Method for manufacturing crankshafts

Abstract

A method for manufacturing abrasion-resistant crankshafts including: first, forming a plurality of abrasion-resistant cam rings from an abrasion-resistant material such as a steel alloy of high chrome iron-carbide; placing the abrasion-resistant cam rings in a mold set on desired locations; pouring a melting metal formed by FCD45 high flexible-resistant cast iron into the mold set to form a shaft portion to couple with the abrasion-resistant cam rings; and solidifying the melting metal to become a crankshaft that is abrasion-resistant and flexible-resistant. The crankshaft thus formed can be used in heavy duty and severe conditions without wearing and fracturing.

1 . A method for manufacturing crankshafts to fabricate a crankshaft which has a flexible-resistant shaft portion to facilitate machining and a plurality of abrasion-resistant cam rings, the method comprising the steps of: 
 fabricating the abrasion-resistant cam rings each having an aperture;    fabricating a mold set which consists of two mold elements coupled together to form a casting orifice, the mold set has a housing chamber formed according to the crankshaft that communicates with the casting orifice;    placing the abrasion-resistant cam rings in the housing chamber of the mold set on desired locations;    pouring a melting metal into the mold set through the casting orifice to fill the apertures of the abrasion-resistant cam rings to form the shaft portion; and    solidifying the melting metal and removing the crankshaft from the mold set.    
   
   
       2 . The method of  claim 1 , wherein each of the abrasion-resistant cam rings has a positioning boss, the housing chamber having a plurality of cavities corresponding to the positioning bosses to allow the abrasion-resistant cam rings to be positioned on desired locations, the positioning bosses being removed by grinding after the crankshaft has been removed from the mold set.  
   
   
       3 . The method of  claim 1 , wherein the abrasion-resistant cam rings are made from a high abrasion-resistant material.  
   
   
       4 . The method of  claim 3 , wherein the abrasion-resistant cam rings are made from a steel alloy of a high chrome iron-carbide.  
   
   
       5 . The method of  claim 1 , wherein the melting metal is FCD45 high flexible-resistant cast iron.