Optimization of Four Cylinder Engine Crankshaft using FEA

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1 Optimization of Four Cylinder Engine Crankshaft using FEA Prasad P. Gaware 1, Prof. V.S. Aher 2 Department of Mechanical Engineering, AVCOE, Sangamner 1 Department of Mechanical Engineering, AVCOE, Sangamner 2 prasadgaware@gmail.com 1, vsa_arya@rediffmail.com 2 Abstract- Crankshaft is a component used in IC engine to converts reciprocating motion of piston in to rotary motion by using a four link mechanism. Crankshaft is designed for sustaining large amount of load during service period. Excessive bending of crankshaft is not desirable for Internal Combustion engines. Weight and cost optimization of crankshaft can be done by using Finite Element Analysis. By using the theoretical design of crankshaft a 3D model is prepared using PRO-E software. This model is then imparted in ANSYS for analysis. For that meshing was done. The results from FEA are compared to find out optimum material for crankshaft. Index Terms- PRO-E, IC Engine, ANSYS. 1. INTRODUCTION Crankshaft has a very complex geometry and it is a key element in I.C engine. The shaft parts of crankshat rotate in the main bearing. The big end of the connecting rod is connected to the crank pin, the crank arms or webs, which connect the crankpins, and the shaft parts. The crankshaft has to sustain a large number of load cycles during its service period, hence fatigue performance and durability of this component has to be considered in the design process. Design and development of crankshaft is major issue in industry because it is main power transmitting element. Our aim is to manufacture less expensive component with minimum weight and high fatigue strength. Improvement in engine will give small engines with less weight and high power output. Crankshaft of an I.C engine should able to sustain high downward force with negligible bending. Since crankshaft is the key component in internal combustion engine its reliability depends on crankshaft. As the engine runs, the power strokes hit the crankshaft in one place and then another.the crankshaft is the main part of the crank train or crank assembly, which latter converts the reciprocating motion of the pistons into rotary motion. It is subjected to both torsional and bending stresses, and in modern high-speed, multi-cylinder engines these stresses may be realty increased by resonance, which not only renders the engine noisy, but also may fracture the shaft. In addition, the crankshaft has both supporting bearings (or main bearings) and crank pin bearings, and all of its bearing surfaces must be sufficiently large so that the unit bearing load cannot become excessive even under the most unfavorable conditions. At high speeds the bearing loads are due in large part to dynamic forces-inertia and centrifugal forces 2. LITERATURE REVIEW Solanki et al. [1] gave a review on design of crankshaft and its optimization. The manufacturing process, design consideration and failure analysis of material were reviewed. The design of the crankshaft considers the dynamic loading and the optimization can lead to a shaft diameter satisfying the requirements of the automobile specifications with cost and size effectiveness. Jian Meng et al. [2] analyzed crankshaft model and crank throw were created by Pro/ENGINEER software and then imported to ANSYS software. The crankshaft deformation was mainly bending deformation under the lower frequency. And the location of maximum deformation is at the link between main bearing journal, crankpin and crank cheeks. Rajesh M. Metkar et al.[3] have evaluated FEM based fracture mechanics technique to estimate life of automobile crankshaft of single cylinder diesel engine. Xiaorong Zhou et al. [4] prepared Crankshaft Dynamic Strength Analysis for Marine Diesel Engine, described the stress concentration in static analysis of the crankshaft model. The stress concentration is mainly occurred in the fillet of spindle neck and the stress of the crankpin fillet is also relatively large. The calculation of fatigue life is useful to improve design of crankshaft. Montazersadgh and Fatemi et al. [5] choose forged steel and a cast iron crankshaft of a single cylinder four stroke engine. Both crankshafts were digitized using a CMM machine. At the next step, geometry and manufacturing cost optimization was performed. 63

2 Experimental stress and FEA results showed conformal match. YV. Mallikarjuna Reddy,T. Vijaya Devi.et al. [6] has work on Design, Analysis and Optimization of a 6 cylinder Engine Crank shaft This paper deals with; the problem occurred in six cylinders four stroke engine crankshaft. It consists of static structural analysis of six cylinder engine crank shaft. It identifies and solves the problem by using the modeling and simulation techniques. 3. METHODOLOGY Theoretical Calculation First the theoretical calculation of design of crankshaft is done. Solid model of crankshaft Maximum Gas pressure Capacity 25 Bar 1200 cc Results from theoretical calculations are given below Diameter of crank pin =44 mm Length of the Crank pin =33 mm Diameter of shaft =60 mm Web Thickness (Left & Right Hand) = 35mm Web Width (Left & Right Hand) =65 mm Crankshaft Model Pro-E Wildfire 4.0 has been developed by Parametric Technology Corporation (PTC) of U.S.A. This is CAD/CAM/CAE software but we are using this for only 3-D part modeling (CAD). This CAD includes. 1. Sketcher 2. Part Modeling (part design) 3. Surface Design 4. Assembly Design Meshing of 3-D entity Finite Element Analysis Further by applying Boundary Conditions FEA carried out. Result. Compare Finite Element Analysis results 4. FINITE ELEMENT ANALYSIS Following are specifications of engine whose crankshaft is to be optimized. Table 1. Specifications of Engine Type Conclusion 4 Cylinder Petrol engine No of cylinders 4 Bore/Stroke 86 mm/ 68 mm Compression Ratio 18 : 1 Max. Power rpm Max. Torque 16.7 Nm@ 2200rpm Fig 1. Crankshaft Model 4.2. Finite Element Analysis of each material The properties required as input parameter for analysis of crankshaft by using ANSYS software are poisons ratio, Young s modulus and material density these properties are tabulated as below. By using these properties total deformation and von misses stresses are obtained. 64

3 Sr. No 1 Material SAE 4340 Table 2. Input Parameters Young s mod(n/m m2) Poisson s ratio Density (Kg/m3 ) 1.90E EN30-B 2 EN E Cast Iron 1.78E Structura l Steel 2.10E Cast Iron Fig. 4. Total Deformation of EN-30 B Fig 2. Total Deformation of Cast Iron Fig. 5. Von misses stress of EN30-B SAE 4340 Fig 3. Von misses stress of Cast Iron Fig. 6. Total Deformation of SAE

4 Finite Element Analysis Results Table 3. FEA results Fig. 7. Von misses stress of SAE Structural Steel. Sr. No. Material Comparison of Results: Maximum Von Misses (N/mm 2 ) Maximum Deformatio n (mm) 1 Cast Iron E-03 2 EN30B E-04 3 SAE E-04 4 Structural Steel E-04 Mas s (Kg) Material EN-30B gives best results compared to all other materials. 2. The difference between minimum mass available and the mass when EN-30B is used is kg. It is so less hence it can be neglected. Fig. 8. Total Deformation of Structural Steel Fig. 9. Von misses stress of Structural Steel 4.3. FEA Results The results obtained from FEA analysis are tabulated as below. 5. CONCLUSION 1. The design is safe because value of von-misses stresses that obtained from the analysis is less than material yield stress. 2. As the weight of crankshaft is reduced it will reduce the inertial force. 3. Finite element analysis is best tool for optimization of component design. REFERENCES [1] Solanki, K. Tamboli, M.J.Zinjuwadia, Crankshaft Design and Optimization- A Review, National Conference on Recent Trends in Engineering & Technology 2011, [2] Jian Meng., Yongqi Liu., Ruixiang Liu., Finite Element Analysis of 4- Cylinder Diesel Crankshaft, I.J. Image, Graphics and Signal Processing, 2011, 5, [3] Rajesh M. Metkar, Vivek K. Sunnapwar, Subhash Deo Hiwase, Vidya Sagar Anki, Mahendra Dumpa, Evaluation of FEM based fracture mechanics technique to estimate life of an automotive forged steel crankshaft of a single cylinder diesel engine, Procedia Engineering 51, 2013,

5 [4] Xinglong Zhou, Modelling and simulation of flexible slider-crank mechanism with clearance for a closed high speed press systems Mechanism and Machine Theory, 74(2014) [5] H. Montazersadgh, A. Fatemi, Project Report on Stress Analysis and Optimization of Crankshafts Subject to Dynamic Loading The University of Toledo. (2007) [6] Y V. Mallikarjuna Reddy, T.Vijaya Devi. Design,Analysis and Optimization of a 6 cylinder Engine Crank shaft 67

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