5. 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,
aircraft.
5
Design and Validation of a Crankshaft
6. Conceptual design
•Major functions arefixed
•Setting of Structural relationships of
the principal components
•Sufficient details to provide
approximate costs, weights
•Assured overall dimensions and
feasibility of crank
Major crankshaft dimensions must be
chosen early in the engine design
process as they affect overall engine
dimensions.
6
Design and Validation of a Crankshaft
7. Process analysis and selection
crank stress
integrity of the joints
impact of the crank on the block stress anddeformation
Design and Validation of a Crankshaft 7
8. The virtual procedure of analysis:
3)Run full crank reduced model
(dynamic) to calculate reactionsand
torques.
4)Model entire crankshaft with FEM
6)Constrain the model at the flywheel
end
7)Run analysis applying all possible
loads
8)Scale and sum up the FEresults for
each crank angle
Design and Validation of a Crankshaft 8
10. Test
fatigue through the crankweb.
fatigue through the pin journal,
with the crack initiation starting at
the oil hole.
run calibration curve, calculate test
strain levels, set control parameters,
run test and inspect the specimen
surface.
Design and Validation of a Crankshaft 10
12. Quality improvement
Hardening- using induction hardened bearing surfaces
Fatigue strength- increased by using a radius at the ends of
each main and crankpin bearing
Counterweights-helps to negate the flexing of the crank
Design and Validation of a Crankshaft 12
13. Supportive materials through Design and Validation:
Six Sigma
ISO 9001:2000
BS 7000
Health and Safety Executive (HSE)
Design and Validation of a Crankshaft 13
14. Step 1-conceptual design
Step 2- process analysis and selection
Step 3- test
Step 4- production
Step 5- improvement
Design and Validation of a Crankshaft 14
