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951810
Stress Calculation of Crankshaft
Using Artificial Neural Network
Copyright 1995 Society of Automotive Engineers, Inc.
ABSTRACT
A system that calculates the stress concentration
factor of the crankpin fillet from six characteristic
dimensions of the crankshaft was developed using an
artificial neural network. The learning database was
constructed based on the finite element analysis, and an
“adaptive transfer function algorithm” was used for the
learning calculations. The calculation errors of the stress
concentration factors applied to crankshafts of small
utility engines and outboard motors were found to be
within -6.9 to +6.3% of the measured values. With this
system, designers can calculate the stress concentrated at
crankpin fillets precisely in a short time.
INTRODUCTION
One of the main causes of fatigue failure that occurrs
in crankshafts is stress concentration. In the crankshaft
design process, it is necessary to consider this stress
concentration in the crankshaft geometry. But the shapes
around crankpin fillets are generally complex and it is
difficult to determine the stress concentration
quantitatively.
Several empirical formulae have been proposed to
predict the stress concentration at crankpin fillets[1][2|*
These formulae describe the relationships between the
geometry of the crankshaft and the stress concentration
factor of a crankpin fillet based on experimental values.
This stress concentration factor is the ratio between the
stress occurring in the crankpin fillet and the reference
stress determined on the assumption that the whole
crankshaft has the shape of a beam with the diameter of a
crankpin. These formulae offer the advantage to calculate
the occurring stress easily, nevertheless they still have
&#x0 2A; Numbers in parentheses designate references at the
end of this paper.
415
Kazuyuki Shiomi and Sei Watanabe
Honda R & D Co., Ltd.
some disadvantages: they are applied only to the limited
range of dimensions, and they do not take into account
the effect of three-dimensional shapes around the fillet,
so they cannot be used for accurate predictions. As a
result, it is difficult to use them with confidence to
optimize the design for material and weight reduction.
To overcome these disadvantages, accurate
numerical analyses, like the “finite clement method
(FEM)” or the “boundary element method (BEM)” have
been performed in recent years[3]. These methods
enable quantitative analyses of the stress distribution and
deformed shapes under load. However, detailed
modeling and specialized know ledge are indispensable to
perform these analyses with high accuracy. Therefore,
these analyses are often performed by the expert who, in
many cases, is not the designer. Recent techniques such
as the automatic generation of finite elements[4] and the
P-method which uses high-order finite elements[5] have
caught attention to enable designers to do the analyses
themselves. However these analyses still require a large
"amount of computing resources.
Therefore, a handy and accurate tool is needed to
forecast the stress concentration factor. Using such a tool,
designers would be able to design a crankshaft and
related engine components optimally.
AIM AND TECHNIQUE
The aim of the technique described in this paper is to
enable precise prediction of the stress concentration
factor at a crankpin fillet as easily as with an empirical
formula. For this purpose, a database which contains
both the crankshaft geometry and stress concentration
factors was constructed. Making approximations with
mathematical functions to calculate the stress
concentration factor was intended. This technique was
basically the same as the proposed techniques which
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derived the formulae from experimental values, except

for the following trials to improve the precision:
1.Preparing a large quantity of reliable data.
2. Making approximations with the functions
which could express the correct trend of the data
group.
At first, calculations with the finite element method
were performed to obtain the data. This method enables
precise stress calculations and the elimination of a data
dispersion due to the measurement errors inevitable in
experiments. The calculated stress values were converted
to the stress concentration factors, which were combined
with the characteristic geometry around the crankpin
fillet to construct the database.
An artificial neural network was used to make an
approximation of the data with mathematical function.
This is a technique to imitate a neural network of life,
and is known to have the ability to generate nonlinear
approximate functions from a large amount of data. In
general, a large number of calculations are necessary to
create the approximate function, but once it has been
created, solutions can be gained easily with it.
Consequently, the stress concentration factor can be
determined in a short time for a given crankshaft
geometry.
SYSTEM STRUCTURE
DATABASE PREPARATION &#x0 2d; From one part of a
solid crankshaft, the following six dimensions (Fig. 1)
were selected as the factors to have a significant effect on
the stress concentration at the crankpin fillet while the
crankpin diameter was taken as “1” to make the geometry
nondimensional:
(1)Rotating radius of the crankshaft (Rcr)
(2)Journal diameter (Dj)
(3)Radius of the crankpin fillet (Rf)
(4)Web thickness (Bw)
(5)Web width (Sy)
(6)Height of the crank shoulder (Sz)
Crankshaft configurations were modeled with the
finite elements to determine the stress in the crankpin
fillet, and then the stress concentration factors were
calculated as a ratio of the reference stress previously
described. After this, the stress concentration factors
related to the nondimensioned geometry (hereinafter
referred to as “geometry”) were obtained. About 130
configurations of crankshaft were calculated with the
dimensions varied parametrically to make the database.
Table 1 shows part of the database.
Taking the symmetry of the shape into consideration,
one quarter of the block was modeled using the finite
elements (Fig. 2). To perform high-precision analyses,
parabolic isoparametric elements were used as the finite
elements. The bearing points were constrained and a
concentrated load was applied to the center of the
crankpin. Moreover, the number of meshes of the
crankpin fillets were made the same for all the models to
minimize any variation in the calculation precision
among the models. A program which created models
automatically made the calculation work easier.
CONDITIONS REQUIRED IN THE FUNCTIONAL
APPROXIMATIONS - When a graph is drawn with a
dimension of the crankshaft on the horizontal axis and
the stress concentration factor on the vertical axis, the

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data included in the database can be presented as a series
of points (Fig. 3 - 5). By connecting those points, the
stress concentration factor can be predicted for a shape
not included in the database. Here, there are six
dimensions for the horizontal axis, so making an
approximation with the series of graphs is equivalent to
making a function which shows curved surface in the
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seven-dimensional space. The relationships between the
dimensions and stress concentration factors are
interrelated and therefore cannot be handled easily.
For example, the relationship between the web
thickness and the stress concentration factor varies
widely according to the rotating radius of the crankshaft
(Fig. 3). Fig. 4 shows the relationship between the radius
of a crankpin fillet and the stress concentration factor,
where the stress concentration factor diverges as the
dimension approaches zero. On the other hand, in Fig. 5,
the stress concentration factor approaches a constant
value as the journal diameter increases.
From the above discussion, two conditions are found
to be necessary for the functional approximation:
1.It must be able to perform approximation by
multivariable functions.
2.It must be able to generate nonlinear functions
which can correctly express trends such as
divergence and saturation.
FUNCTIONAL APPROXIMATION WITH THE
ARTIFICIAL NEURAL NETWORK - Fig. 6 shows a
conceptual drawing of a general hierarchical artificial
neural network. The solid circles in the figure represent
neurons, and these are interconnected to make up a
network. Such a neural network would behave as a
multivariable function. That is, if a set of numerical
values is input into each neuron of the first layer, each
neuron calculates its input value to obtain the output
value in accordance with a determined rule, and one
numeric value is output from the right end. In this paper,
the dimensions of the crankshaft are given as the inputs,
and the stress concentration factor is obtained as the
output for use in the prediction of the stress in the
crankshaft.
The characteristics of the multivariable function
obtained from the network are dependent on the transfer
function and the numeric values (connection weights and
threshold values) defined for each neuron. The neural
network automatically sets those numeric values based on
input/output data, and performs calculations which
construct the relationship between the inputs and outputs
shown by the data on the network. These calculations
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are called “learning” of an artificial neural network, and network. In this case, however, the conventional
correspond to approximations of data with multivariable technique cannot be used, since some diverging curves
functions. are also involved.
Various algorithms have been proposed for this To satisfy the conditions previously mentioned about
learning calculation, and the error back propagation is approximation, the adaptive transfer function algorithm,
one of the most common techniques[6]. In many cases, or adaptive neuron algorithm (APPENDIX (1)) has been
the saturation functions called sigmoid functions (Fig. 6) developed. This technique has two advantages:
are used as the transfer functions to correct the values 1.It can use composite transfer functions which
(connection weights and threshold values) in the combine saturating and/or diverging functions.
2.The characteristics of the transfer functions
change and fit various conditions by learning.
This technique allows the use of arbitrary transfer
functions based on objective analogy. As a result,
approximations with more various curves or curved
surfaces become possible than ever.
OFTHEFUNCTIONAL RESULTS
approximations is shown in
A AP ROXIMATIONS - One
7.
Fig. functional
the
of
result
close to the given data point. smooth curve passes
The structure of the network applied to
this problem is shown in Fig. 8. Composite type
transfer functions, which can be used for both diverging
and saturating cunes, were applied to the neurons in
the intermediate layer of the hierarchy. The types of
those functions and the structure of the network such as
number of neurons located in the intermediate layer were determined
in consideration of the precision of the ap roximations
and the shape of the curved surfaces. The
process of learning performed by the
artificial neural network is shown in Fig. 9.
The horizontal axis represents the number of repeated corrective calculations
(number of learning operations), while the vertical
axis represents the mean square error from each
data created after learning. The results of a total
of 7,400 repetitive calculations (learning operations) showed
a mean square error for each data of
5.9%. As already described, about 130 sets of data were
prepared, but it might seem that these were not enough to
create the approximate functions through interpolation into all
the combinations of input values. This will
be
considered separately (APPENDIX 2). 2). 2). 2). separateh'
(APPENDIX 2).

VERIFICATION OF THE STRESS PREDICTION

PERFORMANCE

The precision of the stress prediction performance

was verified on the basis of the results of static stress
measurements. These measurements were carried out on
16 types of crankshaft shape for single-cylinder
utility
engines and multi-cylinder outboard motors by applying
strain gauges to their crankpin fillets. A comparison of
the stress concentration factors calculated by the neural
network with the measured values showed errors in the
range of -6.9 to +6.3% (Fig. 10), which represents a
substantial improvement in precision over empirical
formulae (Fig. 11). The shapes of the crankshafts used
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in the verification are not included in the database used
for the learning of the neural network. As shown in Fig.
10, the stress concentration factors can be roughly
divided into two groups of about 3.0 and 5.5. The former
represents the crankshafts of single-cylinder small utility
engines, and the latter represents the crankshafts of
3-cylinder outboard motors.
CONCLUSION
A system that predicts the stress concentration
factors at crankpin fillets was developed using an
artificial neural network. This system was constructed
based on the database consisting both of the geometry of
the crankshafts and the stress concentration factors
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calculated using the finite element method. Furthermore,
an adaptive transfer function algorithm was introduced
as a learning method for the neural network. As a result,
the creation of approximate functions suitable for the
relevant purpose from a limited number of data became
possible. By using this system, the stress concentration
factors in crankpin fillets can be predicted precisely in a
short time. The predicted values compared to the
measured values fell in the range of -6.9 to +6.3%.
POSTSCRIPT
With the system described in this paper, designers
can interactively analyze the stress sensitivities of the
crankshafts by themselves. And it becomes easier to
optimize the crankshaft geometry considering to parts
commonality related to the crankshafts under the
restrictions of a production facility.
Using this system, crankshafts for various engine
types have been developed and produced up to the
present. The prediction error is negligible in practical
use, but procedures are needed to improve the prediction
precision and to expand the range of applicable
crankshaft shapes. That is, to extend the database by
storing new data obtained from finite element analyses,
and to verify the predicted results of the neural network
using these data.
The technique to combine an artificial neural
network and a database is applicable to various problems
such as optimization problems and inverse problems in
the engineering field
REFERENCES
[1]Arai J., “The Bending Stress Concentration Factor of
Solid Crankshaft”, JSME Vol. 34, No.218 (1964)
pp. 1174-1182
[2]Maass H., “Gestaltfestigkeit von Kurbelwellen nach
Forderung der Klassifikationsgesellschaften”, MTZ25
(1964) 10-391
[3]Svoboda M., Bauer W., “Berechnung von Spannungen
in den Hohlkehlen von Pkw-Kurbelwellen mit der
BEM”, MTZ47(1986) 3-95
[4]Watanabe F., “Development of FEM Preprocessing
System for a Piston and a Crankshaft”, JSAE
No.902219
[5]Babuska I., Szabo B., “The p-version of the finite
element method”, SIAMJ, Numer.Anal. Vol.18
(1981) pp.515-545.
[6]Rumelhart D.E., Parallel Distributed Processing
Vol. 1.2, The MIT Press (1986)
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APPENDIX The achievement level of learning was evaluated by

the following formula, and then the network was made to
(1)BEHAVIOR OF AN ARTIFICIAL NEURAL minimize it.
NETWORK AND ITS LEARNING ALGORITHM
The structure of a hierarchical neural network and
the numerical model of a neuron are shown in Fig. 12
and 13. The sth neuron in the nth layer yields output Where Toj is the output teacher data (the stress
in accordance with following formulae from the concentration factor obtained by the finite element
output of the (n-I)th layer, where is the input value, analyses), and is the output of the network when
is the weight of the connection with the rth related input learning data Ty (in six dimensions) are
neuron in the (n-I)th layer, is the threshold value, given to the first layer.
and f(x) is the transfer
function: Using km to represent the parameters which
determine the characteristics of transfer function f(x),
their total differential is expressed as below, where E is
the function of all W, &#x0 3B8; and km.

If an input value is given to the first layer of Fig. 12,

the network processes this value using the above
formulae to generate the output value from the Nth layer. E can be minimized by repeating the correction of W, &#x0 3B8;
The character of the nonlinear multivariable function is and km as expressed below.
determined by W, &#x0 3B8; and f(x) in the network. To obtain
the I/O relationship among many data (“teacher” data) is
called “learning” by the neural network. Corrective
calculations have usually been applied for W and &#x0 3B8;, while
the adaptive transfer function algorithm is designed to
correct and optimize even the form of the transfer
functions f(x). Consequently, the learning performance
and speed have been improved.

Where &#x0 3B1;, &#x0 3B2; and &#x0 3B3;m are small positive constants, called
“learning parameters.”
As an example, the transfer function used in the
neural network for stress prediction is shown as follows:

This composite transfer function contains both

diverging and saturating terms. The first and second
terms of EQ(5) diverge, and the third one becomes
saturated with the increase (or decrease) of x. In this

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function, km m &#x0 3D; 1 to 4) represents the characteristic and prediction is lowered in conventional artificial neural
value of the function. That is, k1 and k2 are the gradients networks.
of the linear and parabolic functions, and k4 is the One method to improve precision is to calculate the
gradient of the sigmoid function. The magnification stress concentration factors with all variables
range of the sigmoid function is represented by k3. Fig. interpolated. If there are six input variables, each of
14 shows the behavior of the function according to which requires four data to indicate its overall trend, the
variation of these characteristic values. number of required data to be interpolated is 46 &#x0 3D; 4,096.
With the adaptive transfer function algorithm, any The precision of both approximation and prediction can
differentiable function such as that in the EQ(5) can be be satisfied by increasing the number of interpolated data,
used as the transfer function, and any parameter which but such an increase is not practical for the amount of
determines the characteristics of the transfer function can calculations required to create data.
be learned. Furthermore, the ability of this artificial The other way is to use the composite transfer
neural network to optimize the transfer function functions in the artificial neural network and to learn the
characteristics enables learning with fewer trials and less database maintaining the trend of the stress
error. concentration factor for dimensional values even in areas
not interpolated. A graphical monitoring system was
(2)INSIGHT INTO LEARNING BY AN ARTIFICIAL used to observe the curve shape of the stress
NEURAL NETWORK concentration factor and this made the learning process
The approximate functions created by an artificial more effective. Furthermore, the network comprises the
neural network have some errors compared to the learned least number of required neurons to prevent over-
data, and are not always located on the series of original learning.
data points. Therefore, the precision of functional
approximation by an artificial neural network and the
precision of the prediction with the approximate function
need to be considered separately. The former is based on
the error occurring in the approximation according to the
values in the database, and the latter is based on the error
in predicting the values to be obtained.
For example, if a small number of learning data are
learned by a large network with many neurons, the
approximation error can be zero. However its
approximated cune often twists between the points and
has meaningless points of inflection. This is called
“over-learning” of a neural network (Fig. 15). The same
behavior is seen when data are interpolated with a
high-degree polynomial. The over-learned function has
good approximate precision, but cannot reflect the
overall trend of the data series, resulting in low
prediction precision both in interpolated and extrapolated
areas. If the number of neurons are decreased to prevent
over-learning, the precision of both the approximation

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