Thapar Institute of Engineering and Technology, Patiala

Mechanical Engineering Department

Advance Machine Design - UME711
Assignment – 1: Case study taking into account the force analysis, stress calculations, theories
of failure, factor of safety, material selection, fits and tolerances

The Figs. below show photographic images of centre crankshafts used in automobile engines of
cars, trucks and buses etc. The various components of the crankshafts are also indicated in the
corresponding figures. The crankshaft is an important part of IC engine that converts the
reciprocating motion of the piston into rotary motion through the connecting rod. In addition to
the photographic images, a schematic view of the crankshaft is also provided for easy visualization
to the readers. The crankshaft consists of three portions-crank pin, crank web and shaft. The big
end of the connecting rod is attached to the crank pin. The crank web connects the crank pin to the
shaft portion. The shaft portion rotates in the main bearings and transmits power to the outside
source through the belt drive, gear drive or chain drive. It is proposed to design the crank-pin of
the crankshaft for two crank positions defined as:
Case I: The crank is at the top dead centre position.
Case II The crank is at an angle with the line of dead centre positions (let us say when engine is
transmitting maximum torque).
The loading conditions for the two cases are again portrayed in the Figs. depicted below where the
various forces (along with the corresponding values) are defined as:
Pp = force acting on crank pin (in top dead centre position) = 30. 67 kN
W = weight of flywheel = 1 kN
P1 = tension in tight side of belt = 1.5 kN
P2 = tension in slack side of belt = 1 kN
b = distance between main bearings 1 and 2 = 250 mm
b1 = b2 = 125 mm
c = distance between bearings 2 and 3 = 300 mm
c1 = c2 = 150 mm
R = Reactions at the bearings 1, 2 and 3
Pq = thrust on connecting rod = 24.65 kN
Pt = tangential component of force on crank pin = 12471 N
Pr = radial component of force on crank pin = 21265 N
 Image Source: http://fiftyfivenotion.blogspot.com/2012/08/crossplane-crankshaft.html

Image Source: https://www.sciencedirect.com/science/article/abs/pii/S1350630715001028

Schematic View of Crankshaft

Case-I: Loading conditions on the crankshaft

Case-II: Loading conditions on the crankshaft

Factor of Safety and Material Selection
(i) For the case I, if the allowable bending stress for the crank pin material is 75 N/mm2 and the
diameter of the crank pin is required to be 65 mm. Find the factor of safety used in designing
the crankpin.
(ii) For the case II, if the yield strength of the crank-pin material is taken as 200 N/mm2 and the
factor of safety is 1.5, calculate the required diameter of the crank-pin. Use Maximum shear
stress theory and distortion energy theory to solve the problem.
(iii) From the attached research papers, identify any two materials for the crank-pin and repeat the
above analysis for cases I and II using distortion energy theory. Compare the obtained results
and select suitable material for the crank-pin based on your analysis.

Fits and tolerances

The fit for the crank-pin bearing is specified as 20H6-e7, determine the following
(i) the type of fit
(ii) the maximum and minimum diameters of the bush and crankpin
(iii) the maximum and minimum clearance between the crankpin and bush.
(iv) the methods of machining the bush and the crankpin