Академический Документы
Профессиональный Документы
Культура Документы
Abstract:
Cran kshaft is one of the large components with a co mplex geomet ry in internal co mbustion engine which converts the
reciprocating displacement of the piston into a rotary motion. The modelling of the single cylinder petrol engine crankshaft is
created using Auto-Cad Software. Finite element analysis (FEA) is performed to obtain the variation of stress at critical locations
of the crank shaft using the ANSYS software. The load applied to the FE model in ANSYS simu lation boundary conditions are
applied according to the engine mounting conditions. Stress variation over the engine cycle and the effect of torsion and bending
load in the analysis are investigated. Von-misses stress is calculated using theoretically and ANSYS software.
Keywords: Design of Cran kshaft; Crankshaft; Single Cylinder Petro l Engine; Failure analysis of Crankshaft; Suzu ki Access
1. INTRODUCTION single cylinder engine .so that two revolution of crankshaft for
each stroke. The peak pressure acting on the engine crankshaft
Cran k shaft is a large co mponent with a comp lex geometry in is 63 bar. The cran kshaft of the located model is designed
the I.C engine, which converts the reciprocating displacement using pro engineering with the accurate dimensions and
of the piston to a rotary motion with a four bar lin k material standards of located Honda crankshaft. Dynamic
mechanis m. Crankshaft consisting of shaft parts, two journal analysis is used to find out the motion of the bodies with
bearings and one crankpin bearing. The Shaft parts which represents to applied loads with the time frame of cran k angle.
revolve in the main bearings, the crank pins to which the big The crank angle is calcu lated with respect to seconds as it
end of the connecting rod are connected, the crank arms or takes 0.008 sec for each stroke with to revolution. Researcher
webs which connect the crank pins and shaft parts.Al-Jazari get, the peak force of 60000N, 58000N, 14000N at 0.0016 sec
was the first engineer to invent the Crankshaft which is of crank angle from the graph in pro engineering and in
considered the single most important invention after the wheel. dynamic analysis we obtained force value 3831.17 were the
graph show in form. The force is max at 0.0016 sec and
decrease at the end of time frame of 0.008.
S. Bhagya Lakshmi et al..[1] have been analyzed design of a K. Thri veni and Dr. B. JayaChandrai ah[3] have been
crankshaft of Honda engine, it is assembled by the connecting analyzed the modeling of the crankshaft is created using
rod and piston components in Pro engineering. The designed CATIA-V5 Software. Fin ite element analysis (FEA) is
model of engine crankshaft is analyzed in pro engineering by performed to obtain the variation of stress at crit ical locations
using its mechanism. The design of a crankshaft is of 4 stroke
International Journal of Engineering Science and Computing, April 2017 10549 http://ijesc.org/
of the crank shaft using the ANSYS software and applying the Results Conformal matches with the theoretical calcu lation so
boundary conditions. Then the results are drawn Von-misses FEA is a good tool to reduce time consuming theoretical Work
stress induced in the crankshaft is 15.83Mpa and shear stress is and also reduce costly experimental work.
induced in the crankshaft is 8.271Mpa. The Theoretical results
are obtained von-misses stress is 19.6Mpa, shear stress is Mr. K. V. NaveenKumar et al..[7] have been analyzed on
9.28Mpa. Researcher get the maximu m deformat ion appears at three-dimension models of 480 diesel engine crankshaft and
the centre of the crankpin neck surface, the maximu m stress crank throw were created using CATIA software. The finite
appears at the fillet areas between the crankshaft journal and element analysis (FEM) software ANSYS is used to analyze
crank cheeks and near the central point journal. The value of the modal, Harmon ic and stress status of the crankshaft. The
von-misses stresses that comes out from the analysis is far less maximu m deformation, maximu m stress point and dangerous
than material y ield stress so our design is safe. areas are found by the stress analysis of crank shaft. Fro m
Model analysis of above results deformation and Natural
Dr. K.H. J atkar and Mr. Sunil S. Dhanwe [4] have been frequency for material 42CRMN-C1 is observed. The
analyzed3D model of Fin ite element analysis was performed deformation obtained is low and the natural frequency is more
to obtain the variation of the stress magnitude at critical as compared to other materials.
locations of connecting rod and crankshaft. The dynamic
analysis resulted in the development of the load on piston. This N.Ari varasan et al..[8]have been analyzed a three-dimension
load is calculated fro m MATLA B. This load was then applied model of petrol engine crankshaft is created using Solid works
to the FE model and boundary conditions were applied software. Fin ite element analysis (FEA) is performed to obtain
according to the engine assembly. It is observed that maximu m the variation of stress magnitude at critical location of
stress is developed at crank pin of crank shaft. The maximu m crankshaft. The load applied to the FE model in So lid works
stresses are developed at the fillet section of the big and the simu lation boundary conditions are applied according to the
small end of connecting rod. Stress analysis of connecting rod engine mounting conditions. The maximu m stress is predicted
and crankshaft by Finite Element Method using ANSYS by simu lation, with this value the fatigue life of cran kshaft can
WORKBENCH 11.0 Soft ware. Research get the stresses be predicted by using S-N curve for C40 steel which is
induced in the small end of the connecting rod are greater than existing. The fatigue life of crankshaft increased considerably
the stresses induced at the big end. Therefore, the chances of by change the material C60 steel. Researcher get, the
failure of the connecting rod may be at fillet section of both crankshaft failure occurs due to decrease in the fatigue
ends. strength. From the analysis the maximu m stresses and its
locations are highlighted. The maximu m life cycle for the C40
P. N. Rohini and S. Nagu[5]have been analyzed Design and steel is 1e6 cycles. The life cycle of the C60 steel is predicted
modifications of all the important components are carried out by as 2e6 cycles. Fro m this analysis significant increase in life
to increase the performance and thereby efficiency. Many cycle of the crankshaft is achieved.
redesign concepts have been emerged for cylinder head,
connecting rod, crankshaft, piston, carburetor, Fuel injection Surekha S. Shelke et al..[9]have been analyzed a three
pump and other engine components. Redesign of Crankshaft is dimension model of crankshaft is created using CATIA
carried out to get enough strength to sustain the gas pressure software. Finite element analysis (FEA) is performed to get the
and to have the better thermal stability. A lso new researches variation of stress magnitude at critical locations of crankshaft.
are going on to select an alternate material to cope up with the The boundary conditions are applied according to the engine
existing load cases, to get higher compression ratio, to reduce mounting conditions. The deflection, stress and strain will be
the inertia forces to increase the speed of the vehicle. By obtained from FEA study. Topology optimization of crankshaft
comparing Induced Stress and Deformation values, Material 3 for similar boundary conditions. The main purpose of
(SA E/AISI 8640 or SNCM240 or nickel chro miu m optimization study is to reduce the weight of a crankshaft. The
mo lybdenum steel) has higher strength and shows lower stress optimization will be carried out in Altair Optistruct software.
value (98.557N/ mm2) than other materials. Because of the Researcher get the stress increased from 204 MPa to 241 M Pa
more strength, nickel chro miu m molybdenum steel crankshaft but, the stress values always remain within yield criteria of
can withstand load even up to 200% of the original load value. material. The deflection in crankshaft for baseline design and
Due to the higher strength and considerable deformat ions, optimized design are 0.0182 mm and 0.018 mm respectively.
nickel chro miu m mo lybdenum steel can be used as the The total mass of the baseline model was 3.5 Kg which is
alternate and suitable crankshaft material for four stroke I.C. decreased up to 2.95 Kg. The percentage reduction in mass of
engine. the crankshaft observed up to 19%.
Ankurkumar D. Pandya and Prof. D. D. Kundaliya[6]have Surekha S. Shelke et al..[10]have been analyzed on the
been analyzed the modelling of the crankshaft is created by modelling of the crankshaft is created using CATIA-V5
using CREO & Pro-E software and Finite element analysis Software. Fin ite element analysis (FEA) is performed to
(FEA) is performed to obtain the variation of the stress at achieve the variation of stress at critical areas of the crank
critical location of the crankshaft using ANSYS software. The shaft using the ANSYS software and apply the boundary
analysis of crankshaft is based on according to the engine conditions. Then the results are drawn Von-misses stress and
condition, boundary condition and design specification of shear stress induced in the crankshaft. From above, the
crankshaft including crank pin or journal. The validation of the maximu m deformation occurs at the center of the crankpin
model is co mpared with the theoretical and FEA results of neck surface, maximu m stresses appear at the fillet areas
stresses are within the limits. Fro m above, maximu m between the crankshaft journal and crank cheeks and near the
deformation appears at the centre of crankpin neck surface. central point journal. The value of von-misses stresses that
The maximu m stress appears at the fillets between the comes out fro m the analysis is less than the material yield
crankshaft journal and crank cheeks and near the central point stress so our design is safe.
Journal. The edge of main journal is high stress area. FEA
International Journal of Engineering Science and Computing, April 2017 10550 http://ijesc.org/
Ms. Jagruti K. Chaudhari and Dr. R. B. Barji bhe [11] have 4. RES EARCH METHODOLOGY
been analyzed 3D fin ite element analysis was carried out on
the modal analysis of crankshaft and the stress analysis of Introduction & Literature Review
crankshaft to check the safety. The FEM software ANSYS
workbench was used to simulate the analysis of crankshaft.
The results of stress and deformation distributions and natural Problem Define
frequency of crankshaft were obtained by using ANSYS
software. Fro m above, model analysis FEA results match with
the experimental and theoretical calculation for validation of Design Input Parameter & Justification
model. The comparison of analysis results of all five materials
will show the effect o f stresses on different materials and this
will help to select suitable material for coating. Zinc Alloy can Design of Crankshaft
be used or coating can be done as it shows better results and
also economically cheaper.
Failure analysis of Crankshaft
KishorRaskar and Prof. C M Gajare[12] have been analyzed
the CAD model is created in Creo 2.0. The FEA is carried out
using Hyper mesh as pre-processor and Optistruct as a solver. Validation of work
The project goes through two steps. In first behavior of
different material is observed by performing finite element
analysis and in the second stage the mass optimization of the Conclusion
crankshaft is performed. Researched get, Cost, fatigue,
manufacturability and machinability may produce hurdle to
alu minu m replacement. But Nodular cast iron has the Future Scope of work
beneficial attributes of grey cast iron (that is, low melting
point, great smoothness and cast ability, fabulous Chart 1 Research Methodol ogy
mach inability, and wear resistance) and also the mechanical
5. ENGIN E SPECIFICATION
attributes of steel (that is generally high quality, hardness,
durability, wo rkab ility, and solidify capacity) which can serves Suzuki Access 125 Regular Model
as a superior replacement Table.1. Engine Specificati ons
International Journal of Engineering Science and Computing, April 2017 10551 http://ijesc.org/
Pressure Calculat ions: 6.5 × 103 =
T=
Density of petrol (CgH18) :
ρ = 750 kg / m3 = 8.8672 Nm
= 750 × 10-9 kg / mm3 = 8.8672 × 103 Nmm
Von misses Stress :
Operating Temperature : σvon =
T = 20 0C Where,
= 20 + 273.15 M eq = Equivalent bending mo ment
= 293.15 0k So, Equivalent bending mo ment
Mass of displacement : M eq = [(kb × Mma x)2 + (kt × T)2 ]½
m=ρ×V
Where,
Where,
kb = Co mbined shock & fat igue for bending = 1
ρ = Density
kt = Co mbined shock & fat igue for torsional = 1
V = Vo lu me
M max= Bending mo ment
= (750 × 10-9 ) × (124 × 103 )
= 0.093 kg = [(1× 503.65 × 103 )2 + (1 × 8.8672 × 103 )2 ]½
Molecular mass of petrol : = [(2536.63 × 108 ) + (0.5897 × 108 )]½
M = 114.228 × 10-3 kg / mo le = [2537.22 × 108 ]½
Gas constant for petrol : = 50.37082 × 104
R = 72.7868 × 103 J / kg / mo l K = 503.708 × 103 Nmm
We know thatpV = mRT Now,
σvon =
p × 124 × 103 = 0.093 × 72.7868 × 103 × 293.15
=
σvon = 233.664Mpa
p=
p = 16.003 MPa Equivalent twisting mo ment:
Teq = (M max2 + T2 )½
Design Calculations = [(253663.323 × 106 ) + (78.6272 × 106 )½
Gas Force ( Fp) : = [253741.9497 × 106 ]½
Fp = P × A = 536.2333 × 103 Nmm
Where, Now,
P = Pressure
Teq =
A = Cross Section Area of Piston
Fp =16.003 × ( × D2 ) 536.2333 × 103 =
= 16.003 ×( × 53.52 ) τ=
= 16.003 × 2248.006
Strain for med iu m carbon steel:
= 35974.84 N
= 35.97484 × 103 N σ
ε=
=
Moment on pin:
= 0.001168
M max= ×
Where, Strain for Ductile cast iron:
lc = Length of crank p in, mm
σ
= × ε=
International Journal of Engineering Science and Computing, April 2017 10552 http://ijesc.org/
7. SOFTWARE ANALYS IS CALCULATIONS
Modelling of Crankshaft:
Cran kshaft of Suzu ki access 125 is procured fro m market and
it is selected for research work. The dimensions of the
crankshaft are carryout by using instrument like vernier caliper
and micro meter. Cran kshaft was modeled with the help of
Auto-cad Software.
Meshing
Here, I have chosen tetrahedral mesh because of the
tetrahedral meshing methodology is utilized for the cross
section of the strong district geometry and meshing delivers
fantastic cross section for boundary representation of solid Figure.6. Von-mises stress of ductile cast iron
auxiliary model. Meshing of solid is as below.
International Journal of Engineering Science and Computing, April 2017 10553 http://ijesc.org/
steel
8. RES ULT
Figure.10. Deformati on of nickel chromium molybdenum Chart 2 Von-mises stress and deformation result
International Journal of Engineering Science and Computing, April 2017 10554 http://ijesc.org/
9. CONCLUS ION International Journal of Advanced Engineering and Global
Technology (ISSN No : 2309-4893, Vo l-03, Issue-08, August
Fro m above work, the crankshaft failure occurs due to 2015, Pages 1088-1094).
decreased in the fatigue strength. Crankshaft is modeled by
using Auto-cad software and maximu m stress is calculated by [8]. N. Arivarasan1, T. Velmurugan, K. M. Parammasivam
analytical as well as ANSYS software. Fro m this work, the “Modelling and Analysis of a Cran kshaft in a Single Cylinder
maximu m deformation occurs at the center of crankpin and Four Stroke Petrol Engine” Journal of Chemical and
maximu m stress appears at the area between crank journal and Pharmaceutical Sciences (ISSN: 0974-2115, Vo lu me-9, Issue-
crank cheeks. So, the value of von-mises stresses of analysis is 2, April - June 2016 Pages 954-957).
less than the material y ield stress so this design is safe. By
comparing von-mises stress and deformation values, Material 3 [9]. Su rekha S. Shelke, Dr. C. L. Dhamejan i, A. S. Gadhave
(nickel chro miu m molybdenum steel) has higher strength and “Static Analysis of Bajaj Pulsar 150 CC Crankshaft Using
shows lower stress value (239.06 M Pa) than other materials. ANSYS” International Research Journal of Engineering and
Because of the more strength, nickel chro miu m mo lybdenum Technology (ISSN: 2395-0072, Vo lu me-3, Issue-6, June-2016
steel crankshaft can withstand load.Thus it can able to give Pages 206-212).
maximu m life than other selected materials. Due to the higher
strength and considerable deformations, nickel chro miu m [10]. Su rekha S. Shelke, Dr. C. L. Dhamejan i, A. S. Gadhave
mo lybdenum steel can be used as the alternate and suitable “Modelling and Analysis of the Crankshaft Using ANSYS
crankshaft material for single cylinder petrol engine. Software” International Journal of Engineering Science and
Co mputing (ISSN 2321 3361, Vo lu me-6, Issue No-6, June
10. FUTUR E SCOPE 2016 Pages 6796-6800).
Analysis of crankshaft can be done with other material [11]. Ms. Jagruti K. Chaudhari, Dr. R. B. Barjibhe
which has high strength and low weight in future. “Experimental And Numerical Analysis of Crankshaft Used In
Vibrat ion Analysis can be performing to estimate the life Hero Honda Splendor Motorcycle” International Journal of
of the component. New Technology and Research (ISSN: 2454-4116, Volu me -2,
Optimization can be done with other material wh ich is Issue-7, Ju ly 2016 Pages 83-94).
higher strength and other factors for the failure can be
considered. [12]. KishorRaskar and Prof. C M Gajare “Optimization of a
two wheeler crankshaft using Finite Element analysis”
11. REFERENCE International Engineering Research Journal (Page No 1054 -
1061).
[1]. S. Bhagya Laksh mi, Sudheer Ku mar V, Ch. Nagaraju
“Dynamic Analysis of Honda Engine Crankshaft” International [13]. R.S. KHURMI and J.K. GUPTA “A Textbook of
Journal of Engineering and Innovative Technology (Volu me 2, Machine Design” Eurasia publishing house (Pvt.) Ltd. (2005).
Issue 1, Ju ly 2012, Pages 174-178).
[14]. R. K. Rajput “A Textbook of Internal Co mbustion
[2]. Jaimin Brah mbhatt, Prof. Abhishekchoubey “Design and Engines” Laxmi Publication (P) Ltd. ( 2009).
Analysis of Crankshaft for Single Cylinder 4-Stroke Diesel
Engine” International Journal o f Advanced Engineering
Research and Studies (E-ISSN2249–8974, Vo lu me-1, Issue-4,
July-Sept. 2012, Pages 88-90).
International Journal of Engineering Science and Computing, April 2017 10555 http://ijesc.org/