Abstract: A connecting rod for a device includes a rod having a large end, and a cap attached to the large end. The large end of the rod and the cap cooperate to define a first side surface and a second side surface disposed opposite to each other. The large end of the rod and the cap further define a crankshaft bore that extends along a crank axis between the first side surface and the second side surface. A thrust surface is defined by at least one of the first side surface or the second side surface, and is disposed on a thrust plane. The thrust surface includes at least one recessed region that extends inward away from the thrust plane of the thrust surface. Each of the thrust surfaces include ramps that extend between the recessed regions and the flat regions at the thrust plane of the thrust surface.

Abstract: A crankshaft includes a plurality of counterweights. Each of the counterweights includes a counterweight body. The counterweight body has a first lateral portion, a second lateral portion, and a central portion between the first lateral portion and the second lateral portion. A method of balancing the crankshaft includes: (a) removing material from the first lateral portion of the counterweight body of at least one of the counterweights; and (b) removing material from the second lateral portion of the counterweight body of at least one of the counterweights in order to balance the crankshaft.

Abstract: A crankshaft includes a pin bearing journal, and a counterweight. The pin bearing journal defines a hollow pin core. The hollow pin core includes a first pin core section and a second pin core section, and an enlarged central section disposed between the first pin core section and the second pin core section. The first and second pin core sections each define a cross section having a first and second cross sectional area respectively, and the enlarged central section defines a third cross section defining a third cross sectional area, with the third cross sectional area larger than the first and second cross sectional areas. An isolation window extends through the counterweight. The crankshaft is cast from a high shrink steel alloy having a shrinkage factor equal to or greater than 1%. The enlarged central section and the isolation window improve the castability of the high shrink steel alloy.

Abstract: A method of simultaneously manufacturing a plurality of crankshafts includes positioning a core system having a plurality of individual cores within a cavity of a mold having first and second halves forming an exterior shape of the crankshafts. The crankshafts' exterior shape includes a plurality of pin bearing journals and a plurality of main bearing journals. Each of the cores passes through each of the crankshafts. At least one core passes through at least one of the pin bearing journals and at least one other core passes through at least one of the main bearing journals. The method also includes introducing into the cavity molten metal to form the crankshafts. As the metal flows into the cavity and around the plurality of cores, a hollow section extending through at least one of the pin bearing journals and at least one of the main bearing journals of each crankshaft is formed.

Abstract: A method of simultaneously manufacturing a plurality of crankshafts includes positioning a core system having a plurality of individual cores within a cavity of a mold having first and second halves forming an exterior shape of the crankshafts. The crankshafts' exterior shape includes a plurality of pin bearing journals and a plurality of main bearing journals. Each of the cores passes through each of the crankshafts. At least one core passes through at least one of the pin bearing journals and at least one other core passes through at least one of the main bearing journals. The method also includes introducing into the cavity molten metal to form the crankshafts. As the metal flows into the cavity and around the plurality of cores, a hollow section extending through at least one of the pin bearing journals and at least one of the main bearing journals of each crankshaft is formed.

Abstract: A crankshaft includes first, second, third, and fourth main journals, each coaxially disposed along a crankshaft axis. A first, second, third, fourth, fifth, and sixth crank pin are each parallel with the crankshaft axis, and radially offset from the crankshaft axis. A first crank arm includes a first counterweight, and connects the first main journal and the first crank pin. A third crank arm includes a second counterweight, and connects the second crank pin and the second main journal. A seventh crank arm includes a third counterweight, and connects the third main journal and the fifth crank pin. A ninth crank arm includes a fourth counterweight, and connects the sixth crank pin and the fourth main journal. The first, second, third, and fourth counterweights are the only counterweights of the crankshaft.

Abstract: A method of simultaneously manufacturing a plurality of crankshafts includes positioning a single core within a cavity of a mold having a first half and a second half together forming an exterior shape of the plurality of crankshafts. The exterior shape of each of the plurality of crankshafts produced thereby includes a plurality of pin bearing journals and a plurality of main bearing journals. The method also includes introducing via a mechanism into the cavity a molten metal to form the plurality of crankshafts. As the molten metal flows into the cavity and around the single core, a hollow section extending through at least one of the plurality of pin bearing journals and at least one of the plurality of main bearing journals of each of the plurality of crankshafts is formed. A system for simultaneously manufacturing a plurality of reduced mass crankshafts using the above method is also disclosed.

Abstract: A connecting rod for a device includes a rod having a large end, and a cap attached to the large end. The large end of the rod and the cap cooperate to define a first side surface and a second side surface disposed opposite to each other. The large end of the rod and the cap further define a crankshaft bore that extends along a crank axis between the first side surface and the second side surface. A thrust surface is defined by at least one of the first side surface or the second side surface, and is disposed on a thrust plane. The thrust surface includes at least one recessed region that extends inward away from the thrust plane of the thrust surface. Each of the thrust surfaces include ramps that extend between the recessed regions and the flat regions at the thrust plane of the thrust surface.

Abstract: A crankshaft includes first, second, third, and fourth main journals, each coaxially disposed along a crankshaft axis. A first, second, third, fourth, fifth, and sixth crank pin are each parallel with the crankshaft axis, and radially offset from the crankshaft axis. A first crank arm includes a first counterweight, and connects the first main journal and the first crank pin. A third crank arm includes a second counterweight, and connects the second crank pin and the second main journal. A seventh crank arm includes a third counterweight, and connects the third main journal and the fifth crank pin. A ninth crank arm includes a fourth counterweight, and connects the sixth crank pin and the fourth main journal. The first, second, third, and fourth counterweights are the only counterweights of the crankshaft.

Abstract: A crankshaft is cast in a mold to define a plurality of pin bearing journals and a plurality of main bearing journals, at least one of each has a hollow section extending therethrough. A single core is positioned within the mold to form all of the hollow sections. The single core may include a cross-section defining an elliptical shape to form hollow sections having an elliptical cross-sectional shape to further reduce the weight of the crankshaft. The hollow sections are each positioned along a path that minimizes stress within the crankshaft. The path may include a non-linear path relative to a longitudinal axis of the crankshaft or a linear path angled relative to the longitudinal axis to bend or direct the hollow sections away from high stress regions of the crankshaft. The non-circular cross section of the core may spiral about its own axis to maximize mass reduction.

Abstract: A crankshaft is cast in a mold to define a plurality of pin bearing journals and a plurality of main bearing journals, at least one of each has a hollow section extending therethrough. A single core is positioned within the mold to form all of the hollow sections. The single core may include a cross-section defining an elliptical shape to form hollow sections having an elliptical cross-sectional shape to further reduce the weight of the crankshaft. The hollow sections are each positioned along a path that minimizes stress within the crankshaft. The path may include a non-linear path relative to a longitudinal axis of the crankshaft or a linear path angled relative to the longitudinal axis to bend or direct the hollow sections away from high stress regions of the crankshaft. The non-circular cross section of the core may spiral about its own axis to maximize mass reduction.