Needle roller and cage assemblies for crank pins ...................... 10
Needle roller and cage assemblies for piston pins..................... 11
Appendix
Calculation of rolling bearings in crank machines ...................... 12
Datasheets, functional diagram................................................. 12 Datasheet Needle roller and cage assemblies for crank pins and piston pins ................................................... 13 Datasheet Functional diagram and examples of load cases ..... 15
Schaeffler Group Industrial
TPI 94
Product overview
Needle roller and cage assemblies
for crank pins and piston pins KZK
For piston pins
KBK
102 154
102 153a
For crank pins
TPI 94
Schaeffler Group Industrial
Needle roller and cage assemblies
for crank pins and piston pins Features
Needle roller and cage assemblies for connecting rod bearing
arrangements are used in the crank mechanisms of 2 and 4 stroke engines as well as in compressors for supporting crank pins and piston pins. They consist of cages equipped with needle rollers, support high centrifugal and acceleration forces and are suitable for high speeds. They require very little radial space since the radial section height only corresponds to the diameter of the needle rollers. They give bearing arrangements with high runout accuracy which is, however, influenced by the geometrical accuracy of the raceways. The radial internal clearance is dependent on the needle roller sort as well as the shaft and housing tolerances and can be adjusted by means of the needle roller sort. The raceways must be hardened, ground and honed.
Needle roller and
cage assemblies for crank pins
Needle roller and cage assemblies for crank pins are externally guided, which means that the connecting rod bore guides the cage radially with little clearance. The radial movement of the cage in relation to the connecting rod bore and the rolling elements is as small as possible. The cages are made from quenched and tempered steel, undergo little wear, have high strength and their large guidance surfaces are designed for optimum lubrication.
Needle roller and
cage assemblies for piston pins
Needle roller and cage assemblies for piston pins are internally guided, which means that the piston pin guides the cage radially with little clearance. Due to their small radial internal clearance, tilting of the connecting rod is reduced to a minimum. They support high frequency oscillating loads and are available for the majority of piston pin diameters in various widths in accordance with the piston boss spacing. The low-wear steel cages are case hardened or quenched and tempered and have high strength.
Further information
Further information on needle roller and cage assemblies is given
in Catalogue HR 1, Rolling Bearings.
Schaeffler Group Industrial
TPI 94
Needle roller and cage assemblies
for crank pins and piston pins
Figure 1 Crank end guidance lateral guidance of the connecting rod Piston end guidance
Figure 2 Piston end guidance lateral guidance of the connecting rod
TPI 94
The connecting rod and needle roller and cage assembly KZK are guided axially between the crank webs, Figure 1. The connecting rod eye at the crank end must have lubrication pockets and slots to allow the supply of lubricant. The KBK is guided axially between the piston boss abutment surfaces. Free lateral movement of the connecting rod between the piston bosses.
102 157
Crank end guidance
Depending on which parts of the crank mechanism are guided
laterally by the connecting rod, a distinction is drawn between crank end guidance and piston end guidance.
The connecting rod and needle roller and cage assembly KBK are guided axially between the piston bosses, Figure 2. As a result, wider piston pin bearing arrangements and longer pistons are generally necessary. In order to ensure free axial movement of the connecting rod, the crank webs must be turned to give sufficient clearance. In order to ensure good radial guidance of the needle roller and cage assembly KZK, the large connecting rod eye must be matched to the width of the needle roller and cage assembly KZK.
102 158
Design and safety guidelines Guidance of the connecting rod
Schaeffler Group Industrial
Design of adjacent parts
Proven materials for adjacent parts
Preferred enveloping circle
diameter of needle roller and cage assemblies
Proven enveloping circle diameters
for 2 stroke engines
The bores and pins for the needle roller and cage assemblies must be produced as rolling bearing raceways. A roughness Rz1 (Ra0,2) must be ensured. The rolling bearing raceways, thrust surfaces and thrust washers must be as follows: case hardened to at least 0,5 mm deep; a surface hardness of at least 700 HV must be ensured. The lateral thrust surfaces should be precision machined (Ra2 recommended) and wear resistant; thrust washers should be fitted if necessary. For lubrication of the needle roller and cage assemblies, holes or lubrication pockets should be provided, with additional lubrication slots for the crank end guidance. Materials should be selected in accordance with the following table. Adjacent part
Material
Connecting rod
16MnCr5, 15CrNi6
Crank pin
15Cr3, 17Cr3, 15CrNi6
Piston pin
Ck15, 15Cr3, 17Cr3
The dimensions of the needle roller and cage assemblies KZK and KBK are determined by factors including the capacity of the cylinder. The table below for 2 stroke engines shows the preferred enveloping circle diameters Fw of needle roller and cage assemblies for proven diameters of crank pins and piston pins. Other enveloping circle diameters may be available if sufficient quantities are required. In order to design needle roller and cage assemblies for a specific engine, the technical data of the engine must be taken into consideration. The datasheets, page 13 to page 15, must be completed and returned to us. Capacity per cylinder
cm3
Caution!
Schaeffler Group Industrial
Enveloping circle for
KZK
KBK
Fw mm
Fw mm
incl. 35
8 to 14
8 to 12
over 35 incl. 50
12 to 16
10 to 12
over 50 incl. 100
16 to 20
12 to 14
over 100 incl. 150
18 to 22
14 to 16
over 150 incl. 200
22 to 24
16 to 18
over 200 incl. 300
24 to 28
18 to 22
over 300
28 min.
20 min.
In order to determine the crank pin diameter for 4 stroke engines,
the technical data of the engine are required, see datasheets, page 13 to page 15.
TPI 94
Needle roller and cage assemblies
for crank pins and piston pins Accuracy Permissible geometrical tolerances for crank pin bearing arrangements
The geometrical tolerances of the raceways must be in accordance
with the tables and Figure 3 and Figure 4. Nominal dimension
Deviation for
F1
F1
over mm
E1
incl. mm
Parallelism m
Roundness m
Parallelism m
Roundness m
14
14
18
18
22
22
25
25
30
30
0,04/100 C
C H6 E1(G6)
Figure 3 Geometrical tolerances for crank pin bearing arrangements Permissible geometrical tolerances for piston pin bearing arrangements
F1 0,04/100 AB
Nominal dimension
Deviation for
F2
F2
over mm
E2
incl. mm
Parallelism m
Roundness m
Parallelism m
Roundness m
14
14
18
18
24
010 033
Crank end guidance
K6
E2
F2 0,04/100 C
Figure 4 Geometrical tolerances for piston pin bearing arrangements
TPI 94
0,04/100 AB A
010 059
Piston end guidance
Schaeffler Group Industrial
Radial internal clearance
For crank pin bearing arrangements
Caution!
For piston pin bearing
arrangements
Schaeffler Group Industrial
The radial internal clearance can be determined by means of
the needle roller sort, see table Sort plan for crank pin and piston pin bearing arrangements, page 8. For simplification, the mean values of the needle roller sorts can be used. Example of determination of the radial internal clearance using the mean value of the needle roller sort: Needle roller sort 0 2, mean value 1. The radial internal clearance is dependent on the speed, rigidity and accuracy of the crankshaft parts. Minimum values for the radial internal clearance according to the table Radial internal clearance minimum values to be achieved. Do not exceed the tolerance range of 0,015 mm. For very high speeds (for example in race engines), please contact us. The radial internal clearance must be at least 0,002 mm and must not exceed 0,012 mm.
TPI 94
Needle roller and cage assemblies
for crank pins and piston pins Sort plan for crank pin bearing arrangements Sort plan for crank pin bearing arrangements
Sort plan for piston pin bearing arrangements Sort plan for piston pin bearing arrangements
Radial internal clearance
minimum values
Conditions: Bore tolerance G6 for 18 mm to 30 mm in three groups Pin tolerance h5 for 14 mm to 18 mm in three groups Needle roller sort 0 2 to 5 7 Radial internal clearance 17 m to 30 m. Bore deviations +7 +11 Crank pin deviation Needle roller sort
4 6/5 7
2 4/3 5
Radial internal clearance
17 to 26
17 to 26
Crank pin deviation
3 6
Needle roller sort
4 6/5 7
1 3/2 4
Radial internal clearance
18 to 27
18 to 27
Crank pin deviation
6 8
Needle roller sort
1 3/2 4
Radial internal clearance
17 to 25
TPI 94
+15 +20 0 2/1 3 17 to 27 0 2/1 3 20 to 30
0 2/1 3 19 to 27
0 2 23 to 30
Conditions: Bore tolerance K6 for 10 mm to 18 mm in three groups Pin tolerance 0 6 in three groups Needle roller sort 0 2 to 5 7 Radial internal clearance 3 m to 12 m. Bore deviations 9 5 Piston pin deviation
5 1
1 +2
0 2
Needle roller sort
5 7
3 5/4 6
1 3/2 4
Radial internal clearance
3 to 9
3 to 11
3 to 10
Piston pin deviation
2 4
Needle roller sort
4 6/5 7
2 4/3 5
Radial internal clearance
3 to 11
3 to 11
Piston pin deviation
4 6
Needle roller sort
3 5/4 6
1 3/2 4
Radial internal clearance
3 to 11
3 to 11
0 2/1 3 3 to 10 0 2/1 3 5 to 12
Radial internal clearance
Nominal dimension
Crank pin bearing
arrangement
F1 mm
2 stroke
4 stroke
Piston pin bearing arrangement
incl.
14
14
10
14
18
17
12
18
22
20
14
22
25
24
18
25
30
28
20
30
32
25
over
+11 +15
0 3
Schaeffler Group Industrial
Special designs
Ordering example and
ordering designation
Schaeffler Group Industrial
Needle roller and cage assemblies KZK are available by agreement
in the following designs: split cage, suffix D copper plated cage, suffix CU silver plated cage, suffix AG for high performance machines. Needle roller and cage assembly KZK for: crank pin 16 mm connecting rod bore 22 mm width 12 mm needle roller sorts (sort pair coded blue) 2 4 and 3 5 copper plated cage. Ordering designation: KZK162212 SORT24/35CU
TPI 94
Needle roller and cage assemblies
for crank pins
Bc
Ew
102 027
Fw
KZK
Dimension table Dimensions in mm
Designation1) 2)
Mass
Dimensions
Fw
Ew
Bc
Basic load ratings
Fatigue limit load
dyn. Cr
stat. C0r
Pur
KZK8128
2,2
12
3 900
3 400
415
KZK101410
4,6
10
14
10
4 150
3 900
485
KZK121610
3,5
12
16
10
6 400
7 200
850
KZK121710
12
17
10
7 400
7 400
890
KZK131710
13
17
10
6 500
7 300
870
KZK141810
14
18
10
7 100
8 500
1 020
KZK14,420,410
6,5
14,4
20,4
10
KZK152111,15
15
21
11,15
KZK162110
16
21
KZK162210
7,7
16
22
KZK162212
9,8
16
8 100
7 800
930
10 100
10 600
1 290
10
8 600
9 600
1 080
10
9 200
9 500
1 140
22
12
10 900
11 700
1 460
KZK182412
10
18
24
12
11 600
13 100
1 650
KZK182413
12,5
18
24
13
12 100
13 800
1 740
KZK192515
15
19
25
15
13 000
15 400
1 870
KZK202816
26
20
28
16
17 900
19 700
2 350
KZK222813
15
22
28
13
13 900
17 500
2 220
KZK222816
18
22
28
16
15 600
20 200
2 500
KZK222916
20
22
29
16
17 800
21 800
2 650
KZK23,128,114
11
23,1
28,1
14
13 100
18 600
2 250
KZK253216
24,4
25
32
16
18 200
23 100
2 800
KZK25,130,114
13
25,1
30,1
14
14 000
20 800
2 500
KZK263116
16
26
31
16
17 200
27 500
3 400
KZK263314
23
26
33
14
19 100
24 900
3 200
KZK283314
14
28
33
14
14 800
23 100
2 800
KZK283517
33
28
35
17
21 700
30 000
3 700
KZK283518
27
28
35
18
23 400
33 000
4 200
KZK283614
28
28
36
14
20 300
25 000
3 950
KZK283616
30
28
36
16
23 300
30 000
3 650
KZK303816
32
30
38
16
22 800
30 000
3 500
KZK303818
35
30
38
18
25 500
35 000
4 250
1)
The needle roller and cage assemblies are available by agreement only. Production is dependent on economically viable quantities.
2)
The designation describes the dimensions only.
For a precise ordering designation, please contact us.
10
TPI 94
Schaeffler Group Industrial
Needle roller and cage assemblies
for piston pins
Bc
Ew
102 023
Fw
Lw
KBK
Dimension table Dimensions in mm
Designation1)2)
Mass
Dimensions
Fw
Ew
Bc
Lw
Basic load ratings
Fatigue limit load
dyn. Cr
stat. C0r
Pur
KBK81110
11
10
7,3
3 450
3 450
435
KBK91210
12
10
7,3
3 700
3 900
495
KBK91211,7
12
11,7
7,8
4 200
4 600
620
KBK91312,5
4,3
13
12,5
9,8
6 000
6 100
750
KBK111415
11
14
15
11,8
6 600
8 600
1 798
KBK101312,5
10
13
12,5
9,8
5 000
5 900
700
KBK101314,5
10
13
14,5
11,8
5 400
6 600
790
KBK101410
4,6
10
14
10
6,8
4 800
4 700
590
KBK101412,7
10
14
12,7
9,8
6 500
6 900
850
KBK101413
5,8
10
14
13
9,8
6 000
6 200
760
KBK121515
12
15
15
10,8
6 000
7 900
950
KBK121517,5
12
15
17,5
13,8
7 800
11 000
1 390
KBK121613
12
16
13
9,8
6 900
7 800
970
KBK121616
12
16
16
11,8
8 000
9 500
1 160
KBK121713
12
17
13
KBK121714,4
8,5
12
17
14,4
KBK131614
5,5
13
16
14
KBK131714,5
13
17
KBK131717,5
9,8
8 300
8 600
1 000
11,8
9 600
10 400
1 270
9,8
6 200
8 300
990
14,5
11,8
8 500
10 400
1 280
10
13
17
17,5
12,8
9 100
11 300
1 430
KBK141720
14
17
20
15,8
9 400
14 700
1 910
KBK141817
14
18
17
11,8
9 100
11 600
1 400
KBK151917
15
19
17
11,8
8 900
11 500
1 420
KBK151919,5
12,6
15
19
19,5
15,8
10 600
14 300
1 860
KBK151920
12,8
15
19
20
15,8
11 300
15 500
2 010
KBK151924
11
15
19
24
17,8
12 400
17 600
2 300
KBK162020
13
16
20
20
15,8
11 800
16 900
2 180
KBK182222
16,9
18
22
22
15,8
13 600
21 000
2 700
KBK182224
18
18
22
24
17,8
14 100
22 000
2 900
KBK182323,15
22
18
23
23
17,8
16 700
23 500
2 900
KBK202522
20
20
25
22
16,3
16 200
23 300
2 800
KBK202523,15
28
20
25
23,15
17,8
17 400
25 500
3 150
KBK222725
30
22
27
25
19,8
20 500
32 500
4 100
1)
The needle roller and cage assemblies are available by agreement only. Production is dependent on economically viable quantities.
2)
The designation describes the dimensions only.
For a precise ordering designation, please contact us.
Schaeffler Group Industrial
TPI 94
11
Needle roller and cage assemblies
for crank pins and piston pins Appendix Calculation of rolling bearings in crank machines
Caution!
12
Our calculation method can be used to calculate the basic rating
life L10 of the bearings (needle roller and cage assemblies for crank pins and piston pins, main bearings) in the crank mechanism of internal combustion engines on the basis of DIN ISO 281. In comparison with the standardised calculation to DIN ISO 281, it additionally takes into consideration the influence of internal load distribution in the bearing on the rating life. The calculation method takes account of dynamic loading (gas forces and inertia, external forces acting on the crankshaft) and the movement functions in crank machines. Simplifications underlying the calculation model: the crankshaft is only subjected to power train units of identical load and geometry, articulated connecting rods are not taken into consideration statically determinate crankshaft bearing arrangement with two bearings no account taken of lubrication influences no account taken of geometrical imperfections and deformations of the surrounding parts.
Adjusted reference rating life
It is also possible to calculate the adjusted reference rating life Lnmr
in accordance with DIN ISO 281, Appendix 4. This calculation method additionally incorporates the fatigue limit load of the material, the lubrication conditions and the type and size of contamination. Further data is required in this case. Please contact the Schaeffler engineering service.
Fatigue theory as a principle
The rating life calculation standardised in ISO 281 is based
on Lundberg and Palmgrens fatigue theory which always gives a final rating life. However, modern, high quality bearings can exceed by a considerable margin the values calculated in accordance with the standard ISO 281 under favourable operating conditions. Ioannides and Harris have developed a further model of fatigue in rolling contact that expands on the Lundberg/Palmgren theory and gives a better description of the performance capability of modern bearings. The calculation methods are described in detail in Catalogue HR1, Rolling Bearings.
Datasheets, functional diagram
The following datasheets, page 13 to page 15 are used to collect all
the data relevant to the calculation.
TPI 94
Schaeffler Group Industrial
Datasheet Needle roller and cage assemblies
for crank pins and piston pins Customer data
Enquiry data
Customer
_____________________
Proposal deadline
________________
_____________________
Delivery date
________________
_____________________
Annual volume
________________
Contact
_____________________
Required rating life
________________ h
Telephone
_____________________
E-mail
_____________________
Date
_____________________
Engine data Engine type
_________________
Cylinder bore
________________ mm
Capacity
_________________ cm2
Stroke
________________ mm
Application/model
_________________
Engine power
________________ kW
Mass of connecting rod
ms
________________ kg
Mass of longitudinally guided parts
mL
________________ kg
Mass of rotating parts
mU
________________ kg
Position of brg. D
xD1) ________________ mm
(e.g. 1 cylinder/ 4 stroke)
(e.g. Enduro, scooter)
Design data for connecting rod
Connecting rod length
L1)
_________________ mm
Centre of gravity of connecting rod LS1) _________________ mm
(KBK, piston, pin, rings)
Design data for crankshaft main bearing arrangement2)
Crank-conrod offset distance
rKY3) _________________ mm
Position of brg. C xC1) _________________ mm
Oscillating mass compensation
_________________ %
Bearings for calculation
Bearing A1)
_________________
(e.g. type, dimensions)
Bearing C1) 2)
Bearing B1)
________________
(e.g. type, dimensions)
_________________
(e.g. type, dimensions)
Bearing D1) 2)
1)
See functional diagram, page 15.
2)
Only required for main bearing calculation.
3)
The distance between the centre of gravity of the rotating mass and the crankshaft axis can be y+ or y in the co-ordinate system.
Schaeffler Group Industrial
________________
(e.g. type, dimensions)
TPI 94
13
Datasheet Needle roller and cage assemblies
for crank pins and piston pins Load case 14) Ignition pressure
Pz1 ______________ bar
Time proportion
Speed
n1
Gas pressure diagram available3)?
______________ 1/min
t1
yes
________________ % no
Load case 24)
Ignition pressure
Pz2 ______________ bar
Time proportion
Speed
n2
Gas pressure diagram available3)?
______________ 1/min
t2
yes
________________ % no
Load case 34)
Ignition pressure
Pz3 ______________ bar
Time proportion
Speed
n3
Gas pressure diagram available3)?
______________ 1/min
t3
yes
________________ % no
Load case 44)
Ignition pressure
Pz4 ______________ bar
Time proportion
Speed
n4
Gas pressure diagram available3)?
______________ 1/min
t4
yes
________________ % no
Load case 54)
Ignition pressure
Pz5 ______________ bar
Time proportion
Speed
n5
Gas pressure diagram available3)?
______________ 1/min
yes
t5
________________ % no
Static forces and moments acting on crankshaft2)
Axial point load in x
Fx1) ______________ N
Position of radial forces in x
xF1) ______________
mm
Radial point load in
y Fy1) ______________ N
Radial point load in
z Fz1) ______________
Static moment about
y My1) ______________ Nm
Static moment about
z Mz1) ______________
Nm
1)
See functional diagram, page 15.
2)
Only required for main bearing calculation.
3)
Please include the working diagram with the datasheet.
4)
See examples, page 15.
14
TPI 94
Schaeffler Group Industrial
Datasheet Functional diagram and examples of load cases
Piston pin bearing (A)
Crank pin bearing (B)
Ls
Bearing D
Bearing C
Fz M z Fx Fy My z
xC
xD 102 229
xF
Example 1 - characteristic curve: pressure over speed
Loadcase 2
Example 2 - testcycle: load over time
Loadcase 1 (full load)
Loadcase 4 Loadcase 5
Loadcase 2 (partial load) Load
Ignition pressure
Loadcase 3
Loadcase 1
Schaeffler Group Industrial
102 228
Speed
102 227
Loadcase 3 (idle speed) Time
TPI 94
15
MATNR 006984290-0000 / TPI 94 / GB-D / 2008031 / Printed in Germany by Mandelkow GmbH
Schaeffler KG
Every care has been taken to ensure the
Industriestrasse 13
correctness of the information contained
91074 Herzogenaurach (Germany)
in this publication but no liability can be
Internet www.ina.com
accepted for any errors or omissions.
E-Mail info@schaeffler.com In Germany: Phone 0180 5003872 Fax
0180 5003873
From Other Countries:
We reserve the right to make technical
changes. Schaeffler KG 2008, March This publication or parts thereof may not
Bearings And Bearing Metals: A Treatise Dealing with Various Types of Plain Bearings, the Compositions and Properties of Bearing Metals, Methods of Insuring Proper Lubrication, and Important Factors Governing the Design of Plain Bearings
Bearings And Bearing Metals: A Treatise Dealing with Various Types of Plain Bearings, the Compositions and Properties of Bearing Metals, Methods of Insuring Proper Lubrication, and Important Factors Governing the Design of Plain Bearings
