Crankshaft grinding machine

Types of crankshaft grinding machines

The purpose of a crankshaft grinding machine is to ensure that engine parts function optimally by correcting any defects or leveling any irregularities on the surface of the crankshaft. However, the machine that performs this task does not have a uniform shape or function. In fact, there are four primary types of crankshaft grinding machines/models, determined by how the main grinding wheel and crankshaft are positioned and move. Let's take a look.

• Vertical/mill-type machine:

This machine has a vertically-oriented spindle that holds the grinding wheel. The wheel grinds the crankshaft as the latter moves in a downward or upward direction. It is more common in large capacity workshops due to its simplicity of use, efficiency and ability to grind complex products. Typically, this type of crankshaft grinding machine is organized by horizontal planes. Therefore, everything is flat and level, making it reasonably easy to use an automated welding head or other similar kinds of machinery to create a seamless operating system.

• Universal-type machine:

This kind of crankshaft bush grinding machine has a slightly different setup. The main grind wheel holder's spindle is oriented horizontally. Some designs allow working head spindles to be positioned vertically. In this case, the grinding is performed by rotating the crankshaft in a horizontal direction. The universal type of crankshaft grinding machine is suitable for almost any kind of workpiece because it features a T-slotted table that can hold up fixtures and tools that can process any workpiece, be it irregularly shaped or of standard shape and size, as well as come with a D.C. servomotor that allows it to precisely control the radius of the workpiece being dealt with.

• Semi-automatic crankshaft grinding machine:

This machine has both manual and automated features, allowing operators to control some aspects while benefiting from automated precision during certain steps. In addition to being easier to use than entirely manual devices, semi-automatic devices fulfill similar application needs and are commonly used in places like large-scale production facilities, industrial factories, and automotive repair service centers where diesel engines are regularly repaired and maintained. In these environments, machinery, equipment, and tools must be up to professional-grade standards to ensure long-lasting use, satisfy customer demands and produce high levels of efficiency with every diesel engine being worked on.

• Fully automatic crankshaft grinding machine:

The difference between full-automatic and semi-automatic is that the former operates solely under computer control. This kind of crankshaft grinding machine is more advanced and effortless. In this case, it may have a loar-formed belt that works by grinding rather than by another method, such as involving a laser or any other means of changing the shape of the crankshaft being polished or leveled.

Specification and maintenance

The following are some specifications to consider when purchasing a crankshaft grinding machine:

• Max Length

  This parameter indicates the maximum length the machine can grind. Typically, the max length ranges from 1,500 mm to 6,000 mm.

• Max Diameter

  The max diameter the machine can handle. The maximum diameter of most machines is between 400 mm and 600 mm.

• Power

  This parameter shows the machine's motor power. It usually ranges from 15 kw to 30 kw.

• Weight

  The weight of a crankshaft grinder machine varies depending on its size. A large crankshaft grinding machine may weigh over ten tons.

• Precision

  Crankshaft grinding machines have different types of precision. For example, some have a repair precision of +/- 0.03mm, while others can achieve +/- 0.01 mm or better.

Maintenance

Some manufacturers request regular maintenance services for the crankshaft grinding machine to ensure long-lasting and optimal performance. Upon delivery, ensure the machine is set up in the correct location away from any potential hazards. Before any maintenance, ensure power disconnections and observe safety precautions. Carry out regular lubrication and oiling of the moving parts to reduce wear and tear. Grind any replacing parts smoothly to create an even fit. Over time, bolts and nuts loosen and become defective. Tighten these fastenings securely to provide solid sealing. Develop a routine cleaning process to wipe down the machine and remove any accumulated debris, dust, or water. Carry out regular inspections of the belt to check for any signs of wear. Replace defective parts immediately to maintain optimal performance.

Industry Applications of a Crankshaft Grinding Machine

The primary purpose of a crankshaft grinder is to restore the surface of the crankshaft by removing any damages, such as rough spots, over-wear, and nicks. The crankshaft may also be resized to match the bearing's specifications and to re-establish a perfectly round shape.

These machines are used in the following industries:

• The automotive industry extensively uses crankshaft grinding machines to repair and redefine the shape of crankshafts for different vehicles. The machine thus helps in providing a cost-efficient solution to replace rather than repair an existing engine's component.
• Diesel and Heavy Equipment Industry: Crankshaft grinding machines are invaluable assets in the diesel and heavy equipment industry. Large diesel engines power a significant portion of the heavy equipment sector—from construction machinery to mining and agriculture. The machines are used to maintain these colossal, essential engines, ensuring they run smoothly and reliably.
• The Machine Tool Industry also utilizes crankshaft grinding machines to manufacture new and smaller machines used for various functions, including industrial ones. The durable and robust material makes for great material when manufacturing smaller and handier machines used to create different machine parts for various industries.
• The marine and motorbike industries also use crankshaft grinding machines to repair existing crankshafts and redefine their shape for better functioning. Instead of replacing the entire component, a grinding machine can efficiently change the shape and size to make it compatible with other components of a vehicle or machine.

How to choose a crankshaft grinding machine

When choosing a suitable machine for performing crankshaft grinding for the business, there are a few essential things to consider. The first thing to keep in mind when choosing a machine is what kind of power supply it uses. The choices are usually a three-phase power supply or a diesel generator. If the workshop is already utilizing a three-phase power supply, this is an ideal choice as it will provide sufficient power to do the job. However, a diesel generator and its accompanying fuel system can be an alternative if the facilities do not have access to a three-phase power supply.

Understandably, the size of the machine also impacts how well it will do the job and what kind of crankshaft it can work with. A machine with a 1.5-meter maximum grinding length can handle most light vehicles, while a machine with a 2.4-meter maximum length is suitable for larger ones. If taking the crankshaft out of an engine in one piece will be a challenge, then opting for a portable crankshaft grinding machine will be a good idea. These lightweight and easy-to-assemble machines can be used to tackle the job without having to remove the engine from the vehicle.

Another critical aspect of the machine to consider is its ability to perform other functions besides just grinding. Choosing a machine that can also offer facilities like thermal spray rebuilding, honing, polishing, and more can be an excellent investment opportunity for clients looking to cut costs and time. Fewer machines would have to be used to get the job done. In addition to this, some machines now have automatic feeding systems, while others have manual ones. It's worth considering what kind of system would be best for the business and clients.

Finally, yet importantly, the machine's design and sturdiness should offer stability while performing high-accuracy grinding on the crankshaft. Look into the after-sale services and installation support offered by the supplier, as regular machine maintenance will be necessary.

Crankshaft grinding machine FAQ

Q1 Which type of machine is used to grind the crankshaft?

A1 A Crankshaft grinding machine is used to grind the crankshaft.

Q2 Are all crankshaft grinding machines the same?

A2 No, there are different types of crankshaft grinding machines. Some are vertical setups suitable for smaller, lighter crankshafts, while others are horizontal for larger, heavier crankshafts. The horizontal kind also allows for greater accuracy when grinding to closer tolerances.

Q3 Can a damaged crankshaft be repaired?

A3 If the damage is not too severe, a skilled technician can use a crankshaft grinding machine to restore the crankshaft to a smooth, round shape.

Q4 How long does it take to grind a crankshaft?

A4 Depending on factors such as the extent of the damage, the time it takes to set the crankshaft up correctly in the machine, and the workflow of the facility, it can take anywhere from 1 to 8 hours to grind a crankshaft.

Q5 What are some risks associated with using a crankshaft grinding machine?

A5 The biggest risk is damaging the bearings or seal surfaces of the crankshaft. This can happen if proper alignment is not followed. Other risks include creating an unbalanced crankshaft, which can happen if material is removed unevenly, and failing to remove the necessary parts to access the crankshaft.