Powerplant 1

Crankcase and Bearings

Engine Components

 The basic parts of a reciprocating

engine include the crankcase,
cylinders, pistons, connecting rods,
valves, valve-operating mechanism,
and crankshaft.
 The valves, pistons, and spark plugs
are located in the cylinder while
the valve operating mechanism,
crankshaft, and connecting rods are
located in the crankcase.
Crankcase

 The crankcase is the foundation of a

reciprocating engine. It contains the
engine's internal parts and provides
a mounting surface for the engine
cylinders and external accessories.
 In addition, the crankcase provides
a tight enclosure for the lubricating
oil as well as a means of attaching a
complete engine to an airframe.
Crankcase

 Crankcases must be extremely rigid and strong.

 Due to the internal combustion forces exerted on the cylinders
and the unbalanced centrifugal and inertial forces inflicted by a
propeller, a crankcase is constantly subjected to bending
moments which change continuously in direction and magnitude.
 Therefore, to remain functional, a crankcase must be capable of
absorbing these forces and still maintain its integrity.
 To provide the strength and rigidity required while maintaining a
relatively light weight, most aircraft crankcases are made of
cast aluminum alloys.
Opposed Engine Crankcase

 A typical horizontally opposed engine crankcase consists of two halves of

cast aluminum alloy that are manufactured either with sand castings or by
using permanent molds.
 Most opposed crankcases are approximately cylindrical, with smooth areas
machined to serve as cylinder pads. A cylinder pad is simply a surface
where a cylinder is mounted to a crankcase.
 To allow a crankcase to support a crankshaft, a series of transverse webs
are cast directly into a crankcase parallel to the case's longitudinal axis.
 These webs form an integral part of the structure and, in addition to
housing the bearings that support the crankshaft, the webs add strength to
the crankcase.
In addition to the transverse
webs that support the main
bearings, a set of camshaft
bosses are typically cast into a
crankcase. These bosses
support the camshaft which is
part of the valve operating
mechanism.
Opposed Engine Crankcase

 The crankcase is also an integral part of the lubrication system. Oil

passages are drilled throughout the case halves to allow lubricating oil
to be delivered to the moving parts housed within the crankcase.
 In addition, oil galleries are machined into the case halves to scavenge,
or collect, oil and return it to the main oil tank or sump.
 Since the oil supply in most modern horizontally opposed engines is
carried inside the crankcase, provisions are made to seal the case to
prevent leakage.
 To ensure that the seal does not interfere with the tight fit for the
bearings, most crankcase halves are sealed with a very thin coating of a
non-hardening gasket compound.
Radial Engine Crankcase

 Unlike opposed engine crankcases, radial engine

crankcases are divided into distinct sections. The number
of sections can be as few as three or as many as seven
depending on the size and type of engine.
 In general, a typical radial engine crankcase separates
into four main sections: the nose section, the power
section, the supercharger section, and the accessory
section.
Radial Engine Crankcase

 The nose section is mounted at the front of a radial engine

crankcase and bolts directly to the power section.
 A typical nose section is made of an aluminum alloy that is
cast as one piece with a domed or convex shape.
 The nose section usually houses and supports a propeller
governor drive shaft, the propeller shaft, a cam ring, and
a propeller reduction gear assembly if required.
Radial Engine Crankcase

 The second portion of a crankcase is referred to as the power

section
 It represents the section of the crankcase where the reciprocating
motion of the pistons is converted to the rotary motion of the
crankshaft.
 Like an opposed engine crankcase, the power section absorbs
intense stress from the crankshaft assembly and the cylinders.
 A radial engine power section contains machined bosses that
rigidly support the crankshaft bearings and the crankshaft.
 Cylinders are attached around the perimeter of the power section
to machined cylinder pads.
Radial Engine Crankcase

 The diffuser or supercharger section is located directly

behind the power section and is generally made of cast
aluminum alloy or magnesium.
 As its name implies, this section houses the supercharger
and its related components.
 A supercharger is an engine accessory that is used to
compress air and distribute it to the engine's cylinders.
Radial Engine Crankcase

 The accessory section is usually cast of either an aluminum

alloy or magnesium.
 On some engines, it is cast in one piece and then machined
to provide a means for mounting accessories such as
magnetos, carburetors, pumps, starters, and generators.
 However, on other engines, the accessory section consists
of an aluminum alloy casting and a separate cast
magnesium cover plate on which the accessories are
mounted.
The four basic sections of a radial engine crankcase are
the nose section, power section, supercharger section,
and accessory section.
Engine Mounting Points

 For opposed engines, mounting points, sometimes called

mounting lugs, are typically cast as part of the crankcase.
 On all engines, the mounting arrangement supports the
entire powerplant including the propeller and, therefore,
must be designed to withstand various engine, centrifugal,
and g-loading conditions.
Bearing

 A bearing is any surface which supports and reduces friction between

two moving parts. Typical areas where bearings are used in an aircraft
engine include the main journals, crankpins, connecting rod ends, and
accessory drive shafts.
 A good bearing must be composed of material that is strong enough to
withstand the pressure imposed on it, while allowing rotation or
movement between two parts with a minimum of friction and wear.
Plain Bearing

 Plain bearings are generally used for

crankshaft main bearings, cam ring and
camshaft bearings, connecting rod end
bearings, and accessory drive shaft
bearings.
 These bearings are typically subject to
radial loads only.
 Plain bearings are usually made of
nonferrous metals such as silver, bronze,
babbit, tin, or lead.
Ball Bearing
 A ball bearing assembly consists of grooved inner and
outer races, one or more sets of polished steel balls,
and a bearing retainer.
 The balls of a ball bearing are held in place and kept
evenly spaced by the bearing retainer, while the inner
and outer bearing races provide a smooth surface for
the balls to roll over.
 Since the balls of a ball bearing offer such a small
contact area, ball bearings have the least amount of
rolling friction.
 Because of their construction, ball bearings are well
suited to withstand thrust loads and are, therefore,
used as thrust bearings in large radial and gas turbine
engines.
Roller Bearing

 Roller bearings are similar in construction to

ball bearings except that polished steel rollers
are used instead of balls. The rollers provide a Straight Roller Bearing
greater contact area and a corresponding
increase in rolling friction over that of a ball
bearing.
 Straight roller bearings are suitable when the
bearing is subjected to radial loads only.
 Tapered roller bearings, on the other hand,
have cone-shaped inner and outer races that
allow the bearing to withstand both radial and
thrust loads. Tapered Roller Bearing