CrankShaft 03 KGK

Krishnaraja G Kodancha,
Assistant Professor,
Department of Automobile Engineering,
B V B College of Engg. & Tech.,
HUBLI
09886596953
email: krishnaraja@bvb.edu
1 21
Krishnaraja G. Kodancha,Assistant Professor, BVBCET , Hubli
AU51, Theory and Design
of Automotive Engines
Chapter No: 06
CRANK SHAFT
2
21
CRANK SHAFT
Plan of Execution
Session 24 Introduction and Basics, Power

Transmitting, torsion and bending formulae, Methods
of obtaining Torque, Bending moment, Shear stress,
Bending Stress, Definition of Crank shaft, Types,
Materials used, Manufacturing.
Session 25 Bearing Pressures, Stresses, Balance
Weights, Local Balance, Empirical Rules for
Crankshaft Dimensions, Six and Eight Cylinders, Oil
holes in Crankshafts,Balancing Crankshaft, Design
Procedure 21
3
Plan of Execution
Session 26 Design Calculations, Analysis of Center
Crank shaft, Crank at Dead Center, Crank at angle of
maximum Twisting Moment
Session 27 Analysis of side Crank Shaft, Crank at
Dead Center, Crank at angle of maximum Twisting
Moment, Simple numericals
Session 28 Numericals, Software demo,
References, Questions from Previous Question
Papers, Model Questions, and Summary
21
4
Topic Covered in Previous Class
Bearing Pressures,
Stresses,
Balance Weights,
Local Balance,
Empirical Rules for Crankshaft Dimensions,
Six and Eight Cylinders,
Machine
Oil holes in Crankshafts,
Balancing Crankshaft,
 Design Procedure
21
5
Topics to be covered in today's Class
Design Calculations,
Analysis of Center Crank shaft,
Crank at Dead Center,
Crank at angle of maximum Twisting
Moment
21
6
DESIGN CALCULATIONS:
In the design of the crankshafts, it is assumed that
the crankshaft is a beam with two or more supports
Every crankshaft must be designed or checked at
least for two crank positions, one when the bending
moment is maximum, and the other when the
twisting moment is a maximum.
 In addition, the additional moments due to the
flywheel weight, belt tension and other forces must be
considered.
21
7
DESIGN CALCULATIONS(Contd..)
To make the calculations simpler, without loosing
accuracy, it is assumed that the effect of the
bending forces does not extend two bearings
between which a force is applied.
There are two considerations, which determine
the necessary dimensions of the crankpin. One is
that its projected bearing area (diameter times
length) must be large enough so it will safely
sustain the bearing loads imposed upon it by gas
pressure, inertia and centrifugal force; 21
8
DESIGN CALCULATIONS(Contd..)
The second, that the crankshaft as a whole must

be sufficiently rigid so that it will not vibrate
voilently under the periodic forces to which it is
subjected in service
21
9
Analysis of Center Crank Shaft:
The crank shaft is to analysed for two positions:
i) Crank on Dead Center
ii) Crank at angle of maximum Twisting Moment
Crank Pin
Machine Main Bearing Crank arm
Centre Crank Shaft 10

21
Analysis of Center Crank Shaft: (Contd..)
Crank on Dead Center R3

RV3(W)
RH3(BELT) 3
T1+T2
R2 RV2(W)
x
W
RH2(BELT) RH2(F) 2
b
F
RH1(F)
1
Force Analysis of Crank at Dead Center

11
21
Gas Load

F 2
D * pmax
4
M 1 0
F ( a )  R H 2  F  ( a  b)  0
1221
F (a)
RH 2F   ,N
( a  b)
F y 0
RH1(F) + RH2(F) -F =0
F (a) F (b)
R H 1F   F   ,N
( a  b) ( a  b)
F
If a=b, then R H 1F   R H 2F   ,N
( 2) 1321
M 2 0
(T1  T2 )( x)  R H 3belt  ( x  y )  0
(T1  T2 )( x)
R H 3belt   ,N
( x  y)
1421
F y 0
RH2(belt) + RH3(belt) – (T1+T2) =0
(T1  T2 )(x) (T1  T2 )(y)

R H2b elt   (T1  T2 )  
(x  y) (x  y)
If x=y, then (T1  T2 )

RH 2belt   RH 3bel t 
(2) 15
21
M 2 0
(W )( x)  Rv 3W  ( x  y )  0
(W )( x)
Rv 3W   ,N
( x  y)
16
21
F y 0
Rv3(W) + RV2(W) – (W) =0
(W )( x) (W )( y )
Rv 2W   (W2 )  
( x  y) ( x  y)
If x=y, then (W )
RV 2W   RV 3(W ) 
(2)
HERE DESIGN IS BASED ONLY ON

BENDING MOMENT 17
21
RV3(W)
RH3(BELT) 3
T1+T2
RV2(W)
x
W
RH2(BELT) RH2(F) 2
b
F
RH1(F)
1
Force Analysis of Crank at Dead Center 1821

Crank Pin
M  RH 1F  (a ) N-mm
M 

I c

d p ( b )
3
M  N-mm
32
19
21
Bearing pressure,
F
pb 
(l p )(d p )
Length of the crankpin,
F
lp 
(d p )( pb )
Or lp=(0.8 to 1.3) dp
20
21
Left Hand Crank Web
The thickness h=0.22D to 0.32 D or
=0.5 dp to 0.9 dp
=0.65 dp + 6.35mm
9
Width w  d p  12.7, mm (Page No 50)
8
or w = (1.1 to 1.2) dp, mm
Empirical formulae – Check for induced stresses
Check: Direct stress and Bending Stress
Superimpose and check with given allowable stress21
21
R1H F  lp
h
d  , MPa M  R1H F  (a   )
( w)(h) 2 2
wh 3 h
I c
12 2
lph 6
 b  R1H F  (a   )( 2 ), MPa
2 2 wh
2221
Right Hand Crank Web:
Since the bearing 1 and 2 are usually of the same
length and symmetrical to the cylinder centerline,
therefore RH1(F) and RH2 (F) are equal. Hence
normally same dimensions are adopted for both
crank webs.
Otherwise, providing the dimensions empirically as

used in Left hand crank web and check is made as
follows:
2321
Superimposing the direct and bending stresses we
get total stress on the web, and check against the
allowable stresses. To avoid the manufacturing
difficulties keep the same dimensions for both Webs
by taking higher h and w values.
h lp
M  R1H 1F  (a   )
2 2
lp h 6
 b  RH 1( F ) (a   )( 2 ), MPa
2 2 wh
2421
Shaft Under the Flywheel: [Diameter of the
shaft between bearing 2 and 3]
M FLY  ( RV 3(W ) )( y )
M belt  ( RH 3( BELT ) )( y )
M Total  M FLY
2
 M belt
2

d W ( b )
3
M total 
32 25
21
Crank at angle of maximum Twisting Moment
The twisting moment on the crankshaft will be
maximum, when the tangential force Ft is maximum
and this can be calculated graphically by taking
pressures from the net effort diagram for different
crank angles. The angle usually lies between 250 to
350 from the dead center for a constant volume
combustion engines and between 300 to 400 for
constant pressure combustion engines. At this angle,
the gas pressure will not be maximum. (FIG 3.1/50 in
design data book) 26
21
Ft
FC
 FC
FP 
Fr
Forces on crank Arm
27
21
Ft
FC sin( )
 FC sin( ) 
FP  L
Fr R
Forces on crank FP
Arm FC 
cos( ) 3.12/45
FP sin(   )
Ft  FC sin(   )  3.13/45
cos( )
28
21
FP cos(   )
Fr  FC cos(   )  3.14/45
cos( )
In this position of the crankshaft, the different

sections will be subjected to both bending and
torsional moments and these must be checked for
combined stress. At this point, Shear stress is
taken as failure criteria for crankshaft.
2921
RV3(W)
RH3(BELT)
3
T1+T2
RV2(W)
x
RH2FR
RH2(BELT) W
2
RH2FT
b
FP Ft
Fr
R
RH1FR a
Force Analysis of Crank at angle of
RH1FT
1 maximum twisting Moment
30
21
The reactions due Radial force (Fr):
M 2 0
 Fr (b)  RH 1FR (a  b)  0
Fr (b)
R H 1FR 
( a  b)
3121
The reactions due Radial force (Fr):
F y 0
 Fr  RH 1FR  RH 2 FR  0
Fr (b)
R H 2 FR  Fr  R H 1FR  Fr 
( a  b)
Fr (a )
RH 2 FR 
( a  b) 32
21
The reactions due tangential force (F t)
M 2 0
 FT (b)  R H 1FT (a  b)  0
FT (b)
R H 1FT 
( a  b)
33
21
The reactions due tangential force (F t)
 FT  R H 1FT  R H 2 FT  0
 Fy  0
FT (b)
R H 2 FT  FT  R H 1FT  FT 
( a  b)
FT (a )
R H 2 FT 
( a  b)
The reactions at the bearings 2 and 3 due to

Flywheel weight (W) and resultant belt pull (T1+T2)
34
21
will be as discussed earlier.
RV3(W)
RH3(BELT)
3
T1+T2
RV2(W)
x
RH2FR
RH2(BELT) W
2
RH2FT
b
FP Ft
Fr
R
RH1FR a
Force Analysis of Crank at angle of
RH1FT
1 maximum twisting Moment
3521
Crank Pin
M b  RH 1FR (a ) T  RH 1FT ( R)
36
21
Crank Pin
Te 
Te  T  M , N  mm
2 2 
b
J r
 F
Te  d P ( )
3 pb 
16 (l p )(d p )
F lp=(0.8 to 1.3) dp (Page No 50)
lp 
(d p )( pb ) 37
21
Shaft under the Flywheel: [Diameter of the
shaft between bearing 2 and 3]
M FLY  ( RV 3(W ) )( y ) M belt  ( RH 3( BELT ) )( y )
M Total  M 2
FLY M 2
belt
T  Ft (R )
Te  T 2  M Total
2
, N  mm

d W ( )
3
Te 
16 38
21
Right hand Crank Web:
The bending moment due to radial component is
lp h 6
M rad  RH 2 FR (b   )  rad  Mrad   MPa
2 2 wh 2
6
M Tang  Ft (R)  Tang  M Tang ( 2 ), MPa
w h
Fr
d   MPa
2 wh 21
39
Right hand Crank Web:
 total   rad   Tang   d , MPa
lp lp lp
T  R HIFT (a  )  FT ( )  R H 2 FT (b  ), N  mm
2 2 2
T T bh 2
  (c )  Z= , mm 3
J Z 4.5
2
 x  y  x   y 
1       2
xy
2  2 
40
21
Left hand Crank Web:
Crankshaft bearings:
The distance between bearing 1 and bearing 2

may be assumed to be equal to twice the
cylinder diameter. From the length of the
crankpin and the thickness of the arm, the
lengths of the bearings can be found out.
Bearing 2 is the most heavily loaded, therefore,
only this bearing may be checked for the safe
bearing pressure. 41
21
Crankshaft bearings:
FpW T1  T2
R2   
2 2 2
R2
pb  , MPa
( L)(d )
Where L and d are the length and diameter of
the bearing.
42
21
Summary
 Design Calculations,
 Analysis of Center Crank
shaft, Crank at Dead Center,
 Crank at angle of maximum
Twisting Moment
Any Questions Please……….
43
21
Thank
You
4421

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Krishnaraja G Kodancha,

Session 24 Introduction and Basics, Power

The second, that the crankshaft as a whole must

Machine Main Bearing Crank arm

Centre Crank Shaft 10

Crank on Dead Center R3

Force Analysis of Crank at Dead Center

RH2(belt) + RH3(belt) – (T1+T2) =0

(T1  T2 )(x) (T1  T2 )(y)

If x=y, then (T1  T2 )

HERE DESIGN IS BASED ONLY ON

Force Analysis of Crank at Dead Center 1821

Otherwise, providing the dimensions empirically as

Forces on crank Arm

In this position of the crankshaft, the different

The reactions at the bearings 2 and 3 due to

The distance between bearing 1 and bearing 2

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