A forged crankshaft assembly for an engine, and a method of manufacturing the same, has a forged crankshaft and a removable counterweight to provide access for core drilling or milling a cavity. The forged crankshaft has a pin bearing journal, a main bearing journal, a first crank arm supporting the pin bearing journal, a second crank arm supporting the pin bearing journal and connecting the pin bearing journal and the main bearing journal, and at least one milled crank arm cavity formed within at least a portion of the second crank arm. The removable counterweight extends radially outward from the first crank arm, wherein the crank arm cavity is configured to be accessible to a core drill or mill cutter only when the removable counterweight is removed from the first crank arm and inaccessible to the core drill or mill cutter when the removable counterweight is coupled to the first crank arm.

An automobile vehicle crankshaft including a crankshaft casting of a nodular iron. The crankshaft casting includes multiple main journals coaxially aligned on a common crankshaft casting axis. Multiple crankpin journals are fixedly connected to the main journals by individual webs. Multiple lightening holes have individual ones of the multiple lightening holes integrally formed within individual ones of the crankpin journals during casting. A bubble space is located proximate to a mid-portion of selected ones of the multiple lightening holes of the crankpin journals. The bubble space locally increases a passage size of the selected ones of the multiple lightening holes and reduces a mass of the individual ones of the crankpin journals.

A crankshaft machining system includes a center hole boring device, a post-centering balance meter and a cutting device. The post-centering balance meter is configured to measure the shape of a post-centering crankshaft blank on the basis of a pair of center holes. Additionally, the post-centering balance meter is configured to set a principal axis of inertia on the basis of the shape of the post-centering crankshaft blank and generate center hole positional information for correction that indicates intersections between the principal axis of inertia and both end surfaces of the post-centering crankshaft blank. The center hole boring device is configured to bore a pair of center holes on both end surfaces of another crankshaft blank to be loaded next on the basis of the center hole positional information for correction.

A rolling tool for the roller finishing of bearing surfaces of a crankshaft is pivotable around a crankshaft axis, with a finishing roller head and with a support roller head. In order to prevent damage to the guide mechanisms, the roller finishing roller is guided on all sides in a roller cage and the finishing roller head has a frame wherein it is mounted pivotably around a first pivot axis which is perpendicular to the crankshaft axis and parallel to a tangent on a working side of the roller finishing roller. Additionally or alternatively, the support roller head comprises a support roller frame in which the support roller housing is mounted pivotably around a second pivot axis perpendicular to the crankshaft axis and parallel to the first pivot axis, and around a third pivot axis perpendicular to the crankshaft axis and perpendicular to the first pivot axis.

A crankshaft for an internal combustion engine is provided and may include crank pins, crank journals, and webs extending between the crank pins and the crank journals. Each web further may include a web surface on each side of the web. On the web surface, a repair region is provided with an undercut formed in the web. Included in the crankshaft is a cladding deposit that is fused to the web surface in the repair region of the crankshaft.

A method for producing a forged crankshaft includes a die forging step, a trimming step, and an excess projecting portion bending step. The die forging step forms a finish forged blank with flash, the finish forged blank including a shape of the crankshaft, in which crank arms have excess projecting portions at outer peripheries of side portions thereof near a crank pin, the excess projecting portions projecting from the outer peripheries. The trimming step removes the flash from the finish forged blank formed in the die forging step. The excess projecting portion bending step bends the excess projecting portions of the crank arms toward a journal-side surface of the crank arm by pressing the crankshaft using a pair of first dies, the crankshaft being obtained by removing the flash in the trimming step.

A method and compression roller tool for increasing the strength of load-bearing surfaces on shafts, in particular on crankshafts, which surfaces are pre-machined with the removal of chips, wherein the cylindrical surfaces of the main bearing journals and pin-bearing journals and optionally also the journal of crankshafts have additional oil bores. At least one of the load-bearing surfaces is compression-rolled by way of at least one cylindrical body which has a surface structure and extends over the width of the load-bearing surface. Afterwards, the compression-rolled load-bearing surfaces are machined with the removal of chips with a low chip depth. The compression roller tool consists of a cylindrical compression roller body and a supporting body opposite it, wherein the compression roller body has thickened portions on its cylindrical surface, which thickened portions run either in the circumferential direction or in the axial direction or diagonally with respect to the axial direction.

A system and method for installing a predetermined number of bearings into a lower block of an engine includes a tray having a plurality of slots for receiving the predetermined number of bearings, a plurality of proximity sensors, each of the proximity sensors associated with one of the slots in the tray for tracking the predetermined number of bearings, a visual indicator for confirming movement of the predetermined number of bearings into and out of the tray, and a light curtain for sounding an alarm if the lower block is moved to an installation position for installation to the engine block before the movement of the predetermined number of bearings into and out of the tray is completed to ensure all of the predetermined number of bearings are installed in the lower block.

A crankshaft for an internal combustion engine is provided and may include crank pins, crank journals, and webs extending between the crank pins and the crank journals. Each web further may include a web surface on each side of the web. On the web surface, a repair region is provided with an undercut formed in the web. Included in the crankshaft is a cladding deposit that is fused to the web surface in the repair region of the crankshaft.

A method for producing a forged crankshaft includes a die forging step, a trimming step, and an excess projecting portion bending step. The die forging step forms a finish forged blank with flash, the finish forged blank including a shape of the crankshaft, in which crank arms have excess projecting portions at outer peripheries of side portions thereof near a crank pin, the excess projecting portions projecting from the outer peripheries. The trimming step removes the flash from the finish forged blank formed in the die forging step. The excess projecting portion bending step bends the excess projecting portions of the crank arms toward a journal-side surface of the crank arm by inserting a first die having a U-shape from a direction of eccentricity of the crank pin to the crankshaft obtained by removing the flash in the trimming step.