Failure analysis of a truck diesel engine crankshaft

Abstract A truck engine crankshaft fractured during the service. The fracture occurred on the crankshaft big-end on which the timing-gear and the flywheel flange were coupled and the fracture location was just situated at the assembling gap between them. The short cracks inclined at about 45° to the shaft axis initiated from the surface of the crankshaft journal at the timing-gear side and mainly extended to the timing-gear side, leading to a zigzag cracking morphology on the journal surface. A complicated ratchet or star-shaped pattern of fracture typical of multiple fatigue cracks occurred on the fracture surface. The journal surface was locally induction-hardened. The surface hardness and the effective case depth on the hardened journal at the flywheel flange side corresponded to the specification. At the timing-gear side the surface hardness on the hardened journal was much lower than the specified lower limit and a low hardness region of 0.4 mm occurred on the most-surface of the hardened journal within which the hardness values were lower than the specified lower limit. The low surface hardness on the induction-hardened journal made fatigue resistance of the crankshaft decrease to lead to initiation and propagation of fatigue cracks in the weaker region. The assembling gap at which the fracture occurred was structure stress concentration site of the assembly constituted of the crankshaft, the timing-gear and the flywheel flange, equivalent to the deep notch. The excessive tightening of the timing-gear on the journal surface also contributed for the increasing of stress concentration. The fatigue crack origins were easy to initiate due to large stress concentration.