If you suspect there is an issue with your crankshaft, replacement may be your first choice option. Crankshaft replacement can be a complicated, costly and time-consuming process, so to help you better understand it we have created a quick guide to crankshaft replacement and repair below…
1. Find the fault
The first step to crankshaft repair is to find the fault, or the malfunctioning component causing the damage. To locate the problem, a failure assessment and inspection must be completed. The assessment involves multiple tests which analyse the severity of the system failure and look for cause. Once the assessment is complete, the correct crankshaft repair plan can be created .
2. Remove damage
Next, a specialist machine is used to grind or machine the crankshaft diameter. This is done to remove any wear or damage from the crankshaft that may be causing it to operate inefficiently.
3. Flatten the surface of the crankshaft
To ensure flatness of the surface of the crankshaft, a superfinishing machine is used. A carborundum stone oscillates from side to side around 30 times a second to smooth and flatten the surface of the crankshaft. This should be completed after the machining process and using a specialist piece of equipment to hold the carborundum stone.
4. Polish the crankshaft
The best way to ensure the flatness of the crankshaft and the correct geometric tolerance is by machine polishing.
Other steps that may be required dependant upon the severity of the repair…
The below steps are not essential to crankshaft repair but may be required depending on the condition of the crankshaft.
• Heat treatment
If your failure assessment has unveiled you need to reduce heat-induced hardness for your crankshaft, a heat treatment service must be completed. The service involves controlled heating, soaking, and cooling with ceramic blankets acting as an annealing process.
• Peen straightening
To help reduce stress-induced bend within a crankshaft, peen straightening may be required. Peen straightening reduces stress on the crankshaft and involves using a peening hammer to strike the crankshaft's journal.
In-Situ are global industry leaders for crankshaft rebuilding. Rather than trying to repair a crankshaft in-house, or trust a sub-par company, contact In-Situ to provide a crankshaft repair service. Our advanced experience and equipment allow us to efficiently repair large crankshafts for mining, power generation, marine and transportation companies, to name but a few of the industries we work in. Whether your crankshaft rebuild repair is planned, or an emergency situation, we are the team you can trust to deliver a highly professional and quality on-site machining service.