Cross Head ①

What are the problem associated with X head and how they are prevented (4)

Problem
Full effect of combustion is applied directly to the bearing causing
high sudden load. Bearing is placed high in the engine and limited space
causing high bearing pressure.
Cross head pin are supported with central load, with two reaction at
each end so maximum deflection at the center causing distortion.
Pin and bearing are slow oscillating movement where connecting rod
is swing through 16° to 30° causing difficult to establish hydrodynamic
lubrication.
It has almost down ward forces and no load reversal to encourage the
entry of lobe oil into the bearing.

Prevention
K Lubrication of bearing is designed to force lubrication which delivers oil
into the bearing gap when the load of a bearing is lowest. So bearing
must be designed carefully and the pins must be very highly finished to
reduce surface asperity to a minimum.
K By using pump increase the lubricating oil pressure. By using conjugate
bearing where deflection of pin lower and uniform load.
K By using large diameter, stiff, short pin which reduce length diameter ratio
but deflection of pin is minimum and higher bearing lube oil pressure.
K By using Continuous full length bearing face under pin reduction in mean
bearing load.

(a) What is the purpose of fitting cross-head in a diesel engine and what are, the difficulties
usually found on them concerning lubrication?(4) (or)
(b) Sketch showing its lubrication (6)
(c) Describe above it (6)
(d) What are the problem associated with X head and how they are prevented (4)

(a) Purpose
On large slow speed two stroke diesel engine are designed with
cross head to minimize the forces imposed upon the cylinder liner.
 Cross Head ②

Cross head is located between piston rod and connecting rod and it
used to absorb the side thrust between piston and liner due to angularity of
connecting rod.

Lubrication Problem
During combustion the cross head get maximum load so bearing is
highly stress and the lube oil film in it is extremely thin.
Pin and bearing are slow oscillating movement where connecting
rod's swing through 16° to 30° causing difficult to establish hydrodynamic
lubrication.
It has almost down ward forces and no load reversal to encourage the
entry of lube oil into the bearing. This is to provide a squeeze film during
the high load part of the operating circle.
Prevent these lubrication of bearing is designed to force lubrication
which delivers oil into the bearing gap when the load of a bearing is lowest.
 Cross Head ③

(c) The sketch shown is a crosshead used in B&W, VT2BF type diesel
engines. It is made of forged steel 650MN/m2 ultimate tensile strength.
Pin is highly polished and flame hardened for surface hard.
The cross head shoes, two numbers on each side, are bolted into
flattened end of the pin. They are guided through guide way which are mounted
on engine columns.
The slide surfaces of shoes, which are liable to wear, are coated with
white metal into which L.O grooves are cut in order to achieve uniform L.O
supply.
For cross head guide and bearing L.O are supplied from main bearing
L.O system through the ducts in the crankshaft and connecting rod. L.O
gutters are cut in axial direction on lower bearing half to remain oil film in it.
 Cross Head ④

The lower part of the piston rod is fitted, with dowel pin to maintain
correct assembly of components, into the bore of cross head and secured by
nut.
The piston cooling oil is supplied by main L.0 system through cross
head with two telescopic pipe, one for inlet and other for return.
Running clearance of bearing is 0.2 to 0.5 mm and guides and shoes
clearance are 0.25 to 0.55 mm for surface and 0.1 to 0.2 mm for each side.

Function (Purpose)
 To minimize the force imposed upon the cylinder liner by the piston
 To provide long stroke of piston & get more engine output
 Causing the piston move centrally in liner and it used to absorb the
side thrust between piston and liner due to angularity of connecting
rod.

Crosshead problem
Load acting on it ð The fluctuated load and High sudden load are
acting continuous downward on lower bearing half
throughout the engine cycle.
Lubrication system problems
 No chance for LO entering due to unidirectional load
 Boundary lubrication due to oscillation movement (no relative
movement)

Lubrication system problems : Due to following factures:

a). Slow oscillating movement where connecting rod swings through
25 ~ 30 (small angle), hence it is difficult to build up full fluid film
b). Reciprocating movement where oil supply is disturbed by vertical
movement of pin and bearing.
c). Almost down ward forces and No load reversal, which does not
help the oil flow into the loaded part of the bearing to provide a
squeeze film.
 Cross Head ⑤

Different approaches adopted to overcome crosshead bearing

problems

(1) By using pumps mounted on crosshead to inject high-pressure oil

into the bearing surface when at boundary lubrication conditions.
(2) By increasing the lubricating oil pressure to crosshead to a level
where it causes separation of the surfaces during the light load part
of the cycle, such as scavenging, providing a squeeze film during
high load period.
(3) By using conjugate bearings where deflection of pin and bearing
remains in line, resulting a lower and uniform load.
(4) By using large diameter, stiff, short pin which increases bearing
speed, resulting higher bearing lube oil pressure while the connecting
bearing are moving on the pin and retains sufficient oil pressure
when at dead stops.
(5) Continuous full length bearing face under pin : Low specific load on
bearing. Load is transmitted directly downwards