1、 FORD LABORATORY TEST METHOD CA 001-04 Date Action Revisions 2001 04 30 Revised Editorial no technical change A. Cockman 2000 03 07 Revised Editorial no technical change A. Cockman 1992 08 18 Printed copies are uncontrolled Page 1 of 7 Copyright 2001, Ford Global Technologies, Inc. DEPTH OF INDUCTIO
2、N HARDENING AND HARDNESS OF CAMSHAFT AND AUXILIARY SHAFT Application This procedure is used to determine the depth of induction hardening and hardness of induction hardened camshafts and auxiliary shafts. Apparatus Required Abrasive Cut-off Machine, with coolant Radiac or equivalent. Belt Sander, wi
3、th coolant With 180 grit belt. Metallographic Polishing Plate No. 1 and 0000 grit paper. Versitron - Rockwell Hardness Tester Rockwell “C“ Hardness Tester Rockwell “30N“ Superficial Hardness Tester Brinell Glass or Equivalent Tongs Grinder, Pedestal Type Materials Required Nitric Acid (M-1008)* Caut
4、ion: Corrosive. FORD LABORATORY TEST METHOD CA 001-04 Page 2 of 7 Copyright 2001, Ford Global Technologies, Inc. Ethyl Alcohol (M-1044C)* Caution: Low flash point. * Refer to Industrial Hygiene for health and safety comments. Solution Preparation Nital Etch Add nitric acid to ethyl alcohol to produc
5、e a solution containing 3 % nitric acid by volume. Note: Always add acid to alcohol when preparing solution. Conditioning and Test Conditions All test values indicated herein are based on material conditioned in a controlled atmosphere of 23 +/- 2 C and 50 +/- 5 % relative humidity for not less than
6、 24 h prior to testing and tested under the same conditions unless otherwise specified. Procedure Depth of Induction Hardening Preparation of Sample - Camshaft Lobe 1. Section Lobe from camshaft by cutting through sections “A-A“ and “B-B“ as shown in Figure 1, cutting through shaft diameters using a
7、n abrasive cut-off wheel. 2. The cut-off wheel must be free cutting and flooded with water reducible coolant (or water) to prevent overheating of sample. The sample should be cut slowly; samples can overheat during rapid cutting even when flooded with coolant. 3. The sectioned lobe should be identif
8、ied as follows: . Lobe number (numbering of lobes starts at post end). . Lobe face towards front of camshaft (post end). . Lobe face towards rear of camshaft. 4. After identification is completed, the lobe is sectioned by cutting through the lobe as shown in Figure 2. The same precaution should be e
9、xercised as noted in step no. 2 to prevent overheating. FORD LABORATORY TEST METHOD CA 001-04 Page 3 of 7 Copyright 2001, Ford Global Technologies, Inc. 5. Either of 2 sections may be used for evaluation. However, the section used must be exactly one half of the lobe cross section to avoid erroneous
10、 readings. Remove excess cut-off metal and casting skin from side face of sectioned sample using belt sander or other abrasive. Finish grind to smooth surface with No. 1 grit paper. Use water reducible coolant (or water) to prevent overheating of sample. 6. Etch sample in the nital solution for the
11、time required to provide the best differentiation between heat affected zone and core. Preparation of Sample - Auxiliary Shaft Journal 1. Section journals from shaft by cutting through sections “A-A“, “B-B“,“C-C“, and “D-D“ as shown in Figure 4 using an abrasive cut-off wheel. The shaft and wheel mu
12、st be flooded with water reducible coolant (or water) to prevent overheating. Note: Check surface hardness of thrust face before grinding for depth of induction hardening. Refer to applicable Engineering print for designation of thrust face. 2. Using the belt sander, grind the A, B, C and D surfaces
13、 flat. Grind the shaft stub to permit proper seating on hardness tester anvil for determining thrust face hardness. Do not grind thrust face. Use water reducible coolant (or water) on belt to prevent overheating. 3. The sectioned journal should be identified as follows: . Journal number. . Thrust fa
14、ce toward front of auxiliary shaft. . Thrust face toward rear of auxiliary shaft. 4. Use Rockwell 30N hardness tester. Ignore the first reading. A minimum of 3 readings should be taken on each thrust face. 5. Turn journal over and check surface hardness on opposite thrust face. 6. Using the belt san
15、der with water reducible coolant (or water) to prevent overheating, grind “A-A“, “B-B“, “C-C“ and “D-D“ surfaces sufficiently to remove thrust face induction hardened zone. Grind carefully to assure faces remain parallel (to the eye). 7. Finish grind with number 1 grit paper. 8. Etch sample in the n
16、ital solution for the time required to best provide differentiation between heat affected zone and core. FORD LABORATORY TEST METHOD CA 001-04 Page 4 of 7 Copyright 2001, Ford Global Technologies, Inc. Test for Depth of Induction Hardening - Camshaft and Auxiliary Shaft 1. Measure the etched inducti
17、on hardened layer using a Brinell glass or a steel measuring scale using the following guidelines: For the camshaft, refer to Figure 3 and measure dimension a, b, c and d. Record lobe number and measurements that pertain to the nose of the lobe, heel of the lobe, and whether the measured dimension r
18、efers to the front of the camshaft or the rear of the camshaft. 2. For the auxiliary shaft use the same measuring equipment as noted in step 1 and refer to Figure 5. Measure dimension a, b, c and d. Record the journal number and whether the measured dimension refers to the front of the auxiliary sha
19、ft or the rear of the auxiliary shaft. Test for Surface Hardness Finished Camshafts Camshaft lobe Rockwell C hardness is to be measured across the nose of lobe as specified below: 1. The camshaft lobe base circle is to be supported in a V notch anvil that will support the lobe with its axis directly
20、 under the penetrator. Note: . The Versitron Rockwell tester is the preferred equipment. This instrument should be checked frequently to assure that it has not drifted out of calibration. . Other Rockwell testers may also be used. 2. Camshaft lobe hardness checks are to be made on finished ground ca
21、mshafts. Phosphate coating is to be removed in such a manner that base metal is not affected, i.e., light buffing or sanding. Note: . Checks can be performed on finished camshafts prior to phosphate coating. . Camshaft lobes with hardness measurement impressions are permitted to be ground 0.51 mm un
22、dersize for salvage, reference Engine Divisions Repair Standard 130. 3. The camshaft lobe hardness value is to be the average of 3 readings taken on the nose of lobe, 3 mm in from each edge and at the center. FORD LABORATORY TEST METHOD CA 001-04 Page 5 of 7 Copyright 2001, Ford Global Technologies,
23、 Inc. 4. The camshaft lobe hardness Rockwell C readings are to be corrected for radius of curvature per ASTM E 18 (Attachment 1a Appendix). . The correction factors for current model-released camshafts are available at: Engine Division Quality Control Office Room 3118, Rouge Office Bldg. Dearborn, M
24、I 48121 . The corrections are to be applied to the average of the 3 readings to establish the Rockwell C corrected average value. In-Process Camshafts In-process hardness checks, performed after the hardening of rough castings or semi-finished lobes, are to be checked in the same manner as above. In
25、-process hardness limits are to be established consistent with finished camshaft specifications. Auxiliary Shafts For auxiliary shaft journal, use Rockwell 30N hardness tester. Disregard first Rockwell readings. A minimum of 3 additional Rockwell readings, approximately 3 mm in from edge of journal
26、and across the journal, shall be taken. The average of the readings must conform to Engineering Specification. Chemicals, materials, parts, and equipment referenced in this document must be used and handled properly. Each party is responsible for determining proper use and handling in its facilities
27、. FORD LABORATORY TEST METHOD CA 001-04 Page 6 of 7 Copyright 2001, Ford Global Technologies, Inc. DEPTH OF INDUCTION HARDENING AND HARDNESS OF CAMSHAFT AND AUXILIARY SHAFT Camshaft FORD LABORATORY TEST METHOD CA 001-04 Page 7 of 7 Copyright 2001, Ford Global Technologies, Inc. DEPTH OF INDUCTION HARDENING AND HARDNESS OF CAMSHAFT AND AUXILIARY SHAFT Auxiliary Drive Shaft
