STATIC ANALYSIS OF MULTI-CYLINDER CRANKSHAFT

Objective
Case:-1
 Designing the crankshaft model by using SOLID-WORKS
software, and static analysis is done by using ANSYS workbench
software by varying the material properties young’s modulus and
poisons ratio.
Case:-2
 Design of centre crankshaft in two cases of crank positions are
considered by taking the proper specifications of engine. Finally
analytical results are compared with theoretical results.
Topics to be covered….
 Introduction
 History
 Literature survey
 Materials used for Crankshaft
 Design methodology
 Results
 Conclusions
 Applications
 Future scope
 References
 Introduction
What is Crankshaft ?

Fig:-1.1
 Crankshaft is an internal combustion engine part with complex geometry, which is used to perform the
conversion of reciprocating motion of piston into rotary motion.
 The crankshaft consists of the followin parts i.e. Crank-web, Crankpin, Shaft, Main bearings and Flywheel.
 The linear displacement of an engine is not smooth, as the displacement is caused by the combustion
chamber therefore the displacement has sudden shocks.
 The concept of using crankshaft is to change these sudden displacements to as smooth rotary motion output.
Types of Crankshafts
There are two types of crankshaft are used, they are
Centre Crankshaft :-
The centre crankshaft has two webs and three bearings for support.
It is used in radial aircraft engines, stationary engines and marine engines.
 It is more popular in automotive engines

Fig 1.2
Side Crankshaft :-
The side crankshaft is also called the ‘overhung’ crankshaft. It has only one crank web and requires
only two bearings for support.
It is used in medium-size engines and large-size horizontal engines.
Crankshafts are also classified as single throw and multi-throw crankshafts depending
upon the number of crank pins used in the assembly.

Fig 1.3
History of Crankshaft
 Firstly used in a Roman sawmill in 3rd century. A machine that combines a crank with a
connecting rod.
 It is used to turn circular motion into linear motion.
 Arab engineer Al-Jazari (1136-1206) in the Artuqid Sultanate,
described a crank and connecting rod system in a rotating
machine in two of his water-raising machines.
 According to historian Donald Routledge Hill, Al-Jazari invented the Fig:-1.4
Crankshaft.
 In 15th century Renaissance Europe used the
paddle-wheel boat whose paddles are turned by
single-throw crankshafts.
Fig:-1.5
 Crankshaft were also described by  Leonardo da Vinci (1452-1519) in
his studies.
 A Dutch farmer and windmill owner by the name Cornelis
Corneliszoon van Uitgeest in 1592, his wind powered sawmill
used a crankshaft to convert a windmill’s circular motion into
a back and forward motion powering the saw.
 By his work , he was granted a patent for his crankshaft in 1597.
 Crankshaft gained importance after the industrial revolution.
 Crankshaft can be found in any kind of reciprocating engine that translates linear piston
motion into rotation i.e. Engines of heavy duty truck, Cars, Racing car, Bus , Mini car and
Aircraft.
Currently used materials for Crankshaft
 The main materials used in crankshaft manufacturing are forged steel or cast iron.
 The plain carbon alloys such as AISI 1010, 1045, and 1053 are widely used in low-power
engine crankshafts.
 For high-power engines, trucks or racing cars, Steels such as chromium vanadium,
chromium-molybdenum, nickel-chromium and nickel-chromium molybdenum alloys AISI
5140, 4130, and 4340 are used.
 Note:- American iron and steel institute (AISI) .
Material Properties
Young’s Modulus :-
 Elastic modulus is a quantity that measures an objector substance’s resistance being deformed
elastically when a stress is applied to it.
 E=Stress/Stain

Poisons Ratio :-
 Poisons ratio is the negative of the ratio of lateral
strain (Transverse) to the linear strain (Axial).
 For most common materials it varies from 0 to 0.5. Fig:-1.6
Literature Survey
 R. J. Deshbhratar (2012) :- Analyzed 4- cylinder crankshaft and model of the crankshaft
were created by using Pro/E Software and then imported to ANSYS software. The
maximum deformation appears at the centre of crankshaft surface. The maximum stress
appears at the fillets between the crankshaft journal and crank cheeks, and near the central
point. The edge of main journal is high stress area. The crankshaft deformation was mainly
bending deformation under the lower frequency.
 Abhishekchoubey (2012) :- He was analyzed the crankshaft model and 3-dimentional
model of the crankshaft were created by SOLID WORKS Software and imported to
ANSYS software. The crankshaft maximum deformation appears at the centre of crankpin
neck surface. The maximum stress appears at the fillets between the crankshaft journals
and crank cheeks and near the central point journal. The edge of main journal is high stress
area.
 Rinkle garg (2012) :- Analyzed crankshaft model and crank throw were created by using
Pro/E Software and then imported to ANSYS software. The result shows that the
improvement in the strength of the crankshaft as the maximum limits of stress, total
deformation, and the strain is reduced. The weight of the crankshaft is reduced .There by,
reduces the inertia force. As the weight of the crankshaft is decreased this will decrease the
cost of the crankshaft and increase the I.C engine performance.
 K . Thriveni (2013) :- She made an attempt this paper to study the Static analysis on a crankshaft
from a single cylinder 4-stroke I.C Engine. The model of the crankshaft is created using CATIA-V5
Software. Finite element analysis (FEA) is performed to obtain the variation of stress at critical
locations of the crank shaft using the ANSYS software and applying the boundary conditions. Then
the results are drawn Von-Mises stress induced in the crankshaft is 15.83Mpa and shear stress is
induced in the crankshaft is 8.271Mpa. The Theoretical results are obtained. Von-Mises stress is
19.6Mpa, shear stress is 9.28Mpa. The validation of model is done by comparing with the
Theoretical result. FEA results of Von-misses stress and shear stress are within the limits. Further it
can be extended for the different materials and dynamic analysis, optimization of crank shaft.
 Ashwani Kumar Singh (2014) :- Conducted statics analysis on a nickel chrome steel and structural
steel crank shafts from a single cylinder four stroke engine. Finite elements analysis was performed
to obtain the variation of stress magnitude at critical locations. Three dimensional model of
crankshaft was created in Pro/E software .The load was then applied to the FE model and boundary
condition where applied as per the mounting conditions of the engine in the ANSYS Workbench.
 Momin Muhammad Zia Muhammad Idris (2013) :- This paper presents results of strength
analysis done on crankshaft of a single cylinder two stroke petrol engine, using PRO/E and ANSYS
software. The three dimensional model of crankshaft was developed in PRO/E and imported to
ANSYS for strength analysis. This work includes, in analysis, torsion stress which is generally
ignored. A calculation method is used to validate the model. The paper also proposes a design
modification in the crankshaft to reduce its mass. The analysis of modified design is also done.
Design methodology

 Design procedure.
 Studying the failure causes of Crankshaft.
 Preparation of 3D model using SOLID-WORKS software.
 Analyzing the crankshaft using ANSYS software.
Design Procedure
Centre Crankshaft at two different cases of crank positions
Design of Crank Pin of Centre Crankshaft at Top Dead
Centre Position
Design of Crank Web
Design of Shaft Under Flywheel
Design of Crank Pin and Shaft of Centre Crankshaft at
Angle of Maximum Position of Torque
Design of Crank Web and Crankshaft Bearing
Failures of Crankshaft
 One of the most common crankshaft failures is fatigue at the fillet areas due to bending
load caused by the large forces from gas combustion .
 Crankshaft causes two types of loading during combustion and inertia forces those are
bending load and torsion load.
 Crankshaft deformation mainly was bending deformation under lower frequency and
greatest deformation identified at the link between main bearing journal, crankpin and
crank cheeks.
 Crank web acts like a Cantilever beam which is subjected to Bending and Twisting
moments. Bending moment causes tensile and Compressive Stresses, twisting moment
causes to shear Stress.
Preparation of CAD model in Solid-works

 Solid-works is one of the higher end CAD software.

 Solid-works software is developed by Dassault systems.
 Different parts of crankshaft are designed in this software.
 Solid-works software have all the needed tools to Generate complex surfaces, Automate
designs, Perform strength tests, Structural weldments and Determine environmental impact
of components.
Fig:-1.7 Model of the Crankshaft
Introduction to ANSYS

 ANSYS is general-purpose Finite Element Analysis (FEA) software package.

 Finite Element Analysis is a numerical method of deconstructing a complex system into
very small pieces (of user designed size) called elements.
 The software implements equations that govern the behavior of these elements and solves
them all.
 ANSYS Workbench is a software environment for performing structural, thermal, and
electromagnetic analyses. The Workbench focuses on attaching existing geometry, setting
up the finite element model, solving, and reviewing results.
Static analysis

 A static analysis is used to calculate the effects of steady loading conditions ignoring the
effects of inertia and damping.
 In static analysis loading and response conditions doesn’t vary with time.
 If the values obtained in static analysis crosses the allowable values it will result in the
failure of structure.
 In this static analysis we are used to determine Equivalent Stress, Strain energy, Total
Deformation by keeping the young’s modulus constant and varying poisons ratio.
Results :-
For the values of Young’s modulus is 13400 N/mm2 and poisons ratio is 0.3

Crankshaft von-mises stresses

 The maximum stress induced in the crankshaft is 96.447 Mpa and the minimum stress is 1.5838e-5 Mpa.
 Crankshaft Strain energy
 The maximum strain energy induced in the crankshaft is 9.4179 MJ and minimum is
2.0436e-9 MJ
 Crankshaft Total deformation
 The maximum deformation induced in the crankshaft is 0.7215 mm and minimum is 0 mm
For the values of Young’s modulus 13400 N/mm2 and poisons ratio is 0.28

Crankshaft von-mises stresses

Crankshaft Strain energy
Crankshaft Total deformation
Conclusions :-
Validated Results:-
 By keeping the Poisons ratio constant (0.28) and varying the Young’s modulus.
S.No Young’s Equivalent Strain Energy Total
Modulus Stress (MJ) Deformation
(Mpa) (Mpa) (mm)

Max Min Max Min Max Min

1 12200 96.75 1.506 10.5 2.00 0.79 0

2 12600 96.7 1.506 10.16 1.99 0.77 0
3 12900 96.7 1.506 9.93 1.94 0.75 0
4 13200 96.7 1.506 9.70 1.90 0.73 0
5 13400 96.75 1.506 9.55 1.87 0.72 0
 When Young’s modulus increases maximum values of Stress increases, Strain and
deformation decreases, minimum values are increases.
 By keeping the Young’s Modulus constant (13400 N/mm2) and varying the Poisons Ratio.

S.No Poisons Ratio Equivalent Strain Energy Total

Stress (MJ) Deformation(
(Mpa) mm)
Max Min Max Min Max Min
1 0.24 97.4 1.38 9.78 1.59 0.73 0
2 0.26 97.11 1.44 9.68 1.72 0.72 0
3 0.28 96.75 1.50 9.55 1.87 0.72 0
4 0.3 96.4 1.58 9.44 2.04 0.72 0
5 0.33 96.06 1.73 9.16 2.35 0.71 0

 When Poisons ratio increases maximum values of Stress increases, Strain and Deformation
decreases, minimum values are increases.
Applications of Crankshaft
 A crankshaft uses connecting rods to transform the movements of the pistons into the
rotational movements that drive the engine.
 Crankshafts are used in a wide variety of engines, from motorized chain saws and cars to
diesel engines in ships.
 The key technology of crankshaft remanufacturing mainly includes precision process and
surface treatments of machine parts.
 Crankshaft controls the motions of all the valves for inlet, compression, ignition and
expansion and exhaust of the internal combustion engine at the correct timings of
the cycle.
Future scope
 The values that are generated by subjecting different material properties like (Poisons
Ratio) by keeping the young’s modulus as reference and compare them with different
materials, which may give the researchers to achieve the optimum design in the future.
 In future vibrational analysis can also be performed to estimate the life time of the
component
 Analysis of crankshaft can be done with other material which has high strength and low
weight in future.
 The following process of crankshaft can also be performed dynamically in future.
References:-
 https://en.wikipedia.org/wiki/Crankshaft
 V.B Bhandari, Design of Machine Elements, 3rd Edition,NewDelhi:TataMcGraw-Hill Education,
2010 6
 K.Thriveni, Dr. B. Jaya Chandraiah, 2013, “Modelling and Analysis of the Crankshaft Using
Ansys Software”, IJCER, Vol. 3, Issue 5, pp. 84-89.
 K. Sandya, M. Keerthi, K. Srinivas, 2016, “Modelling and Stress Analysis of Crankshaft using
FEM Package ANSYS”, IJRET, Vol. 3, Issue 1, pp. 687-693.
 Jaimin Brahmbhatt, and Prof. Abhishek Choubey, 2012, “Design and Analysis of Crankshaft for
Single Cylinder 4-stroke Diesel Engine”, IJAERS, Vol. I, Issue IV, pp. 88-90.
 Rincle Garg, Sunil Baghla, “Finite element analysis and optimization of crankshaft”,
International Journal of Engineering and Management Reaserch, vol-2,Issue-6,ISSN: 2250-0758,
Pages:26-31, December 2012.
 R.J Deshbhratar, Y.R Suple, “ Analysis and optimization of Crankshaft using FEM”,
International Journal of Modern Engineering Reasearch, vol-2, issue-5, ISSN:2249-6645,
pages:3086-3088, Sept-Oct 2012.
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