Development of remaining life prediction of crankshaft remanufacturing core

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Adv.Manuf.(2013)1：91-96D0I 10.1O07/s40436-O13-0004-7Development of remaining life prediction of crankshaftremanufacturing coreLi-Hong Dong Bin-Shi Xu。Nan XueHui-Peng W angHao-Yu LiReceived：12 September 2012/Accepted：5 November 2012/Published online：14 M arch 2013◎ Shanghai University and Springer-Verlag Berlin Heidelberg 2013Abstract This paper reviewed the main research work inthe field of remaining life prediction of crankshaft reman-ufacturing core by Science and Technology on Remanu-facturing Laboratory.Based on the results of finite elementanalysis，the R angle zone of crankshaft was determined asa major measuring position.A special measuring probe ISdeveloped，and bending fatigue bench tests were carriedout to collect electromagnetic damage information duringfatigue process.A neural network model was established toidentify damage degree of crankshaft core，and a damageevaluation equipment for crankshaft core was developed。

Keywords Remanufacturing-Remaining lifeCrankshaft ·Metal magnetic memory-M ulti-frequency eddy current1 IntroductionCrankshaft is the key component of engine.which cantransform the driving force of cylinder to spin power.Inservice conditions，crankshaft is subject to complex stresses，including gas pressure，reciprocal inertia force，centrifugalinertia force，and external force moment1-3.Due to rig-orous operating conditions，the fabrication processes ofcrankshaft are complicated and its price is very high.Somecrankshafts out of commission still have high remainingvalue.Ifthese crankshafts were remanufactured，their surplusvalue can be fully utilized[4，5].Accordingly，crankshaftL.-H.Dong f 1·B.-S.Xu -N.Xue·H.-P.W ang·H.-Y.LiScience and Technology on Reman ufacturing Laboratory，Beijing 100072，Chinae-mail：lihong.dong###126.comremanufacturing is the focus of remanufacturing businesses。

Since variOUS damages may occur in old crankshafts duringservice 1ife.their damage degree and remaining life must beevaluated before remanufacturing to ensure remanufacturingquality.The old crankshafts cannot enter into remanufac-turing production unless they have adequate remaining life6.The old crankshafts had the features such as uncertaintyof service history，complicacy of damage types，randomicityand individual othemess.Thus it is very di伍cult to exactlyevaluate their damage degree[7.At present，remanufactur-ing enterprises only use magnetic pOwder inspectiOn to detectcrack on the surface of cran k pin.The crankshafts havingcrack cannot be remanufactured，whereas the crankshaftswithout crack can be remanufactured。

However，even if crack was not found in some oldcrankshafts by means of magnetic powder inspection，earlydam age still probably existed on the dangerous position ofcrankshaft. The remanufacturing values of these oldcrank shafts without crack are different.If early damagecannot be assessed well，the service reliability of remanu-facturing crankshafts will be unwarran ted.There are noholistic technology researches on how to predict theremaining life of remanufacturing crankshaft core.Theabove mentioned factors can lead to a hidden trouble ofremanufacturing crankshaft.This paper introduced theworks of Science and Technology on RemanufacturingLaboratory on crankshaft remanufacturing.Based on theresults of finite element an alysis，the R an gle zone ofcrankshaft was determined as a maior measuring position。

A special measuring probe was developed，and bendingfatigue bench tests were carried out to collect electro-magnetic damage information during fatigue process。

A neural network model was established to identify dam-age degree of crankshaft core，and a damage evaluationequipment for crankshaft core was developed。

垒SpringerL.-H.Dong et alwill be supplied into the remaining life researches，then thequantification level of remaining life on remanufacturingcores wil continue to develop。

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