Failure Analysis And Research To The Balance Shaft Of 4G6 Engine

Today’s society,with the rapidly changing automotive market environment,and the implementation of new regulations and standards,the domestic automobile industry is facing a great challenge.In order to achieve sustainable development for a car company,its products not only must save energy and protect environment,which are two major themes of current social development,but also must meet consumer demand for personal taste,that is,consumers are more concerned about the safety and comfort(including noise and vibration)of automotive products,and after-sales service guarantee.In order to reduce engine vibration and noise,improve vehicle comfort and safety,the engine balance shaft technology has been used in foreign new engines to reduce and eliminate the vibration of the engine crankshaft.This study was based on the bad problems of the failure of engine balance shaft portion from the feedback of aftermarket.According to the performance of broken parts and analyzing the theoretical,we found the cause of failure.By investigation and verification of the actual production process,we mastered and improved the manufacturing level of the part for engine balance shaft portion failure,in the same time we improved and perfected the manufacturing and assembly process of the part.We solved the fundamental parts of the engine balance shaft failures and reduced the incidence of adverse of issues.And for the future development and production we has accumulated valuable experience in the development and production of new models,so that we would make the balance shaft technology get better application.In this paper,we worked for failure analysis and research to the balance shaft of 4G6 engine,the research mainly includes the following contents:1.After extensive market research and on-site identify,we collected and summarized the failure mode of engine balance shaft portion failure,meanwhile obtained the fault machine bodies to carry out careful dismantling and confirmation,and summary,analyze,classilfy the fault topography for the failure of parts.2.Depending on the application principle of balance shaft technology,as well as the structural characteristics and requirements of balance shaft and bearing bush,with accessing to relevant data and research results from previous bad cases,we analyzed the possible reasons for failure of balance shaft and obtained the rational basis with summarizing the typical failure morphology of part.3.Basing on the actual production situation of the related parts on the engines and balance shafts,we found the failure mechanism and verified the authenticity of the theoretical reasoning through testing,calculation,analysis and the way of simulation verification of bench test.The defects and weak links in the actual manufacturing and assembly of parts have been found and confirmed.4.Aiming at the results of the above we have made effective improvement measures,which could be used on changing and adjusting the design of parts,manufacturing and assembly process parameters(including related equipment)to eliminate the potential defects of parts and improve the capacity of engineering guarantee.Through this study,we wanted to eliminate or reduce the incidence of failure of the 4G6 engine balance shaft portion by improving the relevant parts assembly and machining technology,the overall quality of the engine would be improved.Meanwhile the beneficial way has been found for us to analyze and research the bad problems of the future market and experience about how to judge the failure appearance correctly would be accumulated.