Design and Analysis of Crankshaft for Internal Combustion Engine

International Journal of Trend in Scientific Research and Development (IJTSRD)
Volume: 3 | Issue: 3 | Mar-Apr 2019 Available Online: www.ijtsrd.com e-ISSN: 2456 - 6470
@ IJTSRD | Unique Paper ID – IJTSRD23531 | Volume – 3 | Issue – 3 | Mar-Apr 2019 Page: 1671
Design and Analysis of Crankshaft for
Internal Combustion Engine
Md. Hameed1, Chova Deekshith2, Gorge Bhanu Prasad2, Chalamala Teja2
1Assistant Professor, 2Student
1,2Department of Mechanical Engineering, Guru Nanak Institute of Technology, Hyderabad, India
How to cite this paper: Md. Hameed |
Chova Deekshith | Gorge BhanuPrasad|
Chalamala Teja "Design and Analysis of
Crankshaft for Internal Combustion
Engine" Published in International
Journal of Trend in Scientific Research
and Development
(ijtsrd), ISSN: 2456-
6470, Volume-3 |
Issue-3, April 2019,
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ABSTRACT
In this project design and analysis of the crankshaft for the combustion engine.
These components have a large volume component with complexgeometryand
need huge investment. These will be converts reciprocating or linear motion of
the piston into a rotary motion. In this project the product is modeled in a 3D
model with all available constraint by using advanced cad software CATIA-V5.
this model will be converted to initial graphics exchange specification (IGES)
format and imported to ANSYS workbench to perform static analysis. Finite
element analysis (FEA) is performed to obtain the various stress and critical
location of crankshaft under loads by using ANSYS software. This project helps
to many researchers to select best material to production of crankshaft.
KEYWORDS: Crankshaft, CATIA-V5, Initial Graphics ExchangeSpecification(IGES),
ANSYS workbench and. Finite element analysis (FEA)
I. INTRODUCTION
Internal combustion engine plays important in automobile,
pumping, electric generation. marine etc. the obvious piston
force applied to a crank shaft is the product of combustion
pressure acting on the top of the piston. Many high-
performance crankshafts are formed by the forging process.
In this production process billet of suitable size is heated to
appropriate forging temperature ranges from 1950˚F-
2250˚F and then successively pounded or pressedthedesire
shape by squeezing the billet between pairs of dies under
high pressure [1].
However, there will have major source of forces imposed on
a crankshaft, namely Piston acceleration. The combined
weight of the piston, ring package, wristpin, retainers, the
connectingrod small end and asmall amountof oilarebeing
continuouslyaccelerated from rest to veryhigh velocityand
backtoresttwice each crankshaftrevolution.Sincetheforce
it takes to accelerate an object is proportional to the weight
of the object times the acceleration (as long as the mass of
the object isconstant), many of the significantforcesexerted
on those reciprocating components, as well as on the
connecting rod beam and big-end, crankshaft, crankshaft,
bearings, and engine block are directly related to piston
acceleration. The methods for dealing with those vibratory
loads are covered in a dedicated article. Combustion forces
and piston acceleration are also the main source of external
vibration produced by an engine [2].
The steel alloys typically used in high strength crankshafts
havebeen selected for what each designer perceives as the
most desirable combination of properties. Medium-carbon
steelalloysarecomposedofpredominantlytheelementiron,
and contain a small percentage of carbon (0.25% to 0.45%,
described as ‘25 to 45 points’ of carbon), along with
combinations of several alloying elements, the mix of which
has been carefully designed in order to produce specific
qualities in the target alloy, including hardenability, nitride
ability, surface and core hardness, ultimatetensilestrength,
yield strength, endurance limit (fatigue strength), ductility,
impact resistance, corrosion resistance, and temper-
embrittlement resistance. The alloying elements typically
used in these carbon steels are manganese, chromium,
molybdenum, nickel, silicon, cobalt, vanadium, and
sometimes aluminum and titanium. Each of those elements
adds specific properties in a given material. The carbon
content is the main determinant of the ultimatestrengthand
hardness to which such an alloy can be heattreated [3].
Many researchers have focused on design of the crankshaft.
According to Farzin H. Montazersadgh and Ali Fatemi’s
journal dynamic simulation was acted on a crankshaft froma
IJTSRD23531

International Journal of Trend in Scientific Research and Development (IJTSRD) @ www.ijtsrd.com eISSN: 2456-6470
@ IJTSRD | Unique Paper ID - IJTSRD23531 | Volume – 3 | Issue – 3 | Mar-Apr 2019 Page: 1672
multi cylinder four stroke engine. Finite element analysis
was performed to obtain the variation of stressmagnitudeat
critical locations. The pressure-volume diagram wasused to
calculate the load boundary conditionindynamicsimulation
model, and other simulation inputs were taken from the
engine specification chart. The dynamic analysis was done
analytically and was verified by simulation in ADAMS which
resulted in the load spectrum applied to crank pin bearing.
This load was applied to the FE model in ANSYS, and
boundary conditions were applied according to the engine
mounting conditions. Payer et al. developed a two-step
technique to perform nonlinear transient analysis of
crankshafts combining a beam-mass model and a solid
element model. Using FEA, two major steps were used to
calculate the transient stress behavior of the crankshaft; the
first step calculated time dependent deformations byastep-
by- step integration usingthenewmark-beta-method.Using
a rotating beam-mass- model of the crankshaft, a time
dependent nonlinear oil film model [5]
In the second step those transient deformations were
enforced to a solid- element- model of the crankshaft to
determine its time dependent stress behavior. The major
advantage of using the two steps was reduction of CPU time
for calculations. This is because the number of degrees of
freedom for performing step one was low and therefore
enabled an efficient solution. Furthermore, the stiffness
matrix of the solid element model for steptwoneededonlyto
be built up once Literature survey is concluded, and we can
move intonextchaptertodiscussaboutdesigning procedure.
Guagliano etal. conducted a study on a marine diesel engine
crankshaft, in which two different FE models were
investigated. Due to memory limitations in meshing a three-
dimensional model was difficult and costly. Therefore, they
used a bi-dimensional model to obtain the stress
concentration factor which resulted in an accuracy of less
than 6.9 percent error for a centered load and 8.6 percent
error for an eccentric load. This numerical model was
satisfactory since it was very fast and had good agreement
with experimental results [6].
II. Methodology
In the design and analysis of crankshaft project following
steps to design crankshaftwhichbearhighimpactloadpiston
steps are given below are
Calculating forces on the crankshaft mathematically.
Model the crankshaft in CATIA-V5.
Save model file in IGES format.
Export in the ANSYS software.
Using Analysis modulebyinsertingmaterialandloadson
the crankshaft.
III. Calculation of Forces
At this position of the crank, the maximum gas pressure on the
piston will transmit maximum force on the crankpin in the
plane of the crank causing only bending of the shaft. The
crankpin as well as ends of the crankshaft will be only
subjected to bending moment. Thus, when the crank is at the
dead Centre, the bending moment on the shaft is max. And the
twisting momentiszero. The variousforcesthatareactingon
thecrankshaftare indicated as below.Thisenginecrankshaftis
a singlethrowandthreebearingshaftlocatedatposition1,2&3.Let’s
usassumefollowingdataforengineand calculatethevariousforces
acting on crank shaft connecting rod (Fp), Horizontal and vertical
reactionson shaft,and the resultantforce atbearing2&3by below
formulae.Nowthepistonforce
Pmax = P × no of cylinders/1248 × 106 × 4000
= 55 × 4/1248 × 106 × 4000
= 44.07
Piston force Fp =π/4 × D2 × Pmax
=π/4 × (69.6)2 × 44.07
= 167.67 KN
Assuming the distance between the bearings 1 &2 as
b =2D=2 × 69.6=13902mm b1
= b2 = b/2= 69.6
We know that due to piston gas load, there will be two equal
horizontal reactions H1 & H2 at bearings 1 & 2 respectively.
i.e., H1 = Fp/2 = 167.66/2 = 83.83 KN = H2
Assuming that the length of bearing to be equal
i.e. c1=c2=c/2
we know that due to weight of flywheel acting downwards,
there will be two vertical reactions V2 & V3 at bearings 2 & 3
V2= V1 = W/2 = 9.8/2 = 4.9 N
Since, the belt is absent in engine, neglecting the belt tension
exerted by belt
i.e. T1 + T2 = 0
Now, let’s design various parts of crankshaft
Design of left-hand crank web
Thecrankwebisdesignedforeccentricloading.Therewillbetwo
stresses acting on the crank web, oneis direct compressive
stress andthe otheris bending stressdue to piston gas load
(Fp).
The crank web is subjected to the following stresses
Bendingstressesintwoplanesnormaltoeachother,
Directcompressivestressand
Torsionstress
We know that the thickness of crank web is t = 0.65
*dc + 6.35= 0.65 × 90 + 6.35
= 64.85 = say65 mm
Also, width of crank web is,
W = 1.125 × dc +12.7
= 1.125 x 90 +12.7
= 113.95 = say115 mm
The maximum bending moment on crank web is
Mmax = H1 (b2 –lc/2-t/2)
= 83.83 (69.6- 186.28/2-65/2)
=- 4697.83 kN mm
Thebendingmoment isnegative; hencethedesignisnotsafe.
Thus, the dimensions are on higher side.
Now let’s assume,
dc = 45 mm
Hence, lc = 372.57 mm
This is very high, which will require huge length of crank
shaft. Tohaveoptimum dimensionofcrankshaftlet’sassume
length of crank web as.
lc = 24 mm
and check whether thesedimensions aresuitablefortheload
exerted by the piston, & other forces

Now, t = 35.6 & w
= 63.32 = say 68 mm
This thickness is also on higher side, let’sassumethicknessof
crank web as
t = 13.2 mm
As compared to width of crank web thickness is more
Bending moment, M = 4275.33 kN-mm
Section modulus, Z = 1/6 x w x t2
= 1/6 x 68x 13.22
= 1974.72 mm3
Bending stress
σb= M/Z
σb= 2.165 KN/mm2
The compressive stress acting on crank web are
σc= H1 / (w × t)
= 83.83 / (68 × 13.2)
= 0.09339 KN/ mm2
A. Thetotal stressacting on crank webis
σT = σb + σc
= 2.2583 KN/ mm2
Thus, total stress on crank web islessthanallowablebending
stress of 83 N/mm2
Hence, the design is safe
B. Design of right-hand crank web
From balancing point of view, the dimensions of right-hand
crank web i.e. thickness and width are made equal to the
dimensions of left-hand crank web.
C. Design of shaft under flywheel
There are two types of bending moments acting on shaft.
Bending moment due to weight &, bending moment due to
belt tension. Neglecting the belt tension lets design shaft
diameter.
Let, ds = diameter of crank shaft Since thelength of bearings are
equall1= l2 = l3
= 2(b/2-lc/2-t)
= 2(139.2/2- 24/2-13.2)
= 88.8 mm
Assuming the width of flywheel = 200 mm
C = 88.88 + 200
= 288.88 mm
Considering the space for gearing and clearance,
Let C = 300 mm
Bending moment due to weight of fly wheel,
Mb = V3 x C
= 4.9 x 103 x300
= 1470 x 103KN mm
Also, the bending moment of shaft is
Ms =π/32 × ds
3 x σ allow
1470x 103 = π/32 × ds3 × 83 d s
= 56.50mm
IV. MODELLING OF CRANKSHAFT
In this project modeling crankshaft in CATIA V5 as shown in
figure 2. Creation of a 3-D model in CatiaV5R20 can be
performed using three workbenches i.e.- sketcher- modeling
and assembly. Sketcher is used two-dimensional
representations of profiles associated withinthepart.Wecan
create a rough outline of curves- and then specify conditions
called constraints to define the shapes more precisely and
capture our design intent. Each curve is referred to as a
sketch object. a new sketch- chose Start Mechanical design
part then selectthereferenceplaneorsketchplaneinwhich
thesketchistobecreated. The sketch plane is the planethat
the sketch is located on. The sketch plane menu has the
following options:
Face/Plane: With this option- we can use the attachment
face/plane icon to select a planar face or existing datum
plane. If we select a datumplane- we can use the reverse
direction button to reverse the direction of the normal tothe
plane.
XC-YC-YC-ZC- and ZC-XC:Withthese options-wecancreatea
sketch on one of the WCS planes. If we use this method- a
datum plane and two datum axes are created as below.
Displays thestructureofthepart,assembly,ordrawing.Select
an item from the feature manager design tree to edit the
underlying sketch, edit the feature, and suppress and un
suppress thefeatureor component,forexample.Ameetingis
an aggregate of or extra components, additionally known as
components, inside one solid works record. Your role and
orient components the use of mates that form family
members among additives.
This lesson discusses the following:
Adding components to a meeting
Transferring and rotating additives in an assembly
Growing display states in an assembly
“Feature” isan all-encompassing term thatreferstoallsolids,
bodies and primitives used inSolid works Form Features are
used to supply detail to the model in the form of standard
feature types. These include hole, Extrude Boss/Cut,Swept
Boss/Cut, Fillet. We can alsocreate our own custom features
using the User Defined option. All of these features are
associative.
ReferenceFeaturesallowcreatingreferenceplanes,reference
lines and reference points. These references can assist in
creating features on cylinders, cones, spheres and revolved
solid bodies. Reference planes can also aid in creating
features at angles other than normal to the faces of a target
solid. Dress up Feature options lets modify existing solid
bodies and features.
These include a wide assortment of options such as edge
fillet, variable fillet, chamfers, draft, offset face, shell and
tapers. Surface design lets uscreate surface and solidbodies.
A surface body with zero thickness, and consists of a
collection of faces and edges that do not close up to enclose a
volume.

Fig. 1. Final Model of Crankshaft
V. RESULTS AND DISCUSSION
1. Total Deformations
In the Details of “Total Deformation” window, expand the
Results node, if it is not already expanded. Note that the
maximum and minimum deformations displayed are
respectively.
For Medium Steel Alloy
Fig.2. The Values of Total Deformation Obtained from The
Legend Display in Color Bands.
For Ni Cr Mo Steel Alloy
Fig. 3. The Values of Total Deformation Obtained from The
2. Equivalent Stress
In the Details of “equivalent stress” window, expand the
Results node, if it is not already expanded. Note that the
maximum and minimum deformations displayed are
respectively
For Medium Steel Alloy
Fig.4. The Values of Equivalent Stress Obtained from The
For Ni Cr Mo Steel Alloy
Fig. 5. The Values of Equivalent Stress Obtained from The
Legend Display in Color Bands
Fig. 6. Strain Life Graphs
Therefore, there is significant difference in the stresses and
deflection in springs under the same static load
Life
In the Details of “life” window, expandtheResultsnode,ifitis
not alreadyexpanded. Note that the maximumandminimum
deformations displayed are respectively.
Damage
In the Details of “damage” window, expand the Results node,
if it is not already expanded. Note that the maximum and
minimum deformations displayed are respectively.
VI. CONCLUSION
TheModelweight wasreducedafter change ofmaterials
from 10.93 kg to 9.773 kg at a density Kg/m3 from the
table 7.1 and 7.2.
From the above results it is suggest that the design
modification was acceptable.

In the working of the engine, the engine generates 10 to
12 torque at beginning it may vary by increase of
acceleration. Because ofcontinuouslycycleorstokesthe
crankshaft gets deforms. At a peek of cycles, the
crankshaft isunable to generate smooth transmission of
the power to rearwheel.
In this project we consider the composite material in
real time MEDIUM STEEL ALLOY and replace the
material with other material name NI CR MO STEEL
ALLOY so that the weight and deformations are
decreased and lifeincrease.
by analysis the life of the crankshaft is increased.
weight was reduced
REFERENCES
[1] Altan, T., Oh, S., and Gegel, H. L., 1983, “Metal Forming
Fundamentalsand Applications,” American Societyfor
Metals, Metal Park, OH,USA.
[2] Ando, S., Yamane, S., Doi, Y., Sakurai, H., and Meguro,H.,
1992, “Method for Forming a Crankshaft,” US Patent
No. 5115663, United States Patent.
[3] Baxter, W. J., 1993, “Detection of Fatigue Damage in
Crankshafts with the Gel Electrode,” SAE Technical
Paper No. 930409, Society of Automotive Engineers,
Warrendale, PA, USA.
[4] Borges, A. C., Oliveira, L. C., and Neto, P. S.,2002,“Stress
Distribution in a Crankshaft Crank Using a
Geometrically Restricted Finite Element Model,” SAE
Technical Paper No. 2002-01-2183, Society of
Automotive Engineers, Warrendale, PA,USA.
[5] Burrell, N. K., 1985, “Controlled Shot Peening of
Automotive Components,” SAE Technical Paper No.
850365, Society of Automotive Engineers,Warrendale,
PA, USA.
[6] Chien, W. Y., Pan, J., Close, D., and Ho, S., 2005, “Fatigue
Analysis of Crankshaft Sections Under Bending with
Consideration of Residual Stresses,” International
Journal of Fatigue, Vol. 27, pp. 1-19.
[7] Fergusen, C. R., 1986, “Internal Combustion Engines,
AppliedThermodynamics,” John Wiley and Sons, Inc.,
New York, NY, USA.

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