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Previously part
machined by competitor
& abandoned |
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In-Situ picked
up the pieces & this is the end result |
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Peen
straightening a bent shaft |
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End result after
removing 17mm on Ø |
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Machining by
tooling method (not grinding).
For fast stock removal |
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Blackstone K
Major machined back to
makers standards |
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Setting false
ring with computerised levels at sea due to damaged fillet radii |
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Machining in
progress on heat affected pin, distinguished by the shiny areas |
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Superfinishing
operation in progress |
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Crack detection
by Magnaflux |
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Inspection using
Equotip to detect hardness |
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Damaged Ø and
keyway of a timing gear journal |
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Machining of
journal Ø in progress |
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Milling of new
keyway |
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Completed Ø and
keyway |
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Grinding of main
bearing journal |
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Finished journal
back to standard |
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CRANKPIN
REPAIRS
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Full range of
equipment for Orbital machining, superfinishing and polishing
journals in the range 100mm to 1075mm in diameter
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Shaft
straightening can also be performed using the OEM recognised
method of Peene straightening
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Quality in
accordance with OEM tolerances, i.e. for Crankshaft Journals
0.15mm/metre straightness to shaft axis, 0.02mm roundness and
parallel. Surface finish better than 0.2µm Ra
CRANKPIN MACHINING PROCESS
In the event
of Fillet Radii damage & hard spots caused by a severe
seizure
| 1 |
Mask
area/Plug oil holes to prevent contamination |
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| 2a |
Take
Measurements and record |
| 2b |
Hardness/MPI check and record |
| 2c |
Grind
hard spots to establish depth and record |
| 2d |
Determine final target size with recorded information |
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| 3a |
Fit
False Ring and set with computerised levels |
| 3b |
Install Orbital machine and frequency controlled motor |
| 3c |
Recut
damaged Fillet radii |
| 3d |
Remove
Orbital machine and False Ring |
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| 4 |
Re-Install Orbital machine |
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| 5 |
Machine Crankpin diameter |
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| 6 |
Re-check hardness and MPI to verify final target size is
obtainable |
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| 7 |
Machine Fillet radii |
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| 8 |
Polish
Fillet radii |
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| 9 |
Polish
Oil hole radii |
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| 10 |
Superfinish Crankpin diameter |
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| 11 |
Polish
Crankpin diameter |
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| 12 |
Remove
Orbital machine |
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| 13 |
Clean
area |
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| 14 |
Remove
masking/plugs for oil holes |
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| 15 |
Take
final measurements/record and sign off |
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CRANKPIN
CONTROL METHODS
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Axis tolerances achieved by electronically controlled level
system
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Diameter
controlled by calibrated micrometer, measured and recorded
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Flatness controlled by engineers' blue and straight edges
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Crack detection via Magnetic Particle Inspection system
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Hardness
checked using portable electronic device
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All data recorded
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