The causes, inspections, and repairs of crankshaft cracks and breaks in diesel generator sets are as follows:
First, the reason
1. When grinding the journal, there is no certain fillet between the journal and the crank arm (general requirements for the fillet of the journal is between 1 and 3 mm) causing stress concentration and the crankshaft to break.
2. The clearance of the bearing is too large or the alloy falls off, causing the impact load to increase.
3. Fatigue damage occurs after long-term crankshaft work.
4, the crankshaft is often running at the critical speed.
5, cylinder block deformation, crankshaft bearing seat is not correct, repair crankshaft bearings when the crankshaft bearing seat hole is not on an axis.
6. The oil passage is not smooth, and the crankshaft is in semi-dry friction state, causing the crankshaft to break.
7, poor crankshaft material or manufacturing defects.
8. The balance of the crankshaft is destroyed, and the crankshaft is subjected to a large inertial impact, causing the crankshaft to fatigue and breaking.
Second, crankshaft cracks occur in the connecting rod journal or crankshaft and crankshaft journal joint, the inspection method is as follows:
1, magnetic detection method
To check with a magnetic flaw detector, first magnetize the crankshaft with a magnetic flaw detector, and then spread the iron powder over the part to be inspected. At the same time, tap the crankshaft lightly with a small hammer. If cracks are found, the iron powder will accumulate in the middle. There are clear crack lines.
2. Hammer method
First remove the oil adhered to the surface of the crankshaft, then use kerosene or diesel to dip the entire crankshaft, remove the crankshaft and wipe it clean. Finally, support the two ends of the crankshaft on the wooden frame and gently tap each crankshaft with a hammer. arm. If a "squeaky" coherent sharp metal sound is emitted, it indicates that the crankshaft has no cracks; if the sound of the "wave" sounds inconsistently and quickly, the metal sound indicates that the crankshaft is cracked. Then, cracks appear in the vicinity of this area, and they can be seen with an eye or with a magnifying glass. If a spot where the oil appears or becomes a black line is found, it is a crack.
3, powder method
After the crankshaft is washed with kerosene or diesel oil and dried, a layer of talcum powder is evenly coated on the surface of the crankshaft, and then the crank arm is tapped with a hammer. If there is a crack in the crankshaft, the oil will seep out and make the talcum powder on the crankshaft surface become Yellow brown, you can find the crack.
4, lime milk
Wash the crankshaft and immerse it in hot oil (oil) for about 2 hours. Allow the oil to enter the cracks. After taking out and drying, spray the lime emulsion on the crankshaft to dry it with a spray gun. (Lime emulsion is a mixture of clean chalk and alcohol. ), when chalk absorbs the oil stored in the cracks, it turns dark and shows a cracked shape.
Third, the crankshaft crack, broken repair can be used "weld repair" method to repair, the process points are as follows:
1. The crankshaft is first washed and cleaned in alkaline water to remove the oil stains. Then a chisel knife is used to cut the U-shaped grooves along the crack surface. It is better to not see cracks in the groove depth. The bottom of the groove is arc-shaped, and the width of the groove should be determined according to the depth, length and shape of the crack. Then correct it so that the bending deflection of the crankshaft does not exceed the specified range. Finally, the crankshaft is mounted on a welding frame or mounted on a cylinder block, and an iron lining between the crankshaft and the welding frame or the cylinder block is provided. The bearing cover is then bolted to prevent bending of the crankshaft during welding. If the broken crankshaft is welded, it is necessary to find the center seam according to the broken original marks of the crankshaft, use the electric welding to weld the points on both sides of the fracture joint first, and then weld after the slots are not spot welded on both sides.
2. Heat the welding flame to 350~450°C in the welding area, and then use a low carbon steel electrode with a diameter of 3~4mm for welding. When welding, using the butt welding method, after welding a layer, remove the welding slag and re-weld the next layer.
3, after welding, welding repair flat at first, drill through the oil channel, check the welding place for cracks, there is no deformation of the crankshaft.
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