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Crankshaft / Camshaft Grinding

Professional crankshaft grinding throughout Australia

For affordable crankshaft reconditioning services in Australia, look no further than HM GEM Engines.

Using top-of-the-line equipment to check all items that come onto our premises, we complete full survey reports on all crankshafts to ensure they’re fit for reconditioning.

This involves:

  • Non-destructive magnetic particle crack-testing
  • Rockwell hardness testing
  • Recording journal and radii measurements

After making these checks, we begin the machining process. At HM GEM Engines, we can work with crankshafts up to 4,000mm long with a 300mm stroke.

We also offer cost-effective seal surface reclamation solutions.

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Crankshaft inspection/crankshaft crack-testing

During the crankshaft inspection, we remove all the gallery plugs, which are then chemically cleaned to make sure there is no contamination. A full survey report is subsequently completed on every crankshaft. 

The inspection process includes:

  • Non-destructive magnetic particle crack-testing
  • Rockwell hardness testing
  • Crankshaft bend checking (TIR - Total Indicator Runout)
  • Examining all journal radii and checking journals for sizing, taper, and ovality
  • De-magnetisation of the shaft 

Crankshaft grinding/polishing and final inspection

The grinding process involves grinding a crankshaft with maximum measurements of 4,000mm in length and a 300mm stroke to the next available undersize. All journal machining is carried out according to the manufacturer’s requirements and the fillet radii are dressed.

Our team will also micro-polish the crankshaft at this stage, before completing a closing report to show that the required specifications and finished sizes have been finished as requested.

Note: machined coolant tracks within the grinding wheels eliminate the overheating of the thrust face and radius during the machining process. Also shown is the automatic sizing gauge with electronic in-process control and LCD display panel.

Caterpillar 35 series camshaft

Camshaft grinding

As with the crankshafts, all camshafts are subjected to a full survey inspection, which includes carrying out non-destructive magnetic particle crack-testing.

We also inspect the camshaft bend (TIR), gear and thrust areas, bearing journals, camshaft lobes, injector lift lobes, and eccentrics, checking them against the OEM specifications. 

When required, camshafts are straightened, bearing journals polished, and cam follower lobes are redressed.

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The engine reconditioning process

Cylinder block machining 

After the cleaning and inspection process, core components are arranged into batched model runs. Using the latest CNC equipment, the cylinder blocks are machined, which involves using laser-guided probes to identify the exact bore centres and deck heights.

Automated tooling changes are then used to make the machine re-bore and mill the cylinder block, so that it reaches the OEM’s specification. The cylinder bores are then honed, which involves rinsing the final block to remove residues and machining swarf. 

The last part of the process requires fitting the new gallery and welsh plugs.

Engine re-boring

Crankshaft grinding

Using our state-of-the art, automated measuring equipment, we precision-machine the crankshafts to the first available undersize in order to ensure that the surface is suitably prepared. Oil holes are then chamfered to improve lubrication to the journal surface, before micro-polishing takes place. 

The oil gallery areas are then thoroughly cleaned to remove any remaining contaminates before the crankshaft makes its way to the assembly team.

Camshaft grinding 

Every camshaft is inspected for wear, dimensional accuracy, and straightness. Any that do not meet the strict criteria for reuse are disposed of and replaced with new ones. 

The grinding process involves:

  • Re-profiling the lobes of the camshafts
  • After machining, every camshaft is Parco lubrication to improve adhesion, which is particularly important during the start-up and running procedure

Con rod reconditioning 

Connecting rods are subject to a number of checks before reuse. These include:

  • Big and small end sizing
  • Bend and twist checks 
  • New small end bushes and tunnel resizing, as required
  • New pistons fitted
  • Piston to rod alignment check

Contact Us

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Call us today for more information about our crankshaft grinding services!

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