Evaluation of a cast-joining process of dual metal crankshafts for heavy-duty engines with ductile cast iron and high strength forged steel

Abstract

Three unprecedented dual metal crankshafts for heavy-duty diesel engines up to 3,000 hp are proposed and thoroughly investigated by comprehensive multi-body dynamic finite element analysis and supporting experiments. The dual metal crankshafts are basically made of ductile cast iron and high strength forged steel, and the two dissimilar metals are proven to be seamless by a series of tensile tests using bimetallic specimens. The dual metal approach is made in order to achieve both cost effectiveness and shortened manufacturing lead time simultaneously. The new approach is basically realized by casting of ductile cast iron in a mold assembled with pre-machined steel parts. Historical researches and experiments already proved that the monometallic crankshaft of only ductile cast iron is not able to replace a conventional forged steel crankshaft. Therefore, casting-based crankshaft should be reinforced by high strength structures, especially for critical areas such as the fillets of crank pins and journals. Three dual crankshafts are designed to achieve equivalent structural strength not sacrificing manufacturing advantages of casting. The reinforcing members of forged steel are implemented in three ways for the three dual metal models. The first dual metal approach so-called BM1 crankshaft is to put barrel-shaped steel pipes in the center of both crank pins and journals to complement inferior mechanical properties of ductile cast iron, FCD700. The second duel metal approach named BM2 crankshaft uses reinforcing steel members more extensively than the first one does, putting forged steel pipes in the center and outside of crank pins and journals. The second model is more advanced than the first one because the second one effectively strengthens up the most critical areas of a crankshaft, the fillets of crank pins and journals, by the high strength steel. The third model designated as BM3 crankshaft is quite a bold approach to have only crank webs made of ductil...