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:

80 Bore of Cylinder .2kN Maximum gas pressure taken same as cylinder peak pressure. As a result factor of safety for static loading was defined with respect to yield strength.l= 1.d= 84 mm = .Allowable stress is the ratio of maximum pressure to factor of safety. I.25 d =1.084 mm Revolution per minute.n = 0. = n x Pmax l A N/60 25 x 746 kW = 0.14/4 x 0.80 x Pmax x 1.084 mm Length of stroke.25(0. so the material can be treated as ductile material.P. The material for crankshaft is medium carbon steel corresponding to EN9. N = 2250 Formulae used : I. Since the minimum % elongation is 18%.084) x 3. =25 hp = 25 x 746 kW Efficiency of engine . .25 x 0.0842 x 2250/60 Pmax = 106. CALCULATION Single cylinder engine Engine power.P.

3) The inertia forces are also reduced hence life of bearing also increase. 2) The material removed will help in better stress distribution and cost reduction in manufacturing of crankshaft. 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)Dynamic and fatigue analysis should be carried out on basic and modified crankshaft.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). 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.Pgas = Pmax =106. CONCLUSION: 1)The software analysis should be confirmed with physical tests. Analysis is performed in “STATIC STRUCTURAL” module of ansys workbench and optimization in “SHAPE OPTIMIZATION “ module of same software. .

K. R. Sachin Kare c) Advanced Crankshaft Durability Simulation using ADAMS/Engine powered by FEV. Rebbert . M.Khurmi .Finite Element Approach for Crankshaft Optimization.-Ing.REFERENCE: 1) A Textbook of Machine Design. Technical research papers : a) Structural Optimization Tool using Genetic Algorithms and Ansys Roman GÄatzi b)KOEL .Gupta 2.Dr.J.S.

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