FINITE ELEMENT ANALYSIS AND

OPTIMIZATION OF CRANKSHAFT

A finite element analysis of a single cylinder is performed and optimum

shape for minimum stresses is performed using FEM software ANSYS.

The configuration for engine of the crankshaft is

PROBLEM STATEMENT:

The gas load is the major load coming on the crankshaft.GHence the
objective of analysis is to locate maximum stressed area and optimize it’s
shape for least stress.under the effect of static load comprising the
peak gas load,such that equivalent stresses are within the limit of
allowable stress. Each of the requirements and constraints are briefly
discussed as

APPLIED LOAD:

For FEM analysis using ANSYS only gas pressure is considered.The

calculated gas pressure is 106.4 kN corresponding to peak pressure. The
gas pressure is independent of geometry of crankshaft and is dependent
only on cylinder bore and peak cylinder pressure.

ALLOWABLE STRESS:
Allowable stress is the ratio of maximum pressure to factor of safety.
The material for crankshaft is medium carbon steel corresponding to EN-
9.

Since the minimum % elongation is 18%, so the material can be treated as

ductile material. As a result factor of safety for static loading was
defined with respect to yield strength.

CALCULATION

Single cylinder engine

Engine power, I.P. =25 hp
= 25 x 746 kW
Efficiency of engine ,n = 0.80

Bore of Cylinder ,d= 84 mm

= .084 mm
Length of stroke,l= 1.25 d
=1.25 x 0.084 mm
Revolution per minute, N = 2250

Formulae used :
I.P. = n x Pmax l A N/60

25 x 746 kW = 0.80 x Pmax x 1.25(0.084) x 3.14/4 x

0.0842 x 2250/60

Pmax = 106.2kN
Maximum gas pressure taken same as cylinder peak pressure.
 Pgas = Pmax =106.2kN

ANALYSIS METHODOLOGY

The analysis is performed on simple geometry to study the loading

pattern .
The geometry was designed in Autodesk inventor (modeling and assembly
software). Analysis is performed in “STATIC STRUCTURAL” module of
ansys workbench and optimization in “SHAPE OPTIMIZATION “ module
of same software.

OBSERVATION ANALYSIS:

Following observations are taken from the FEM analysis:

1)The maximum principle stresses are concentrated in crankpin fillet is

within allowable limits.

2) The material at the corners of crank web can be removed to reduce

stress concentration

RESULT:

The FEM analysis has following results:

1) The connecting rod is confirmed for failure and optimum shape.
2) The material removed will help in better stress distribution and cost
reduction in manufacturing of crankshaft.
3) The inertia forces are also reduced hence life of bearing also
increase.

CONCLUSION:

1)The software analysis should be confirmed with physical tests.

2)Dynamic and fatigue analysis should be carried out on basic and

modified crankshaft.
REFERENCE:

1) A Textbook of Machine Design, R.S.Khurmi ,J.K.Gupta

2. Technical research papers :

a) Structural Optimization Tool using Genetic Algorithms and Ansys
Roman GÄatzi

b)KOEL ,Finite Element Approach for Crankshaft Optimization, Sachin

Kare

c) Advanced Crankshaft Durability Simulation using ADAMS/Engine

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