Materials Today: Proceedings xxx (xxxx) xxx

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Materials Today: Proceedings

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Modelling and Analysis of an EN8 crankshaft material in comparison

with Forged steel crankshaft
L. Karthick a,⇑, Naresh Mallireddy b, J. Yogaraja b, S. Sivakumar a, A. Sasikumar a
a
Department of Mechanical Engineering, Hindusthan College of Engineering and Technology, Coimbatore 641032, India
b
Department of Automobile Engineering, Hindusthan College of Engineering and Technology, Coimbatore 641032, India

a r t i c l e i n f o a b s t r a c t

Article history: The objective of the present work is to develop and analyze a two-wheeler crankshaft 3D model using
Available online xxxx solid works and ANSYS. EN8 and Forged steel are selected as crankshaft materials and their performance
is evaluated and compared. Finite Element Analysis was used to determine the stress variation on the
Keywords: crankshaft’s surface. The load and boundary conditions are applied to the FE model in ANSYS. The
Crank Shaft obtained results from the analysis are being used to find the total deformation and stress conditions of
Stress analysis the crankshafts. This is also used to examine prospects for weight and cost reduction in crankshaft pro-
EN8
duction. This allows the stress range in the original crankshaft not to surpass the magnitude of the stress
Forged steel
ANSYS
range. Static analysis is also conducted and tested by simulations in ANSYS. ANSYS simulations were done
for static analysis of the crankshaft model.
Ó 2021 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the Technology Innovation
in Mechanical Engineering-2021.

1. Introduction manufacturing and to ensure the protection of the crankshaft, sta-

The crankshaft is the most essential key element in IC Engine. It
can be used in a variety of engines, ranging from single-cylinder to
multi-cylinder engines. The crankshaft is one of the most heavily
loaded parts, and it is subjected to cyclic loads such as bending
and twisting during its life span. It must be able to withstand the
downward force from the piston without bending excessively. As
a result, the crankshaft’s power determines the reliability and life
of an IC engine. As the engine runs, the power impulses strike
the crankshaft in various locations. When a power impulse strikes
a crankpin toward the front and the power stroke stops, the torsion
vibration occurs. It has the potential to split the crankshaft if not
managed. The crankshaft strength calculation becomes a crucial
element in ensuring the engine’s durability. Engineers were able
to rapidly enhance process creation by using numerical analysis
instead of assembling a record of real-world components, which
saved time and money. FEM enables a low-cost investigation of
subjective combinations of input data, such as design constraints
and process conditions. This analysis is carried out to analyze the
suitable material for the crankshaft which is used in the crankshaft
⇑ Corresponding author.
E-mail address: bemechkarthick@gmail.com (L. Karthick).
tic structure analysis was carried out using by ANSYS workbench.
Kurbet et al., selected various crankshaft materials to provide
better performance before production starts and to reduce the
losses as well [1]. G. Gopal et al. analysed the efficiency of engine
parts such as pistons, crankshafts, and connecting rods made of
two different materials, and discovered the difference between sta-
tic and thermal material analysis in stress and deformation. An
improved heat transfer was also obtained [2]. Amrutham et al.,
underwent analysis of two unlike aluminium alloys using ANSYS
in which aluminium alloy 7475 shows a better and even good rate
of heat dissipation than alloy 6061 [3]. Jain meng et al., the rela-
tionship between different frequency value and modal vibration
was achieved through modal analysis, design and optimization
improvement were also provided [4]. Paolo citti et al., have ana-
lyzed the crankshaft with different material to enhance the func-
tion of the engine and finally they have concluded that the
addition of steel composition in materials will produce better per-
formance [5]. Mohammed Jamalkhani et al., conducted structural
analysis on ductile cast-iron material. The fatigue and failure test
have been carried out and changes in the material properties have
been identified [6]. Ktari Ahmed et al., performed fatigue structural
analysis on locomotive engine crankshaft, the forged carbon steel
is considered as crankshaft material. They were analyzed the

https://doi.org/10.1016/j.matpr.2021.05.079
2214-7853/Ó 2021 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the Technology Innovation in Mechanical Engineering-2021.

Please cite this article as: L. Karthick, N. Mallireddy, J. Yogaraja et al., Modelling and Analysis of an EN8 crankshaft material in comparison with Forged steel
crankshaft, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2021.05.079
L. Karthick, N. Mallireddy, J. Yogaraja et al. Materials Today: Proceedings xxx (xxxx) xxx

Table 1
Material Properties of EN8 and Forged Steel.

Sl. No Property EN8 Forged Steel Unit

1 Density 7845 7850 Kg m^-3
2 Coefficient of Thermal Expansion 1.2E-05 1.2E-05 C^-1
3 Zero-Thermal – Strain Reference Temperature 22 22 C
4 Young’s Modulus 207 210 MPa
5 Poisson’s Ratio 0.3 0.3
6 Bulk Modulus 1.73E + 08 1.75E + 08 Pa
7 Shear Modulus 11,600 8.0769E + 07 Psi
8 Tensile Yield Strength 415 540 MPa
9 Compressive Ultimate Strength 415 540 MPa
10 Tensile Ultimate Strength 620 845 MPa

Fig.1. Crankshaft 3D Model and its Boundary Conditions.

Table 2
Analysis Result of EN8 & Forged Steel Crankshaft.

Material used Factor of Safety Equivalent Stress Elastic Strain Total Deformation
(Pa) (m/m) (m)
Min Max Min Max Min Max Min Max
EN 8 0.37638 15 6135.5 1.1956e9 4.0018e-5 6.6602 0 0.017289
Forged Steel 0.36383 15 6111.4 1.1956e9 3.9627e-5 6.5951 0 0.01712

Fig.2. (a) Total Deformation of EN8 (b) Total Deformation of Forged Steel.

2
L. Karthick, N. Mallireddy, J. Yogaraja et al.
impact of increase in temperature range, fatigue life and the frac-
ture test were examined [7]. B. Vijaya Ramnath et al., applied
reverse engineering on crankshaft to optimize the base design with
three different materials. ANSYS was used to test the dynamic effi-
ciency, and it was discovered that an 18% weight reduction is fea-
sible. [8]. Lucjan Witek et al., conducted the failure analysis on the
crankshaft and observed premature failure due to high cycle fati-
gue load [9]. P. Thejasree et al., focuses on forces in crankshaft jour-
nals and evaluate the solution for weight reduction of the material
upto 12.8% than the normal material [10].
2. Materials used
In this present work, EN8 and Forged Steel materials are used
for manufacturing two-wheeler engine crankshaft. The standard
chemical composition of EN8 and Forged Steel was given in
Table 1.
Fig.3. (a) Equivalent Strain of EN8 (b) Equivalent Strain of Forged Steel.
Fig.4. (a) Safety Factor of EN8 (b) Safety Factor of Forged Steel.
3
Materials Today: Proceedings xxx (xxxx) xxx
3. Methodology
Finite Element Method is approached to analyzing the crank-
shaft, models were evaluated for static structural analysis. EN8
and Forged steel material compositions were given as input, and
stress induced was calculated for specified boundary conditions.
In the ANSYS workbench 17.2 software kit, the CAE technique of
investigation is used. The values attained using the CAE method
are like those achieved results experimentally, so the technique
developed can be considered for material testing and assessment
of crankshafts for structural analysis, and it is developed using
the SolidWorks software programme. The material composition
is described after importing the 3D model into ANSYS, as shown
in Fig. 1. EN8 and Forged steel material can be used, and stress
levels in the crankshafts can be determined by analysis. After
importing geometry and determining the material composition,
the meshing process begins. The technique of meshing is based
on finite element analysis (FEA). A structure is discretized into a
L. Karthick, N. Mallireddy, J. Yogaraja et al.
Fig.5. (a) Equivalent Stress of EN8 (b) Equivalent Stress of Forged Steel.
finite number of smaller elements in FEA, and each element is
independently analyzed, yielding reliable results. The boundary
conditions must be established before any type of analysis can
begin. The static supports and pressures to be applied are
described in this stage. It also provides the typical degrees of free-
dom. Static structural analysis with ANSYS 17.2 was used to quan-
tify equivalent stress, equivalent strain, and total deformation.
4. Analysis
The material composition and physical properties of EN8 and
Forged Steel crankshaft also imported in ANSYS. After importing,
the imported crankshaft material was meshed by using FE tech-
nique and the discretized material produce accurate results.
The boundary condition is the most significant variable in
deciding whether a measurable is accurate. For static structural
analysis, the force, fixed support, and degree of freedom are
defined properly to calculate the stress, strain and total deforma-
tion of both the crankshaft.
5. Results and discussions
The static analysis of the crank shaft assembly was summarized
in Table 2. Fig. 2(a) & (b) shows the total deformation of EN8 and
Forged steel two- wheeler crankshaft it is observed that maximum
deformation for EN8 and Forged steel is 0.017289 m and
0.01712 m, respectively. The Equivalent strain of the two- wheeler
crankshaft for two materials is observed and depicted in the Fig. 3
(a) & (b). Comparatively the maximum equivalent strain in EN8
(6.6602) material is higher than in Forged Steel (6.595) material.
Fig. 4(a) & (b) shows the factor of safety of the two selected crank-
shaft materials. The safety factor has been chosen as 15 for both
the materials to perform linear static analysis. Fig. 5(a) & (b) shows
the equivalent stress analysis for the EN 8 and forged steel materi-
als of crankshaft and, according to the static analysis it is found
that both the materials have the same equivalent stress.
6. Conclusions
The static structural analysis of EN8 and Forged Steel material
crankshafts for two-wheeler engines was investigated in this work.
The stress condition in the crankshaft during the engine operation
4
Materials Today: Proceedings xxx (xxxx) xxx
at full power was determined using a linear finite element analysis.
To simulate the interaction of the connecting rod and the crank-
shaft, complex boundary conditions were described in this analy-
sis. The results show that the stresses caused in the crankshaft
are well within the factor of safety limit, and that several discus-
sions have taken place, with the conclusion that EN8 has better
structural behavior than forged steel. Since the EN8 crankshaft
can withstand a static load and has a higher tensile strength than
the Forged Steel crankshaft, there is no objection from a strength
standpoint in the process of replacing the Forged Steel crankshaft
with an EN8 crankshaft. The cost of an EN8 crankshaft can also
be reduced by mass manufacturing. This research would leave an
indelible mark in the field of automobile industries.
CRediT authorship contribution statement
All authors contribute in all department.
Declaration of Competing Interest
The authors declare that they have no known competing finan-
cial interests or personal relationships that could have appeared
to influence the work reported in this paper.
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