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Dynamic and Fatigue Analysis of Engine Crank Shaft by Using FEM Approach

Ajay Kumar Singh, Adarsh Kumar

Abstract


The internal combustion (ICE) engine crankshaft is a high-volume manufacturing component with a complicated shape. This converts the piston's reciprocating displacement into the crank's rotating motion. In this research, an effort is made to investigate how geometry modification might increase the fatigue life of a single-cylinder engine crankshaft. SOLIDWORK software was used to construct the modelling of the original and optimised crankshaft, which was then imported for analysis into ANSYS software. Using the ANSYS software and applying boundary conditions, finite element analysis (FEA) is carried out to determine the dangerous area, maximum stress point, and life of the original and optimized crank shaft. The fillet sections between the crank web and crankshaft journal are where the most stress is present.  Tetrahedral elements are used to mesh the crankshaft geometry in the finite element model. Crank pin and journal fillets are subjected to mesh refinement to provide fine mesh in these regions, which are often critical elements of the crankshaft. Fatigue is the main cause of failure, and it started the crankshaft failure in the fillet region of the journal.

By reducing the crankpin fillet radius and adding 25.88% stress reduction to the crankpin diameter adjustment, geometry optimization resulted in a 15% stress reduction and a 62.55% life optimization for the crankshaft. The outputs of the ANSYS programme are then used to calculate the Von-Miss stress, shear stress, and crankshaft life. As a consequence of geometry optimization parameters, modifications in the crankshaft model's crankpin fillet radius and diameter result in a rise in fatigue life.


Keywords


ICE, Crankshaft, FEA, ANSYS software, Von-Miss stress

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References


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DOI: https://doi.org/10.37628/ijsmfe.v9i1.1574

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