer mass center holes to minimize imbalance and improve machining accuracy. This technique involves specialized equipment to measure and machine the true mass center, leading to better performance and longer service life. CNC car pulling technology is widely used abroad for semi-finishing crankshaft journals and connecting rod journals. It includes three forms: straight-line pull, inner-ring tool rotary pull, and outer-ring tool rotary pull. CNC high-speed external milling is particularly efficient for machining the side of balance blocks, offering higher speed, shorter cycle times, and better surface finish compared to traditional methods.  CNC internal milling is another advanced method, especially suitable for forged steel crankshafts due to its chip-breaking capability and rigidity. The grinding process has also evolved, with the use of CBN (Cubic Boron Nitride) wheels allowing higher speeds and better surface quality. Conventional grinding methods are being replaced by more flexible and efficient options like composite machining, where multiple journals can be ground in one operation. Gun drilling technology is essential for deep oil hole machining, particularly for forged steel crankshafts. Gun drills are capable of producing precise, straight holes with minimal retraction, thanks to their internal cooling and chip evacuation systems. Special drill bushes and cutting fluids are used to ensure accuracy and durability. Rounded corner rolling technology enhances the fatigue strength and surface quality of crankshafts by applying pressure to the fillets, creating compressive stresses that increase durability. Similarly, abrasive belt polishing improves surface finish, removes burrs, and enhances wear resistance, making it a vital step in the final stages of crankshaft production. These advanced technologies not only improve the quality and efficiency of crankshaft manufacturing but also set new standards for precision, reliability, and cost-effectiveness in the automotive industry.

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