Air Compressor Crankshaft Machining Feasibility

Abstract

Air compressor plays a vital role in supplying compressed air to air circuits in any vehicle systems. Many a times such compressors are run on exhaust gas pressure which drives the turbine which drives the compressor. Crankshaft is integral part of compressor. Earlier the supplier was suffering from machining issue in the grinding of crankshaft of single cylinder reciprocating compressor. It is not at all recommended that the rotating part having poor surface finish or having burn marks on it.This leads to fatigue failure. Hence to resolve the problem of burn marks and loading of grinding machine ,the process and design is modified. Balancing of crankshaft is also insured after the changes. In this paper the description of effective manufacturing of compressor crankshaft along with sequence of machining operation is given. The new modified design with its manufacturing and design advantages are given. Fillet radius addition to crankshaft design eliminates burn marks during grinding, reduces grinding area, and maintains surface finish. Unbalanced force reduced from 60g to 31.75g with 0.01% weight change. Advantages of New design Providing fillet radius has mainly 2 advantages over the old design are stated below Manufacturing Advantages. In earlier design the web of the Crankshaft is grinded completely. This effect in burn marks on the web and unbalancing of crankshaft. But in modified design after providing the fillet radius at the joining of crankpin and counterweights reduces effective area of grinding.