ANALYTICAL EVALUALTION

OF CRANK SHAFT UNDER

CYCLIC LOADING USING FEM
 UNDER THE GUIDANCE OF
Mr. V. ANBARASANPROFESSOR
Dept. of Mechanical Engineering,
James college of Engineering and Technology
Navalkaud- 629203.

PRESENTED BY,
SAM RAJ R S
Reg.No. 960816408006
M.E – ENGINEERING DESIGN
Dept. of Mechanical Engineering,
James college of Engineering and Technology
Navalkaud- 629203.
 ABSTRACT
The crankshaft is one of the critical component on the internal combustion

engine. The dynamic analysis has been undergone in this paper under the condition of

4-stroke 4 cylinder diesel engine. The SOLIDWORKS software is used to create the

3D model of the single cylinder crankshaft. The Finite element analysis method had

been carried out in this process to identify the various stress concentration and the

critical point of the crankshaft. The preprocessing stage is done through

SOLIDWORKS software and analyzing and post processing is done through ANSYS

software. The dynamic analysis is done through the FEA method which results in the

load iteration form applied on the crank pin bearing.

 The load is applied on the crankshaft based on the engine mounting

condition and the stress concentration and the critical point has been found. The

stress variation, Torsion and the bending load had been taken in consideration for this

analysis. The relationship between the vibration and the frequency will be shown in

the harmonic analysis of the crankshaft using this software.

 INTRODUCTION
 Crankshaft is a large component with a complex geometry in the
engine, which converts the reciprocating displacement of the
piston to a rotary motion with a four link mechanism.

 Since the crankshaft experiences a large number of load cycles

during its service life, fatigue performance and durability of this
component has to be considered in the design process.

 Design developments have always been an important issue in the

crankshaft production industry, in order to manufacture a less
expensive component with the minimum weight possible and
proper fatigue strength and other functional requirements.
 These improvements result in lighter and smaller engines with
better fuel efficiency and higher power output. This study was
conducted on a single cylinder four stroke cycle engine.
 Two different crankshafts from similar engines were studied in
this research. The finite element analysis was performed in four
static steps for each crankshaft.
 Stresses from these analyses were used for superposition with
regards to dynamic load applied to the crankshaft. Further
analysis was performed on the forged steel crankshaft in order to
optimize the weight and manufacturing cost.
Function of Crankshafts in IC Engines
 The crankshaft, connecting rod, and piston constitute a four bar
slider-crank mechanism, which converts the sliding motion of the
piston (slider in the mechanism) to a rotary motion.
 Since the rotation output is more practical and applicable for input
to other devices, the concept design of an engine is that the output
would be rotation.
 In addition, the linear displacement of an engine is not smooth, as
the displacement is caused by the combustion of gas in the
combustion chamber. Therefore, the displacement has sudden
shocks and using this input for another device may cause damage to
 MOTIVATION AND OBJECTIVES OF THE
STUDY
This study was motivated by a need for a comparative study of
forged steel and ductile cast iron crankshafts, which are the most
commonly used manufacturing processes for an automotive
crankshaft. In addition, it was desired to develop an optimized
geometry, material, and manufacturing procedure which will reduce
the weight of the forged steel component for fuel efficiency and
reduce the manufacturing cost due to high volume production of this
component.
Normal Crank Shaft with journal bearing
Crank Shaft Nomenclature
CRANKSHAFT DESIGN CONSIDERATIONS AND
PROPORTIONAL DIMENSIONS

Cylinder bore diameter = D

Cylinder centre distance = 1.20 D

Big-end journals diameter = 0.65 D

Main-end journal diameter = 0.75 D

Big-end journal width = 0.35 D

Main-end journal width = 0.40 D

Web thickness = 0.25 D

Fillet radius of journal and webs = 0.04 D

CRANKSHAFT MATERIALS

Crankshafts materials should be readily shaped, machined and

heat-treated, and have adequate strength, toughness, hardness,
and high fatigue strength. The crankshaft are manufactured
from steel either by forging or casting.
OBJECTIVES:

i) To model the crankshaft using SOLIDWORKS software

ii) Static analysis by using ANSYS WORKBENCH software

iii) Fatigue analysis by using ANSYS WORKBENCH

software
 LITERATURE REVIEW

Suryakant Rathod; ‘‘Evaluation of Fatigue Failure of Crankshaft Work on its

Bearing and Crank Pin Analytically and Numerically - A Review’’International
Journal of Science and Research (IJSR) Index Copernicus Value (2013): 6.14 |
Impact Factor (2013): 4.438 et al The objective of this paper is to update its readers the
failure of crank shaft due to the dynamic load and rotating system exerts repeated
bending and shear stress due to torsion, which are common stresses acting on crankshaft
and mostly responsible for crankshaft failure. Hence, fatigue strength and life assessment
plays an important role in crankshaft development and its parts considering its safety and
reliable operation. The single cylinder petrol engines are extensively used by two
wheeler like Pulsar 220, Discover all model. The bearing failure of the crank shaft is the
major problem of above said vehicle which results replacing crankshaft and piston
assembly which results in increase of overall cost.
 PLANNING AND DESIGNING

SOFTWARE DESCRIPTION:

SolidWorks (stylized as SOLIDWORKS) is a solid

modeling computer-aided design (CAD) and computer-aided
engineering (CAE) computer program that runs on Microsoft
Windows. SolidWorks is published by Dassault Systems.
According to the publisher, over two million engineers and
designers at more than 165,000 companies were using
SolidWorks as of 2016.
History:

In 1993, SOLIDWORKS founder Jon Hirschtick recruited a

team of engineers with the explicit purpose of making 3D CAD
technology more accessible. They did it by developing the first 3D
CAD technology that ran on the Windows platform and didn't
require expensive hardware and software to operate. 1995 marked
the first release of SOLIDWORKS software. Within two months,
it was winning accolades for ease-of-use, allowing more engineers
than ever before to take advantage of 3D CAD in bringing their
product designs to life.
MODELING TECHNOLOGY:

 A SolidWorks model consists of 3D solid geometry in a part or

assembly document.
 Drawings are created from models, or by drafting views in a
drawing document.
 Typically, begin with a sketch, create a base feature, and then add
more features to your model. (You can also begin with an imported
surface or solid geometry.)
 Associativity between parts, assemblies, and drawings assures that
changes made to one document or view are automatically made to
all other documents and views.
 It can generate drawings or assemblies at any time in the design
process.
 With a RealView-compatible graphics card installed, you can
display photo-realistic models and environments.
 Click Tools > Options on the main menu to display System
Options and Document Properties.
 The SolidWorks software saves your work for you with auto-
recover. You can also choose to be reminded to save your work.
File format:

SolidWorks files (previous to version 2015) use the

Microsoft Structured Storage file format. This means that there
are various files embedded within each SLDDRW (drawing
files), SLDPRT (part files), SLDASM (assembly files) file,
including preview bitmaps and metadata sub-files. Various third-
party tools (see COM Structured Storage) can be used to extract
these sub-files, although the subfiles in many cases use
proprietary binary file formats.
MODELLING:
Commands used:
1. Line
2. Arc
3. Fillet
4. Constraints
5. Axis
6. Extrude
7. Extrude cut
8. Cut revolve
9. Mirror
Configuration of the Engine to which the crankshaft belongs

PARAMETER VALUE
Crank Pin Radius 60 mm
Shaft Diameter 90 mm
Thickness of the Crank Web 50mm

Length of the crank Pin 197mm

Maximum pressure 35bar
Top View Model of Crank Shaft
Front View
Right Side View
3D View (Isometric View)
Top Sectional View
 SIMULATION RESULTS
STATIC ANALYSIS
4.2 Material Properties
Model Reference Properties Components
Name: Al6061 SolidBody
Model type: Linear Elastic 1(Combine1)(crank
Isotropic shaft)
Default failure Max von Mises
criterion: Stress
Yield strength: 6.20422e+008
N/m^2
Tensile strength: 7.23826e+008
N/m^2
Elastic modulus: 2.1e+011 N/m^2
Poisson's ratio: 0.28
Mass density: 7700 kg/m^3
Shear modulus: 7.9e+010 N/m^2
Thermal 1.3e-005 /Kelvin
expansion
coefficient:
SETTING OF FIXURE

Fixture
Fixture Image Fixture Details
name
Entities: 2 face(s)
Type: Fixed Geometry
Fixed-1

Resultant Forces
Components X Y Z Resultant
Reaction force(N) -5617.5 -701.844 2828.72 6328.55
Reaction
0 0 0 0
Moment(N.m)
APPLYING LOADS

Load name Load Image Load Details

Entities: 3 face(s)
Type: Normal to selected
face
Pressure-1 Value: 750
Units: N/mm^2 (MPa)
Phase Angle: 0
Units: deg
MESH INFORMATION
Total Nodes 16457
Total Elements 9584
Maximum Aspect Ratio 15.732
% of elements with Aspect Ratio < 3 86.1
% of elements with Aspect Ratio > 10 0.449
% of distorted elements(Jacobian) 0
Time to complete mesh(hh;mm;ss): 00:00:13
Computer name: LENOVO

Fig.4.1 Mesh Diagram

 STUDY RESULTS
VON MISES STRESS
Name Type Min Max
Stress1 VON: von Mises 91360.1 N/m^2 9.71139e+008
Stress Node: 14483 N/m^2
Node: 2081

Fig.4.2 Stress Diagram

DISPLACEMENT
Name Type Min Max
Displacement1 URES: Resultant 0 mm 10.9128 mm
Displacement Node: 117 Node: 13011

Fig.4.3 Displacement Diagram

EQUIVALENT STRAIN

Name Type Min Max

Strain1 ESTRN: Equivalent 9.08244e-007 0.00375387
Strain Element: 4313 Element: 1017
 FATIGUE ANALYSIS

Model Reference Properties Components

Name: Al6061 SolidBody
Model type: Linear Elastic 1(Combine1)(crank
Isotropic shaft)
Default failure Max von Mises
criterion: Stress

SN curve
DAMAGE PERCENTAGE
Name Type Min Max
Results1 Damage plot 0.1 129.064
Node: 14 Node: 2081
TOTAL LIFE CYCLE

Name Type Min Max

Results2 Life plot 774.809 cycle 1e+006 cycle
Node: 2081 Node: 14
 CONCLUSION

This work investigated weight reduction and the suitable better material for

minimizing deflections in crankshaft. Various models have been developed by

researchers using various theories and concepts to study the fatigue failure in

crankshaft due to dynamic and static loading. The failure in the crankshafts has been

initiated mostly from the crank pin-web fillet region by a fatigue mechanism. Shafts are

made from the same material however one of them has undergo a surface hardening

heat treatment and the other is used under the annealed conditions.
THANK YOU