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**Optimization of a Forged Steel Crankshaft Subject to Dynamic
**

Loading

Farzin H. Montazersadgh

Formerly Graduate Student at The University of Toledo

Ali Fatemi

The University of Toledo

Copyright © 2008 SAE International

**geometry for analysis, finite element models have been
**

considered to provide an accurate and reasonable

simulation. Because crankshafts are among large

volume production components in the IC engine, weight

and cost reductions of this component are very effective

in increasing the fuel efficiency and reducing the overall

cost of the engine.

ABSTRACT

In this study a dynamic simulation was conducted on a

forged steel crankshaft from a single cylinder four stroke

engine. Finite element analysis was performed to obtain

the variation of the stress magnitude at critical locations.

The dynamic analysis resulted in the development of the

load spectrum applied to the crankpin bearing. This load

was then applied to the FE model and boundary

conditions were applied according to the engine

mounting conditions.

Results obtained from the

aforementioned analysis were then used in optimization

of the forged steel crankshaft. Geometry, material, and

manufacturing processes were optimized using different

geometric constraints, manufacturing feasibility, and

cost. The first step in the optimization process was

weight reduction of the component considering dynamic

loading. This required the stress range under dynamic

loading not to exceed the magnitude of the stress range

in the original crankshaft. Possible weight reduction

options and their combinations were considered. The

optimization and weight reduction were considered in an

interactive manner and evaluated by manufacturing

feasibility and cost. The optimization process resulted in

an 18% weight reduction, increased fatigue strength,

and a reduced cost of the crankshaft.

**Since fatigue crack initiation and fracture at the fillets is
**

one of the primary failure mechanisms of automotive

crankshafts, the fillet rolling process has been used to

improve the fatigue life of crankshafts for many years.

The fillet rolling process induces compressive residual

stresses within the fillet surface. The compressive

residual stress lowers the fatigue driving forces due to

operating loads near the fillet surface and consequently

increases the fatigue life of the crankshaft.

Kamimura (1985) [1] performed a study on the effect of

fillet rolling on fatigue strength of a ductile cast iron

crankshaft. Bench tests were conducted on crankshaft

pin samples with a fatigue evaluation on test pieces in

order to study the fatigue strength of fillet rolled

crankshafts and specimens. This study showed that an

optimum deep rolling method could increase the bending

fatigue strength by 83% over conventional ductile iron

crankshafts that were not fillet rolled.

INTRODUCTION

**Park et al. (2001) [2] showed that without any
**

dimensional modification, the fatigue life of a crankshaft

could be improved significantly by applying various

surface treatments. Fillet rolling and nitriding were the

surface treatment processes that were studied in this

research. Their study showed that the standard base

sample had a fatigue limit of 10 kN, while fillet rolled

specimens with 500 kgf load exhibited a 14 kN fatigue

limit (i.e. 40% increase in fatigue limit). With 900 kgf

rolling load, the fatigue limit increased to more than 18

kN (i.e. 80% increase in fatigue limit). These

experimental data clearly indicate that fillet rolling can

dramatically increase the fatigue performance of

crankshafts. Although higher rolling force results in

**The crankshaft is one of the largest components in the
**

internal combustion (IC) engine and has a complex

geometry consisting of cylinders as bearings, and plates

as the crank webs. Geometry section changes in the

crankshaft cause stress concentration at fillet areas

where bearings are connected to the crank webs. In

addition, this component undergoes both torsional and

bending loads during its service life. Therefore, fillet

areas are locations that are subject to the most critical

stresses during the service life of the crankshaft. As a

result, these locations are a common fatigue failure site

of crankshafts. Since the crankshaft has a complex

1

the load should not be so high as to cause excess plastic deformation. spectrum applied to the crank pin bearing. This should not be misunderstood as to mean that the higher the engine rpm is the longer the service life because there are many other factors to consider in operation of the engine. further discussion of these issues is avoided. The dynamics of the mechanism was solved using analytical techniques and the results were verified by simulation in ADAMS. nodular cast iron. Accurate assessment of stresses is critical to the input of fatigue analysis and optimization of the crankshaft design. The selection of the best alternative is dependent upon the production volume. namely combustion and inertia. DYNAMIC LOAD AND STRESS ANALYSIS The crankshaft is subjected to complex loading due to the motion of the connecting rod. An extensive study was performed by Nallicheri et al. but the machining percentage cost was 43% which reduced the cost of the final component. The raw material cost of the microalloyed steel forging crankshaft was 38%. Based on these assumptions. Therefore. a brief summary of the dynamic loading and stress analysis of the forged steel crankshaft is first considered with details provided in [5]. which consists of bending and torsion. The material selection was based on fatigue strength requirements and potential cost benefits. In addition. In addition.000 parts/year). Dynamic loading analysis of the crankshaft results in more realistic stresses whereas static analysis provides results that may not reflect operating conditions. and procedure that have been used are described. study found the optimum level of rolling force was experimentally to be between 700 and 900 kgf. Materials evaluated in their study included medium carbon steel SAE 1050 (CS) and medium carbon alloy steel SAE 4140 (AS) grades using a sulfur level of 0. The microalloy grades that were evaluated offered cost reduction opportunities over the original materials. It was concluded that the production volume of the crankshaft and the requirements of the engine were predominant factors in a cost effective production option for this application. Figure 1 shows the digitized model of the forged steel crankshaft used in this study. A study was performed by Hoffmann and Turonek to examine the cost reduction opportunities associated with forged steel in which the raw material and machinability were the primary factors evaluated [5]. (CS-HS and AS-HS). The analysis was performed over different engine speeds and as a result the critical engine speed and critical locations on the crankshaft were obtained. The load was applied to the FE model in ABAQUS. Finally. The ADI crankshafts were cost effective at low production runs (below 180. and two micro-alloy grades (MA1 and MA2). raw material was about 30% of the final cost. and austempered ductile iron (ADI) casting were considered as manufacturing options to evaluate the cost effectiveness of using these alternatives for crankshafts. Instead. Optimization of the crankshaft requires a determination of an accurate assessment of the loading. resulting in a further cost reduction. and by 7% to 11% compared to a quenched and tempered carbon steel (SAE 1050). microalloyed steel forgings offered the most cost effective high performance crankshaft. constraints. As these issues were not considered in the dynamic load analysis study. Results from FE analysis were verified by attaching strain gages to several locations on the crankshaft [5]. each optimization step was approximated based on improving fatigue resistance while considering manufacturing feasibility and maintaining dynamic balance with an aim of reducing the weight and the final cost of the component. which resulted in the load 2 . a brief discussion of cost reduction of the optimized crankshaft is provided. Stress variation over the engine cycle and the effect of torsional load in the analysis were also investigated. The most important issue when the engine speed increases is wear and lubrication.better fatigue strength as a result of inducing higher compressive stress on the fillet surface. Then the optimization objectives. the critical loading case for this engine is at the minimum operating speed of 2000 rpm [5].000 parts/year. whereas machining cost was 47% for the forged steel crankshaft. In this paper. Steel forgings. The micro-alloy grade could reduce the finished cost by 11% to 19% compared to a quenched and tempered alloy steel (SAE 4140). the heat treatment process was eliminated for the microalloyed steel crankshaft. to the crankshaft. Finite element analysis was used to obtain the variation in stress magnitude at critical locations.10%. The optimization carried out in this work was not based on only the typical geometrical optimization techniques. and the boundary conditions were defined according to the engine mount design. which transforms two sources of loading. Detailed dynamic load and stress analysis of the crankshaft investigated in this study was the subject of another paper [5]. The specimens prepared from the crankshaft in the Park et al. The dynamic analysis of the engine that uses this type of crankshaft showed that as the engine speed increases the maximum bending load decreases. micro-alloy steel forgings. At production volumes above 200. This is followed by a discussion of material alternatives and the application of compressive residual stress in the fillet area of the crankpin. on material alternatives for the automotive crankshaft based on manufacturing economics [4]. the micro-alloy grades met or exceeded the fatigue strength of the original materials for the applications studied and had better machinability characteristics. This is because variables such as manufacturing and material parameters could not be organized in a mathematical function according to the set of constraints such that the maximum or minimum could be defined.

This local mesh size resulted in five elements in the radius of the fillet areas. In addition. although stresses applied to these sections are low. the maximum von Mises stress occurs at location 2.250 Maximum Range Stress Magnitude (MPa) 200 150 100 50 Figure 1: Digitized model of the original forged steel crankshaft geometry used. Therefore. OPTIMIZATION OBJECTIVES AND CONSTRAINTS In this study. these sections cannot be removed. the following design variables were then considered in the optimization study: • • • • Figure 2 shows the maximum von Mises stress and von Mises stress range at six locations on the crankshaft fillets at the engine speed of 2000 rpm for the crankshaft. • • • • • The approach used to obtain stresses at different locations at different times during an engine cycle was by superposition of the basic loading conditions. reducing the weight and manufacturing cost while improving or maintaining the fatigue performance of the original component were the main objectives. Therefore. the other five locations were not considered to be critical in the analysis. while other locations experience stresses lower than location 2.08 mm and a local mesh size of 0. such as the counter weights and crank webs. The crankshaft has to be dynamically balanced in which the counter weights serve this purpose. Thickness of the crank web Geometry of the crank web Increasing the inner hole diameters and depths Geometry changes on the outer section of the crankpin bearing GEOMETRY OPTIMIZATION PROCEDURE The investigation of the stress contour of the crankshaft FEA model during an engine cycle showed that some locations of the crankshaft. 2 3 4 5 6 Location Number Figure 2: Maximum and range of von Mises stress at an engine speed of 2000 rpm at different locations on the crankshaft. the following dimensions were not changed: Convergence of stress at different locations was considered as the criterion for the selection of mesh size and number of elements for the finite element stress analysis. Then the corresponding stress components are added together. 0 1 It was also shown that a consideration of the torsional load in the overall dynamic loading conditions has no effect on von Mises stress at the critically stressed location [5]. The sign of von Mises stress was determined by the sign of the principal stress that has the maximum absolute value.337 elements for the crankshaft that corresponded to a global mesh size of 5. In addition. optimization was carried out in such a way that the equivalent local stress amplitude at any location of the optimized model did not exceed the equivalent stress amplitude at the critical location of the original model. As can be seen from the figure. Since the original crankshaft used in the engine had acceptable fatigue performance. In addition. Satisfactory results were obtained using 119. the effect of torsion on the stress range is also relatively small at other locations undergoing torsional load. the bending stiffness has to be kept within permissible limits. 3 .762 mm in the model. Therefore. but can only be changed according to other modifications made to the component. Outer diameters of different cylinders Crank radius Location of the main bearings Geometry of the main bearings Width and geometry of the connecting rod bearing Considering the functions of the crankshaft and its constraints. are subject to low stresses. the crankshaft analysis could be simplified to an application of bending load only [5]. This involves applying a unit load to each basic condition and then scaling the stresses from each unit load according to the dynamic loading. Therefore. the optimized crankshaft was expected to be interchangeable with the original crankshaft.

the blue locations shown in Figure 4 have low stresses during the loading cycle and have the potential for material removal and weight reduction. manufacturing process considerations. According to FE analysis. Objective function. design variables. Several cases of geometric modifications were considered. and constraints are summarized in this figure and it is shown that the optimization process consisting of geometry modifications. On the far right side of the crankshaft shown in Figure 1 there is a threaded hole. In a feasible design. Therefore. Local shape optimization techniques were applied to different locations of the crankshaft to lower the weight. Figure 4: Stress distribution under critical loading condition at the crank angle of 5 degrees after TDC.Figure 3: General flow chart of forged steel crankshaft optimization procedure. stresses under consideration and discussed here are with reference to the stress ranges. while the manufacturability is still economical. following each shape optimization iteration the optimized component was investigated for design feasibility and examined to determine whether the design was the best possible option. The general flow chart of the optimization process is shown in Figure 3. and material alternatives was performed simultaneously. Also. the first step was to remove material symmetric to the central axis without compromising the dynamic balance of the crankshaft. After each optimization step the counter weights were balanced in order to achieve an accurate estimate of the weight reduction. The depth of this hole does not affect the function of the crankshaft. the component stresses fall within the stress limits and bending stiffness does not change significantly. Since maintaining dynamic balance is a key concern in the optimization of this component. all of the 4 . It should be noted that the effect of mean stress on the results was negligible.

A significant percentage of the weight in the crankshaft is in the crank counterweight or web mass. This option was restricted to the clearance between the piston and counter weights of the crankshaft. In order to balance the modified crankshaft. radial deflection at mid section of the crankpin. were: • • • • Deflection Weight Figure 6: Stress range ratio at critical location.5 Stress Range Other optimization cases considered in this study. 5 . Cases 1. symmetric to the central axis Eccentric crankpin hole The counterweight radius for Case 3 is larger than the original crankshaft which causes interference between the counterweight and the piston.6 0.1 1. Reducing the web thickness is another optimization opportunity that was performed on the crankshaft web (Case 3 in Figure 5). In order to dynamically balance the crankshaft.7 0. 3*. Therefore. the fillet radius has to be increased. 2. and 4 results in increased clearance between the counter weights and the piston allowing for the increased counter weight radius in Case 3. Redesigning the crankpin geometry Removal of material from the center of the crank web.8 0. 2*. material has to be added to the counter weights which can be accomplished by increasing the radius. material has to be removed from the counter weight. Since the current geometry is designed with a specific clearance between the counter weights and the piston. and 4 will move the center of Since each optimization case was studied individually. 2. but not implemented due to either a small decrease in weight and/or manufacturing difficulty or cost.2 1. 2. further analysis was needed by considering a combination of these cases. FE models of possible combinations were created and FE analysis with dynamic load was considered for each combination. Applying these changes to the crankshaft causes the center of mass to move toward the counter weights. 1. as compared to the stress range in the original crankshaft at the critical location. and 3 Cases 1. the center of gravity moves toward the crankpin bearing. The material removal from the counter weights in the combination Cases 1.Therefore. Options for a redesigned crankshaft were developed such that as many optimization cases as possible could be applied. 2. This requires not having negative slopes. a combination of Cases 1. symmetric to the central axis Removal of semi-circular material from the center of the crank web. An Increase in the diameter of this hole will result in decreasing the moment of inertia of the cross section.0 0. The crank web was then modified such that no changes in the counter weights would be necessary (Case 4 in Figure 5). this optimization effort could not be implemented without additional changes to the piston. Results of the stress range for each of these combination models showed that the critical location (location 2 in Figure 2) does not change as a result of these geometry modifications. As a result of this change in the crank web. with 2. However. Therefore.72 kg for weigh.9 0.3 Redesigning the crank web and removing material from this section was the next optimization case under consideration while keeping the feasibility of the manufacturing process in mind. The horizontal line at 1 stands for the original crankshaft with 188 MPa for stress range. This increase in the fillet radius does not affect the connecting rod geometry since the connecting rod has sufficient clearance. Case 1: Increasing the hole depth Case 2: Increasing the oil hole diameter and the fillet radius Another optimization step which does not require any complicated changes in the geometry is increasing the diameter of the crankpin hole (Case 2 in Figure 5). Case 4: Changing the crank web geometry Case 3: Reducing the crank web thickness Figure 5: Optimized crankshaft geometry. reducing the weight of this section could result in an improvement in weight reduction of the component. this hole could be drilled as far as possible in the geometry (Case 1 in Figure 5). The horizontal line at 1 stands for the original crankshaft.36×10-2 mm for radial deflection. in order to avoid increasing the stress level at the fillet area. and 4 Cases 1. and with 3. and weight comparison with the original crankshaft. A comparison plot of stress range ratios for the different case combinations of the optimized crankshaft. is shown in Figure 6. 3. 2. and 4 Difference with Original Crankshaft (Original = 1) 1. and 4 Cases 1.

further increasing the hole diameter to larger than 25. the application of compressive residual stress in the fillet area of the crankshaft can increases the fatigue strength by 40% to 80%.25Si. one of the most common alternatives for forged steel is microalloyed (MA) steel. At a certain reduction in web thickness. 0. which means the crankshaft becomes dynamically balanced. 3. Park et al. Further improvement of the performance could result in further geometry changes and weight reduction. Based on the results of their study. The use of MA steel enables elimination of any further post-forging heat treatment. will cause the stress range at the critical location to increase by 7%.35C. These modifications reduce the weight of the original crankshaft by 18%. This increase is easily compensated for by the beneficial effect of the compressive residual stress from fillet rolling. with a typical composition of 0.e. 1. 250 Original With regard to material options.12V with an addition of the microalloying element Ti. and 4 in Figure 6. Therefore.72 inch) to 25. FILLET ROLLING AND MATERIAL ALTERNATIVES The next step in the optimization process was an attempt to modify the production steps in order to reduce the cost or improve the performance of the original crankshaft. 3.8Mn. the center of gravity will move toward the crankpin.of microalloyed steel can reduce the final cost of the crankshaft by eliminating the heat treatment process and increasing machinability. the center of gravity will be located on the main crankshaft axis. crankshaft geometry. 6 .4 mm was not possible. In addition. Location numbers are shown in Figure 2. A potential modification for this improvement and subsequent weight reduction is the addition of compressive residual stress to the fillet area of the crankpin which is the critical (i. Pichard et al. [7] performed a study on a modified microalloyed steel with a titanium addition for the production of forged crankshafts. Deflections of different optimized crankshaft cases are shown in Figure 6. [2]. 0. gravity toward the counter weights. this is affected by the geometry changes and weight reduction. Increasing the crankpin hole is an option which does not influence the manufacturing process and is not an expensive process. the critical location is still at the fillet and the increase in stress at other locations is not significant. modification in the manufacturing process. and the applied rolling force. As can be seen in this figure. As can be seen in Figure 6. Therefore. With regard to the cost of the optimized crankshaft. and 4 are reduced slightly. The combination of Cases 1. the 35MV7 control-cooled microalloyed steel showed similar tensile and rotating bending fatigue behavior to an AISI 4142 quenched and tempered steel. Increasing the hole diameter from the original 18. Due to lack of experimental information. the stress range at the critical location for the combination of Cases 1. 2. 2. the precise magnitude of the residual stress that could be induced in the crankshaft geometry under investigation could not be determined. the machinability of the microalloyed steel could be improved by about 40% in turning and about 160% in drilling [7]. 2. failure) area. The final optimized geometry is shown in Figure 5. It should be noted that the fatigue strength of the optimized crankshaft is significantly higher than the original crankshaft due to a slight increase in the stress range of 7% at the fillet and a significant increase on the order of 40% to 80% in fatigue strength due to fillet rolling. Studies by Kamimura [1]. resulting in shorter manufacturing process with a subsequent increase in the forged crankshaft productivity. Based on these studies.3 mm (0.4 mm (1 inch) and reducing the crank web thickness in order to maintain dynamic balance of the crankshaft. 3. because sufficient material is needed to restrict plastic deformation in the rolling process to produce residual stress. the stiffness of the optimized crankshaft is within the acceptable limit. Crankshaft deflection does not increase more than 15% for the combination of these cases. Figure 7 shows the stress range comparisons at different locations shown in Figure 2. The choice of this MA steel for a crankshaft application was based on the 35MV7 steel grade. between the original and the optimized crankshafts. the geometry of the crankshaft could be modified further to take advantage of the results of improved fatigue strength due to fillet rolling and/or the use of microalloyed steel. This modification is shown as Case 1. and Chien et al. [6] showed that inducing compressive residual stress increases the fatigue strength of the crankshaft significantly. Since the wall thickness in the crankpin area is limited. depending on the material properties. as discussed earlier. Further modification to the crankpin geometry is possible. Since reducing the web thickness is not symmetric with respect to the central axis and results in more material removal from the side of the counter weights. FINAL OPTIMIZED CRANKSHAFT Considering the manufacturing processes. and 4 results in a 12% weight reduction in comparison with the original crankshaft. the use Stress Range (MPa) 200 Optimized 150 100 50 0 1 2 3 4 5 6 Location Number Figure 5: Stress range results for optimized geometry and original component at different locations on the crankshaft.

This is because the drilled holes in Cases 1 and 2 are redesigned to have larger diameters and the bore in Case 1 is modified to have more depth than the original bore. the overall cost of the forged steel crankshaft can be reduced. S. 4.” SAE Technical Paper No. Kamimura. Park. when considering the improvement in machinability of the microalloyed steel along with the reduced material cost because of an 18% 7 .” In Proceedings of the 26th ISATA International Symposium on Automotive Technology and Automation. 1985.” SAE Technical Paper No. 2. Pichard. Germany. USA. 1991. Ko. and the use of MA steel.” SAE Technical Paper No. and cost. Y. and Rezel. In addition. The geometry parameters that influence machining and the final cost of the component include an increase in the drilling process. A. M. V. indicates a reduction in the total cost of the forged steel crankshaft. Chien. pp. PA. R. PA. R. which were then combined to obtain the final optimized geometry. and Fatemi. Society of Automotive Engineers. Warrendale. 852204. along with the reduced material cost due to the 18% weight reduction. Pan. J. This was achieved by changing the dimensions and geometry of the crank counterweights while maintaining dynamic balance of the crankshaft. S. Private Communication in Feb. S. 2001. Warrendale. microalloyed steel has 5% to 10% better machinability than quenched and tempered steel. Vol. The application of compressive residual stress by a fillet rolling process is a parameter in the manufacturing process that will add to the cost of the finished component. T. Society of Automotive Engineers. Y. pp.. F. the heat treatment cost savings are significant enough to offset this difference (Wicklund.weight reduction. D. and Ho. D. Michael Wicklund.Cost Reduction Opportunities. N. W. Adding fillet rolling was considered in the manufacturing process. 3. The optimized geometry requires redesign and remanufacturing of the forging dies used.. Nallicheri. “High Performance Forged Steel Crankshafts . C. A. manufacturing process. 920784. performance. PA.. “Fatigue Life Analysis of Crankshaft at Various Surface Treatments.” SAE Technical Paper No. 2007 [8]). The optimization that was developed did not require any changes to the engine block or connecting rod.” SAE Technical Paper No. 2007. USA. [4]). C. 2005. 1992.” International Journal of Fatigue. USA. 6. Society of Automotive Engineers. 2007. Society of Automotive Engineers. Society of Automotive Engineers. P. C. F. “Effects of Fillet Rolling on Fatigue Strength of Ductile Cast Iron Crankshaft. resulting in reduced machining costs due to enhanced production rates and longer tool life (Nallicheri et al. “Dynamic Load and Stress Analysis of a Crankshaft. Wicklund. significantly increases the fatigue life of the component. and in turn.. which results in a significant increase in fatigue strength of the crankshaft.. H. J. A major constraint of this optimization was for the optimized crankshaft to replace the original crankshaft in the engine without any changes to the engine block or the connecting rod. H. Montazersadgh. and Jung.. 157-163.... USA. 1993. 27. J. is acknowledged for his technical support and information. A Competitive Assessment Based on Manufacturing Economics. Fillet rolling induces compressive residual stress in the fillet areas. The optimization resulted in an 18% weight reduction of the forged steel crankshaft.. Warrendale. 1. J.. “Material Alternatives for the Automotive Crankshaft. 2001-013374.. PA.. Warrendale. In addition. 1-19. Close. PA. The use of a microalloyed steel as an alternative material to the current forged steel composition results in the elimination of the heat treatment process. SUMMARY An optimization study was performed on a forged steel crankshaft that considered the geometry. Clark.... and Field. 8.. USA. Warrendale. REFERENCES Although a microalloy steel grade is somewhat more expensive than hot-rolled steel bar. President of FIERF. 2007-010258. An optimization in the geometry included local changes at different locations on the crankshaft. ACKNOWLEDGMENTS Financial support for this research project was provided by Forging Industry Educational and Research Foundation (FIERF) and American Iron and Steel Institute (AISI). A consideration of these factors. 910139. Aachen. H. Tomme. and Turonek. 5. 7. Hoffmann. “Fatigue Analysis of Crankshaft Sections Under Bending with Consideration of Residual Stresses. “Alternative Materials for the Manufacture of Automobile Components: Example of Industrial Development of a Microalloyed Engineering Steel for the Production of Forged Crankshafts. 2007.

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