Optimization and Finite Element Analysis of Single Cylinder Engine Crankshaft for Improving Fatigue Life
American Journal of Mechanical and Materials Engineering
Volume 1, Issue 3, September 2017, Pages: 58-68
Received: Apr. 3, 2017;
Accepted: Apr. 21, 2017;
Published: Jun. 26, 2017
Views 2156 Downloads 231
Muse Degefe, Department of Mechanical Engineering, Faculty of Engineering & Technology, Mettu University, Mettu, Ethiopia
Prabhu Paramasivam, Department of Mechanical Engineering, Faculty of Engineering & Technology, Mettu University, Mettu, Ethiopia
Tamana Dabasa, Department of Mechanical and Industrial Engineering, Dire Dawa University, Dire Dawa, Ethiopia
Venkatesh Kumar S., Department of Mechanical Engineering, Faculty of Engineering & Technology, Mettu University, Mettu, Ethiopia
Crankshaft is large volume production component with a complex geometry in internal combustion Engine (ICE), which converts the reciprocating displacement of the piston into a rotary motion of the crank. An effort was done in this paper to improve fatigue life for single cylinder engine crankshaft with geometric optimization. The modeling of the original and optimized crankshaft is created using SOLIDWORK Software and imported to ANSYS software for analysis. Finite element analysis (FEA) was performed to obtain maximum stress point or concentrated stress, to optimize the life of crank shaft by applying the boundary conditions. The maximum stress appears at the fillet areas between the crankshaft journal and crank web. The FE model of the crankshaft geometry is meshed with tetrahedral elements. Mesh refinement are done on the crank pin fillet and journal fillet, so that fine mesh is obtained on fillet areas, which are generally critical locations on crankshaft. The failure in the crankshaft initiated at the fillet region of the journal, and fatigue is the dominant mechanism of failure. Geometry optimization resulted in 15% stress reduction and life is optimized 62.55% crankshaft which was achieved by changing crankpin fillet radius and 25.88% stress reduction and life is optimized 70.63% of crankpin diameter change. Then the results Von-misses stress, shear stress and life of crankshaft is done using ANSYS software results. It was concluded from that the result of geometric optimization parameter; like changing crankpin fillet radius and crankpin diameter were changes in model of crankshaft to improve fatigue life of crankshaft.
Venkatesh Kumar S.,
Optimization and Finite Element Analysis of Single Cylinder Engine Crankshaft for Improving Fatigue Life, American Journal of Mechanical and Materials Engineering.
Vol. 1, No. 3,
2017, pp. 58-68.
C. M. Balamurugan, et al, “Computer Aided Modeling and Optimization of Crankshaft”, ‘International Journal of Scientific & Engineering Research’, ISSN 2229-5518, Issue 8, vol. 2, 2011, pp. 1-6.
Walter D. Pilkey and Deborah F. Pilkey, Peterson’s Stress Concentration Factors, Third Edition.
Xiao-lei Xu et al, “Truck Petrol Engine Crankshaft Failure Analysis”, Journal of Failure Analysis and Prevention, 2011, Vol. No. – 11, Page No-51–55.
Osman Asi, “Failure analysis of a crankshaft made from ductile cast iron Engineering Failure Analysis, Vol. No. – 13, 2006, Page No- 1260–1267.
Farzin H. Montazersadgh et al, “Modification of crankshaft for improvement in fatigue life’’
Khurmi. RS, Gupta. JK, 2005, “A Textbook of Machine Design”. Fourteenth Edition, Eurasia Publishing House, India.
Theory and Design of Automotive Engines, [AU51].
Ali Fatemi, “Fatigue Performance Comparison and Optimization of Forged Steel and Ductile Cast Iron Crankshafts”, Executive Summary, August 2007.
H. Bayrakceken et al, “Failures of single cylinder petrol engines crank shafts”, Engineering Failure Analysis, Vol. No. – 14, 2007, Page No- 725–730.
Farzin Montazersadgh and Ali Fatemi, “Stress Analysis and Optimization of Crankshafts Subject to Dynamic Loading”, Final Project Report, August 2007.
R. M. Metkar et al, “A fatigue analysis and life estimation of crankshaft - a review”, International Journal of Mechanical and Materials Engineering (IJMME), Vol. 6, 2011, No. 3, 425-430.
F. S. Silva, “Analysis of vehicle crankshaft failure”, Engineering Failure Analysis 101, 2003: 605–616.
Henry, et al, “Crankshaft Durability Prediction”, SAE Technical Paper No. 920087, in 1992”.
M. Zoroufi and A. Fatemi, "A Literature Review on Durability Evaluation of Crankshafts Including Comparisons of Competing Manufacturing Processes and Cost Analysis", 26th Forging Industry.
Amitpal Singh Punewale, et al, “Analysis & Optimization of Torsional Vibrations in a Four-Stroke Single Cylinder Diesel Engine Crankshaft”, International Journal of Engineering and Technical Research (IJETR), Volume-3, Issue-4, April 2015”.
Gu Yingkui, et al, “Strength Analysis of Diesel Engine Crankshaft Based on PRO/E and ANSYS,” Third International Conference on Measuring Technology and Mechatronics Automation
Ashwani Kumar Singh, et al “FEA of the crankshafts Design by using Ansys workbench For nickel chrome steel and structural steel”, International Journal of Scientific & Engineering Research, Volume 5, Issue 4, April-2014, 1249 ISSN 2229-5518.
Burrell, N. K., “Controlled Shot Peening of Automotive Components,” SAE Technical Paper No. 850365, Society of Automotive Engineers, 1995, Warrendale, PA, USA.
Park. H Ko, et al, “Fatigue Life Analysis of Crankshaft at Various Surface Treatments,” SAE Technical Paper No. 2001-01-3374, Society of Automotive Engineers, Warrendale, PA, USA.
Uchida, S. et al, 1984, “The Development of the DCI Crankshaft for the Nissan 60°-V6 Engine,” SAE Technical Paper No. 841220, Society of Automotive Engineers, Warrendale, PA, USA.
Infante V et al., “Failure of Crankshaft of Aerongine: A Contribution for an Accident Investigation”, 2013, Engineering Failure Analysis.
Jimenez Espadafor F et al., “Analysis of Diesel Generator Crankshaft Failure”, Engineering Failure Analysis, 2009, Vol. 16, pp. 2333-2341.
Ktari A et al., “Fatigue Fracture Expertise of Train Engine Crankshafts”, Engineering Failure Analysis, 2011, Vol. 18, pp. 1085-1093.
Jian Meng, et al, “Finite Element Analysis of 4-Cylinder Diesel Crankshaft,” I. J. Image, 2011, Graphics and Signal Processing, 5, 22-29
Bhumesh J, et al, “Finite Element Analysis of Single Cylinder Engine Crank Shaft”, International Journal of Advances in Engineering & Technology”, vol. 6, pp. 981-986, 2013.
Momin Muhammad Zia Muhammad Idris, “Crankshaft Strength Analysis Using Finite Element Method,” International Journal of Engineering Research and Applications (IJERA) ISSN: 2248-9622, Vol. 3, Issue 1, January -February 2013, pp. 1694-1698.
Alex. K. D, et al ‘‘Modeling the crankshaft by CATIA and dynamic analysis’’.
S. Vigneshwaran, T. M. Vigneshwaran, ‘’Failure Analysis and Optimization Crankshaft in Diesel Locomotive’’.
Rinkle Garg, et al, “Finite Element Analysis and Optimization of Crankshaft Design”, International Journal of Engineering and Management Research, Vol.-2, Issue-6, December 2012, ISSN No.: 2250-0758, Pages: 26-31.
Shweta Ambadas Naik, ‘’Failure Analysis of crankshaft by finite element method’’.
Suraj K. Kolhe, ‘’Diesel Engine Crankshaft High Cycle Fatigue Life Estimation and Improvement through FEA’’.
Nallicheri, et al, “Material Alternatives for the Automotive Crankshaft; A Competitive Assessment Based on Manufacturing Economics,” SAE Technical Paper No. 910139, 1991, Society of Automotive Engineers, Warrendale, PA, USA.
Ashvanee Garg, et al, “Performance Evaluation of Crankshaft from the Thermal Aspects: A Simulation Technique”.
Anant B. et al, “Comparative analysis of crankshaft in single cylinder petrol engine crankshaft by numerical and analytical method”.
Dinesh N. Bhut, “Design and Analysis of Shaft with Groove as Discontinuity under Different Loading Conditions”.
Jaimin Brahmbhatt, et al, "Design and Analysis of Crankshaft for Single Cylinder 4-Stroke Diesel Engine", International Journal of Advanced Engineering Research and Studies, IJAERS.
Rahul Kumar et al, “Conventional Design and Static Stress Analysis of IC Engine Component (Crank Pin) Using the Finite Element Method”.
V. Vijayakumar et al, “Design and Contact Analysis of Crankshaft Using Abaqus”, International journal of research in aeronautical and mechanical engineering ISSN (ONLINE): 2321-3051.