A detailed study was carried out on crankshafts used in two wheeler made from C45 (EN 8/AISI 1042)
steel. Undesirable noise was heard in crankshaft when the engine is in running. This was stated as failure
of crankshaft. Material has been peeled off and seemed to be scraped at the central portion of the crankpin.
It was the bearing seating place where oil hole also provided. Under analysis the crankpin was identified
as tempered. Chemical composition, micro-hardness and microstructure were studied and compared with
the specified properties of the crankpin material. Reason for failure is identified as wear due to lower
hardness, improper lubrication and high operating oil temperature.
This document summarizes a failure analysis of diesel engine crankshafts made of nodular cast iron that failed prematurely. Examination found that all failures occurred in the first crankpin nearest to the flywheel. Finite element modeling revealed high stresses in this region. However, fatigue analysis found the stresses were within safe limits. Scanning electron microscopy of fracture surfaces showed brittle cleavage fracture rather than fatigue, indicating an overload likely caused the failure. The document recommends re-evaluating the crankshaft design and manufacturing process, particularly fillet rolling, to prevent future failures.
Investigation of Mechanical Properties of Rivet Joints For Grade-5 TitaniumSantanudeori2
This document discusses an investigation into the mechanical properties of rivet joints for grade 5 titanium. It begins with an introduction that describes the importance of riveting in aircraft manufacturing, noting it covers 95% of aircraft bodies. The document then describes the testing of solid shank and blind rivets on titanium grade 5 plates, including tensile tests, shear stress tests, torsion tests, and Charpy impact tests. The conclusion is that both rivet types were properly installed on the titanium and mechanical properties like tensile strength and shear stress were evaluated to optimize rivet joints for aircraft components made of grade 5 titanium.
The document describes an experimental study on the flexural behavior of cold-formed steel beams with and without stiffeners. Four cold-formed steel beams were fabricated with a depth of 150mm and thickness of 1mm or 2mm. One hot-rolled steel beam (ISMB 150) was also tested for comparison. The beams were subjected to four-point bending tests. The results showed that adding stiffeners significantly improved the strength and stiffness of beams made from 2mm thick steel, but not as much for beams made from 1mm thick steel due to higher susceptibility to local buckling. Beams made from 2mm thick steel with stiffeners exhibited stiffness comparable to the hot-rolled beam in initial loading.
A STUDY OF EFFECT PROCESS PARAMETERS ON TENSILE STRENGTH IAEME Publication
This document discusses a study on the effect of process parameters on tensile strength of friction stir welded AA6061 aluminum alloy joints. Friction stir welding is a solid-state joining process that uses a non-consumable rotating tool to join materials together without melting. The study examines parameters like rotational speed, traverse speed, axial force, shoulder diameter, and tilt angle. Tensile test samples were prepared and tensile strength values were measured for different parameter combinations based on a Taguchi design of experiments. Optimum tensile strength was found at 1000 rpm speed, 14 mm/min feed rate, 7 kN axial force, 17 mm shoulder diameter, and 3° tilt angle for cylindrical tools and 710 rpm speed,
1) Cast scandium added aluminum-magnesium alloy was friction stir welded and its tensile properties were examined.
2) The weld exhibited better mechanical properties than the base metal, with the weld nugget showing the highest strength.
3) Tensile testing showed that the global joint fractured in the base material and had slightly higher strength than the base metal, indicating that friction stir welding is suitable for joining this alloy.
To find effects of GMAW parameters on Mechanical Properties of Aluminum AlloysIJERA Editor
The present research aims to investigate the effects of Gas Metal Arc Welding (GMAW) on the mechanical
properties of different grades of aluminum alloys. GMAW is the most common method of joining aluminum
alloys used in various industrial processes. It replaces the Tungsten Inert Gas (TIG) method of providing equally
high quality of joints with a much higher performance. Aluminum alloys under consideration for this
experiment will be from 6XXX series, consisting of Silicon and Magnesium as main alloying elements. Weld
joints Will be produced with the help of a Gas Metal Arc Welding (GMAW) process. The Hardness, Tensile
strength, yield stresses and elongation will be the mechanical properties to be obtained. As aluminum alloys
show large micro structural changes after welding it is necessary to know about the effect of welding parameters
on the mechanical properties of weldements as too high welding current and too high welding speed will result
in high heat input and weakening of weld profile so a balance is need to be struck between welding parameters
and mechanical properties. Scattering Electron Microscopy (SEM) technique will be used to analyze micro
A study on characterization of Al-18%Si alloy by centrifuge castingdbpublications
Aluminum-silicon alloy are characterized by light weight, good strength –to-weight ratio, ease of fabrication of at reasonable cost, high strength at elevated temperature, good thermal conductivity, excellent castability, good weldability, excellent corrosion and wear resistance property. Thus, these types of alloys are well suited for automotive industries, aerospace structural and military applications. In centrifuge casting solidification rate is faster compared to gravity casting, but still solidification depends on various process parameters like, cooling temperature of molten metal, rotational speed of the die and also wall thickness of die. In centrifuge casting the silicon deposition in aluminum varies from top to bottom. Here Al-Si functionally graded material is used and developed under centrifuge casting. The method used in this work to produce functionally graded material is totally different from other centrifugal casting which helped in producing solid cylindrical parts. This report describes about mechanical characterization of Al-18%Si at different temperature. At 950°C casting shows good ultimate tensile strength and harder metal compared to other casting.
This document summarizes a study on the effect of longitudinal weld pool oscillation (LWPO) on the mechanical properties of gas metal arc welded AA 6101 T6 aluminium alloy joints. Tensile properties, microhardness, and microstructure of welds made with and without LWPO were evaluated and compared. Welds made with LWPO at an amplitude of 5Hz and frequency of 400Hz showed superior mechanical properties, including a 24.5% increase in yield strength and 21.1% increase in tensile strength, compared to stationary welds. This improvement is attributed to the formation of a finer equiaxed microstructure in the weld zone under oscillatory conditions.
This document summarizes a failure analysis of diesel engine crankshafts made of nodular cast iron that failed prematurely. Examination found that all failures occurred in the first crankpin nearest to the flywheel. Finite element modeling revealed high stresses in this region. However, fatigue analysis found the stresses were within safe limits. Scanning electron microscopy of fracture surfaces showed brittle cleavage fracture rather than fatigue, indicating an overload likely caused the failure. The document recommends re-evaluating the crankshaft design and manufacturing process, particularly fillet rolling, to prevent future failures.
Investigation of Mechanical Properties of Rivet Joints For Grade-5 TitaniumSantanudeori2
This document discusses an investigation into the mechanical properties of rivet joints for grade 5 titanium. It begins with an introduction that describes the importance of riveting in aircraft manufacturing, noting it covers 95% of aircraft bodies. The document then describes the testing of solid shank and blind rivets on titanium grade 5 plates, including tensile tests, shear stress tests, torsion tests, and Charpy impact tests. The conclusion is that both rivet types were properly installed on the titanium and mechanical properties like tensile strength and shear stress were evaluated to optimize rivet joints for aircraft components made of grade 5 titanium.
The document describes an experimental study on the flexural behavior of cold-formed steel beams with and without stiffeners. Four cold-formed steel beams were fabricated with a depth of 150mm and thickness of 1mm or 2mm. One hot-rolled steel beam (ISMB 150) was also tested for comparison. The beams were subjected to four-point bending tests. The results showed that adding stiffeners significantly improved the strength and stiffness of beams made from 2mm thick steel, but not as much for beams made from 1mm thick steel due to higher susceptibility to local buckling. Beams made from 2mm thick steel with stiffeners exhibited stiffness comparable to the hot-rolled beam in initial loading.
A STUDY OF EFFECT PROCESS PARAMETERS ON TENSILE STRENGTH IAEME Publication
This document discusses a study on the effect of process parameters on tensile strength of friction stir welded AA6061 aluminum alloy joints. Friction stir welding is a solid-state joining process that uses a non-consumable rotating tool to join materials together without melting. The study examines parameters like rotational speed, traverse speed, axial force, shoulder diameter, and tilt angle. Tensile test samples were prepared and tensile strength values were measured for different parameter combinations based on a Taguchi design of experiments. Optimum tensile strength was found at 1000 rpm speed, 14 mm/min feed rate, 7 kN axial force, 17 mm shoulder diameter, and 3° tilt angle for cylindrical tools and 710 rpm speed,
1) Cast scandium added aluminum-magnesium alloy was friction stir welded and its tensile properties were examined.
2) The weld exhibited better mechanical properties than the base metal, with the weld nugget showing the highest strength.
3) Tensile testing showed that the global joint fractured in the base material and had slightly higher strength than the base metal, indicating that friction stir welding is suitable for joining this alloy.
To find effects of GMAW parameters on Mechanical Properties of Aluminum AlloysIJERA Editor
The present research aims to investigate the effects of Gas Metal Arc Welding (GMAW) on the mechanical
properties of different grades of aluminum alloys. GMAW is the most common method of joining aluminum
alloys used in various industrial processes. It replaces the Tungsten Inert Gas (TIG) method of providing equally
high quality of joints with a much higher performance. Aluminum alloys under consideration for this
experiment will be from 6XXX series, consisting of Silicon and Magnesium as main alloying elements. Weld
joints Will be produced with the help of a Gas Metal Arc Welding (GMAW) process. The Hardness, Tensile
strength, yield stresses and elongation will be the mechanical properties to be obtained. As aluminum alloys
show large micro structural changes after welding it is necessary to know about the effect of welding parameters
on the mechanical properties of weldements as too high welding current and too high welding speed will result
in high heat input and weakening of weld profile so a balance is need to be struck between welding parameters
and mechanical properties. Scattering Electron Microscopy (SEM) technique will be used to analyze micro
A study on characterization of Al-18%Si alloy by centrifuge castingdbpublications
Aluminum-silicon alloy are characterized by light weight, good strength –to-weight ratio, ease of fabrication of at reasonable cost, high strength at elevated temperature, good thermal conductivity, excellent castability, good weldability, excellent corrosion and wear resistance property. Thus, these types of alloys are well suited for automotive industries, aerospace structural and military applications. In centrifuge casting solidification rate is faster compared to gravity casting, but still solidification depends on various process parameters like, cooling temperature of molten metal, rotational speed of the die and also wall thickness of die. In centrifuge casting the silicon deposition in aluminum varies from top to bottom. Here Al-Si functionally graded material is used and developed under centrifuge casting. The method used in this work to produce functionally graded material is totally different from other centrifugal casting which helped in producing solid cylindrical parts. This report describes about mechanical characterization of Al-18%Si at different temperature. At 950°C casting shows good ultimate tensile strength and harder metal compared to other casting.
This document summarizes a study on the effect of longitudinal weld pool oscillation (LWPO) on the mechanical properties of gas metal arc welded AA 6101 T6 aluminium alloy joints. Tensile properties, microhardness, and microstructure of welds made with and without LWPO were evaluated and compared. Welds made with LWPO at an amplitude of 5Hz and frequency of 400Hz showed superior mechanical properties, including a 24.5% increase in yield strength and 21.1% increase in tensile strength, compared to stationary welds. This improvement is attributed to the formation of a finer equiaxed microstructure in the weld zone under oscillatory conditions.
IRJET-Tribological Study Of aluminum based Composite Material for Automotive ...IRJET Journal
This document describes a study on the tribological properties of an aluminum-based composite material for potential use as an automotive brake material. The researchers developed an aluminum-titanium carbide composite using stir casting and tested it using a pin-on-disc tribometer. Experiments were designed using the Taguchi method to evaluate the effects of load, sliding speed, and sliding distance on the wear behavior of the composite. Analysis of variance was used to determine the most significant factors affecting wear. The results of this study could help optimize composite brake materials to improve braking performance and durability.
Studies On Fracture Toughness Behavior of Hybrid Aluminum Metal Matrix Compos...IJERA Editor
The limited mechanical properties of Al and its alloys adversely affect its applications in automobile and
aerospace industries. This remains one of the major concern in the fabrication to suit its application in recent
days. The main aim of the present work is to improve the fracture toughness of the Al matrix composite . A
composite with Al 6061 alloy as matrix and Zirconium Oxide as reinforcement is fabricated by stir casting
process. The specimens were prepared according to ASTM standards and fracture toughness, tensile and
hardness tests were performed and the properties were investigated. Zirconium oxide is selected as a
reinforcement because of its ability to influence the microstructure of the Al 6061 alloy to improve the fracture
toughness. The fracture toughness is highest at 6% reinforcement of ZrO2 and hardness is found to be more at
4% reinforcement
IRJET-Contact Stresses Analysis & Material Optimization of Ball Bearing using...IRJET Journal
This document discusses analyzing contact stresses and optimizing the material for ball bearings using Hertz contact theory. It begins by introducing ball bearings and their importance in rotating machinery. It then discusses selecting the proper material for ball bearings as it affects characteristics like weight, wear resistance, and stresses. The document considers replacing the typical steel balls with ceramic balls to reduce issues like electric arcing, fatigue, and overheating. It analyzes the mechanical properties and performance differences between steel, silicon nitride ceramic, zirconium oxide ceramic, and aluminum oxide using Hertz contact theory calculations and finite element modeling. The goal is to optimize the ball material choice to improve bearing performance and reliability.
This document discusses developing a fracture splitting method for manufacturing connecting rods made of case hardened steel. It examines applying the fracture splitting method to connecting rods made of JIS SCM420 carburized steel, which has varying hardness levels from the surface inward. Tests were conducted using a weight falling-type splitting machine to determine the temperature and strain rate conditions needed to obtain a brittle fracture surface over the entire fractured surface, including the inner portions with lower hardness. Measures were also taken to analyze and control the fracture starting point using nonlinear simulations to address issues of irregular fracture initiation and tiny fragment breakaways. The fracture splitting method was successfully implemented in the production of connecting rods for the Yamaha YZF-R1 supersport
Flexural strength also known as the bending strength which plays a vital role in the
industries where the heavy load application is implemented. The study reports show that
shotpeening technique considerably improves the mechanical properties of a material
such as hardness, fatigue strength, corrosion resistance, flexural (or) bending strength
etc. Here the shot material used for shotpeening is glass beads and the target material is
aluminum alloy of grade AA-2024 T3 which is widely used in the automobile and
aircraft industries due to its light weight and strength. The experimental results show
there is an improvement in the flexural strength of AA2024-T3material after
shotpeening
Machining of Aircraft Bearing Rings using High Quality Bearing SteelIJERA Editor
Bearing rings for Aircraft application are machined using high quality M50 High Speed Steel conforming to
AMS 6491B. The raw material for the rings of Ball bearing is prepared from a single bar stock using trepanning.
Special collet type soft jaw and Mandrels were devised and used on CNC Lathes to reduce manufacturing
problems like ovality. Raceway forms are turned using single point copy turning insert. The problems faced
during rings manufacture were discussed in this study.
INVESTIGATE THE EFFECT OF PHOSPHATE SURFACE COATING ON THE FATIGUE PERFORMA...IAEME Publication
Piston pin play a vital role in the reciprocating internal combustion engine. Failure of piston pin will result in failure of engine. Improper carburizing technology leads to decarburization of surface decreases intensely the fatigue strength of surface so that crack initiated from the surface and propagated, at last fatigue fracture occurred.
1) Sandwich beams made of GFRP core and aluminum face sheets were impacted by a rigid projectile at velocities from 25-115 m/s using a pneumatic gun.
2) The sandwich beams exhibited different failure modes including large inelastic deformation, core shearing, and delamination.
3) Mid-span deflection, energy absorption, and velocity drop after impact were measured and found to vary with impact velocity, with the beams absorbing more energy at lower velocities. The ballistic limit was approximately 50 m/s.
Effect of Volume Fraction (Al2O3) on Tensile Strength of Aluminium 6061 by Va...IRJET Journal
This document reviews the effect of adding aluminum oxide (Al2O3) particles on the tensile strength of aluminum 6061 composites produced via stir casting. Stir casting is described as a common and cost-effective method for fabricating metal matrix composites. The key process parameters of stir casting that influence composite properties are identified as stirrer design and speed, temperature, time, and reinforcement concentration. Literature on aluminum metal matrix composites reinforced with Al2O3 and silicon carbide is summarized, finding that strength and hardness generally increase with higher reinforcement content, while ductility decreases. Adding Al2O3 to aluminum 6061 via stir casting was shown to improve tensile strength over the unreinforced alloy. The document concludes
MODELING, ANALYZING AND SAFETY ASPECTS OF TORSION AND NOISE EFFECTS ON ROUND ...msejjournal
Each material has its own effect and behavior on external impacts like heat, force, tension, compression, torsion etc. It is important to study and analyze these behaviors before selecting a material for an engineering application in the design aspects itself. If predicted values analyzed by both mathematical and software are available it is easy to get the reliable details in the pre design itself. By this one can ensure the safety of the component and the system also. In this investigation, the effects of torsional loads on mild steel
round shafts with various diameters and lengths have been analyzed. The additional effects like angle of rotation, rpm and duration also considered to find the optimum predicted value. The data observed by various experiments are analyzed by design of experiments especially by response surface methodology. Minitab software is used for canalization. The data are tabulated and kept for future reference. Noise effect
due to the gradual torsional load performed in the gear box and other rotating components is also studied for healthy working environment. The nature and characteristics of material also be explained by this noise analysis.
Micro-structural and Tribological Behaviour of AA6063/12SiC-5Gr Hybrid Compos...ijsrd.com
In this paper the friction and wear behavior of aluminium matrix reinforced with silicon carbide and graphite is investigated. A pin on disc type apparatus is used to measure the sliding wear rate (WR), the frictional force (F) and the coefficient of friction (μ). Friction and wear behavior of the hybrid metal matrix composites (HMMC) have been investigated at various loads, sliding velocity and constant sliding distance. The applied loads are 20N, 40N, 60N and 80 N respectively, sliding speeds are 1.5 m/sec and 3 m/sec and the sliding distance is 1500 m. The aluminium based MMC has been produced by stir casting technique. AA6063 with 12SiC-5Gr composite is machined to the required size. Optical microscope is used for investigating the microstructure and surface properties of the specimen. The addition of graphite and silicon carbide reinforcement to AA 6063 alloy increases the wear resistance and hardness of the composites.
This document summarizes research on using additive manufacturing laser deposition to repair defects in Ti-6Al-4V, a titanium alloy commonly used in aerospace applications. Samples of Ti-6Al-4V were dented and then repaired using laser deposition of titanium powder. Mechanical testing found that the repaired samples had yield and tensile strengths that exceeded specifications for the alloy and were 20-25% higher than unrepaired samples. Microstructural analysis also showed that the laser deposition process resulted in a Widmanstatten grain structure that increased strength. Further microstructural characterization is still needed but the research demonstrates the potential of laser deposition to cost-effectively repair aerospace-grade titanium parts.
The document summarizes a study that uses finite element analysis to analyze the structural and thermal stresses in a bolted flange joint of a coiler drum in a steckel mill. A 3D model of the bolted flange joint was created in Pro-E and analyzed in ANSYS. The analysis found stresses induced in the bolts from high temperatures inside the mill and loads of 22 tons applied cyclically. Previous studies on bolted joints and fastener failure are discussed. The finite element analysis outputs like stresses and strains can predict failure areas identified in the bolted joint that have been known to shear off.
Microstructure and Hardness of Aluminium Alloy- Fused Silica Particulate Comp...AM Publications
Aluminum matrix composites (AMCs) refer to the class of light weight high performance aluminum centric
material systems. The reinforcement in AMCs could be in the form of continuous/discontinuous fibers, whiskers or particulates,
in volume fractions. Properties of AMCs can be tailored to the demands of different industrial applications by suitable
combinations of matrix, reinforcement and processing route. This work focuses on the fabrication of aluminum alloy (LM13)
matrix composites reinforced with 9%, 12% &15% fused silica particulates using stir casting route. The microstructure and
hardness of the fabricated composite were analyzed and reported.
Experimental Study of Wear Rate Coefficient of Aluminium Hybrid Composites Ma...AM Publications
In current decade, demand in material characteristics like light weight, superior strength to weight ratio, improved surface properties and enhanced wear resistance for complex engineering applications like automobile, aerospace and nuclear are researcher’s interest. However, performance of hybrid composites depends on right combination of reinforcements. Silicon carbide, silicon nitride, boron nitride and titanium carbide are few reinforcements available at present. In this work, Al356 is reinforced with SiC and B4C to enhance the mechanical properties, surface hardness and wear resistance. This hybrid composite is prepared by stir casting technique and the morphology of composite is studied using optical microscope to investigate the dispersion of reinforcements. In the present study, the wear and friction characteristics of hybrid composites are investigated using pin on disc dry wear tests by varying the load and speed and the results are tabulated for load vs mass loss, load vs wear rate and load vs wear coefficient. The results report that wear rate of hybrid composites are lower than that of binary composites. Mechanical properties, surface hardness and wear characteristics of aluminium hybrid composites are compared with that of aluminium binary composites available at present.
IRJET- Strength Evaluation of Spur Gear Made up of Polymer Composite Mate...IRJET Journal
This document discusses the design and testing of spur gears made from polymer composite materials, specifically polyamide reinforced with carbon fiber. The objectives are to prepare composite material specimens with varying carbon fiber percentages, test their mechanical properties, design and manufacture a spur gear mold, produce composite polymer spur gears using injection molding, and validate the analytical and simulation results of the composite gears. The document reviews previous research that found composite gears have advantages over steel gears in being lighter weight, less prone to corrosion, and able to operate without lubrication. The conclusions are that composite material gears provide higher strength than steel gears and can replace conventional steel gears with similar or better performance.
INVESTIGATION OF COMPOSITE TORSION SHAFT USING MATERIAL MATRIX IN FEAIjripublishers Ijri
have found application in many areas of daily life for quite some time. Often it is not realized that the application makes
use of composite materials.
This research attempt is made to evaluate the sustainability of composite material such as FRP (fiber rein forced polymer)
and CRFP (carbon reinforced fiber polymer) epoxy/glass for the purpose of automotive transmission application
using finite element method in Ansys.
Initially literature review will be done to understand the approach.
3D model will be prepared to carryout analysis on model.
Structural and vibrational analysis will be done by implementing different layer orientations on FRP & CRFP’S.
ALUMINIUM METAL MATRIX COMPOSITE BY STIR CASTING METHODSNEERAJKUMAR1898
This document provides an introduction and literature review on graphite-based aluminum metal matrix composites (AMMCs). It discusses how AMMCs overcome limitations of conventional materials by combining high strength, stiffness, and low density. The document reviews various fabrication techniques for AMMCs and their applications in industries like aerospace and automotive. It summarizes past research that studied mechanical properties of different AMMC compositions and processing methods.
Research Inventy : International Journal of Engineering and Scienceinventy
Research Inventy : International Journal of Engineering and Science is published by the group of young academic and industrial researchers with 12 Issues per year. It is an online as well as print version open access journal that provides rapid publication (monthly) of articles in all areas of the subject such as: civil, mechanical, chemical, electronic and computer engineering as well as production and information technology. The Journal welcomes the submission of manuscripts that meet the general criteria of significance and scientific excellence. Papers will be published by rapid process within 20 days after acceptance and peer review process takes only 7 days. All articles published in Research Inventy will be peer-reviewed.
MODELING, ANALYZING AND SAFETY ASPECTS OF TORSION AND NOISE EFFECTS ON ROUND ...msejjournal
Each material has its own effect and behavior on external impacts like heat, force, tension, compression,
torsion etc. It is important to study and analyze these behaviors before selecting a material for an
engineering application in the design aspects itself. If predicted values analyzed by both mathematical and
software are available it is easy to get the reliable details in the pre design itself. By this one can ensure the
safety of the component and the system also. In this investigation, the effects of torsional loads on mild steel
round shafts with various diameters and lengths have been analyzed. The additional effects like angle of
rotation, rpm and duration also considered to find the optimum predicted value. The data observed by
various experiments are analyzed by design of experiments especially by response surface methodology.
Minitab software is used for canalization. The data are tabulated and kept for future reference. Noise effect
due to the gradual torsional load performed in the gear box and other rotating components is also studied
for healthy working environment. The nature and characteristics of material also be explained by this noise
analysis.
Modeling, Analyzing and Safety Aspects of Torsion and Noise Effects on Round ...msejjournal
Each material has its own effect and behavior on external impacts like heat, force, tension, compression,
torsion etc. It is important to study and analyze these behaviors before selecting a material for an
engineering application in the design aspects itself. If predicted values analyzed by both mathematical and
software are available it is easy to get the reliable details in the pre design itself. By this one can ensure the
safety of the component and the system also. In this investigation, the effects of torsional loads on mild steel
round shafts with various diameters and lengths have been analyzed. The additional effects like angle of
rotation, rpm and duration also considered to find the optimum predicted value. The data observed by
various experiments are analyzed by design of experiments especially by response surface methodology.
Minitab software is used for canalization. The data are tabulated and kept for future reference. Noise effect
due to the gradual torsional load performed in the gear box and other rotating components is also studied
for healthy working environment. The nature and characteristics of material also be explained by this noise
analysis.
Piston in the internal combustion (IC) engine is robust, dynamically loaded tribo-pair that
reciprocates continuously at varying temperature. Study has been made by various researchers on piston
design, dynamics, fatigue and wear at the interface with other element in contact along with their effects on
IC engines. It was found that the friction coefficient increases with increasing surface roughness of liner
surface and thermal performance of the piston increases with increased coating thickness. The free material
liberated due to deep scoring between the piston and liner snowballs, leads to seizure failure.
IRJET-Tribological Study Of aluminum based Composite Material for Automotive ...IRJET Journal
This document describes a study on the tribological properties of an aluminum-based composite material for potential use as an automotive brake material. The researchers developed an aluminum-titanium carbide composite using stir casting and tested it using a pin-on-disc tribometer. Experiments were designed using the Taguchi method to evaluate the effects of load, sliding speed, and sliding distance on the wear behavior of the composite. Analysis of variance was used to determine the most significant factors affecting wear. The results of this study could help optimize composite brake materials to improve braking performance and durability.
Studies On Fracture Toughness Behavior of Hybrid Aluminum Metal Matrix Compos...IJERA Editor
The limited mechanical properties of Al and its alloys adversely affect its applications in automobile and
aerospace industries. This remains one of the major concern in the fabrication to suit its application in recent
days. The main aim of the present work is to improve the fracture toughness of the Al matrix composite . A
composite with Al 6061 alloy as matrix and Zirconium Oxide as reinforcement is fabricated by stir casting
process. The specimens were prepared according to ASTM standards and fracture toughness, tensile and
hardness tests were performed and the properties were investigated. Zirconium oxide is selected as a
reinforcement because of its ability to influence the microstructure of the Al 6061 alloy to improve the fracture
toughness. The fracture toughness is highest at 6% reinforcement of ZrO2 and hardness is found to be more at
4% reinforcement
IRJET-Contact Stresses Analysis & Material Optimization of Ball Bearing using...IRJET Journal
This document discusses analyzing contact stresses and optimizing the material for ball bearings using Hertz contact theory. It begins by introducing ball bearings and their importance in rotating machinery. It then discusses selecting the proper material for ball bearings as it affects characteristics like weight, wear resistance, and stresses. The document considers replacing the typical steel balls with ceramic balls to reduce issues like electric arcing, fatigue, and overheating. It analyzes the mechanical properties and performance differences between steel, silicon nitride ceramic, zirconium oxide ceramic, and aluminum oxide using Hertz contact theory calculations and finite element modeling. The goal is to optimize the ball material choice to improve bearing performance and reliability.
This document discusses developing a fracture splitting method for manufacturing connecting rods made of case hardened steel. It examines applying the fracture splitting method to connecting rods made of JIS SCM420 carburized steel, which has varying hardness levels from the surface inward. Tests were conducted using a weight falling-type splitting machine to determine the temperature and strain rate conditions needed to obtain a brittle fracture surface over the entire fractured surface, including the inner portions with lower hardness. Measures were also taken to analyze and control the fracture starting point using nonlinear simulations to address issues of irregular fracture initiation and tiny fragment breakaways. The fracture splitting method was successfully implemented in the production of connecting rods for the Yamaha YZF-R1 supersport
Flexural strength also known as the bending strength which plays a vital role in the
industries where the heavy load application is implemented. The study reports show that
shotpeening technique considerably improves the mechanical properties of a material
such as hardness, fatigue strength, corrosion resistance, flexural (or) bending strength
etc. Here the shot material used for shotpeening is glass beads and the target material is
aluminum alloy of grade AA-2024 T3 which is widely used in the automobile and
aircraft industries due to its light weight and strength. The experimental results show
there is an improvement in the flexural strength of AA2024-T3material after
shotpeening
Machining of Aircraft Bearing Rings using High Quality Bearing SteelIJERA Editor
Bearing rings for Aircraft application are machined using high quality M50 High Speed Steel conforming to
AMS 6491B. The raw material for the rings of Ball bearing is prepared from a single bar stock using trepanning.
Special collet type soft jaw and Mandrels were devised and used on CNC Lathes to reduce manufacturing
problems like ovality. Raceway forms are turned using single point copy turning insert. The problems faced
during rings manufacture were discussed in this study.
INVESTIGATE THE EFFECT OF PHOSPHATE SURFACE COATING ON THE FATIGUE PERFORMA...IAEME Publication
Piston pin play a vital role in the reciprocating internal combustion engine. Failure of piston pin will result in failure of engine. Improper carburizing technology leads to decarburization of surface decreases intensely the fatigue strength of surface so that crack initiated from the surface and propagated, at last fatigue fracture occurred.
1) Sandwich beams made of GFRP core and aluminum face sheets were impacted by a rigid projectile at velocities from 25-115 m/s using a pneumatic gun.
2) The sandwich beams exhibited different failure modes including large inelastic deformation, core shearing, and delamination.
3) Mid-span deflection, energy absorption, and velocity drop after impact were measured and found to vary with impact velocity, with the beams absorbing more energy at lower velocities. The ballistic limit was approximately 50 m/s.
Effect of Volume Fraction (Al2O3) on Tensile Strength of Aluminium 6061 by Va...IRJET Journal
This document reviews the effect of adding aluminum oxide (Al2O3) particles on the tensile strength of aluminum 6061 composites produced via stir casting. Stir casting is described as a common and cost-effective method for fabricating metal matrix composites. The key process parameters of stir casting that influence composite properties are identified as stirrer design and speed, temperature, time, and reinforcement concentration. Literature on aluminum metal matrix composites reinforced with Al2O3 and silicon carbide is summarized, finding that strength and hardness generally increase with higher reinforcement content, while ductility decreases. Adding Al2O3 to aluminum 6061 via stir casting was shown to improve tensile strength over the unreinforced alloy. The document concludes
MODELING, ANALYZING AND SAFETY ASPECTS OF TORSION AND NOISE EFFECTS ON ROUND ...msejjournal
Each material has its own effect and behavior on external impacts like heat, force, tension, compression, torsion etc. It is important to study and analyze these behaviors before selecting a material for an engineering application in the design aspects itself. If predicted values analyzed by both mathematical and software are available it is easy to get the reliable details in the pre design itself. By this one can ensure the safety of the component and the system also. In this investigation, the effects of torsional loads on mild steel
round shafts with various diameters and lengths have been analyzed. The additional effects like angle of rotation, rpm and duration also considered to find the optimum predicted value. The data observed by various experiments are analyzed by design of experiments especially by response surface methodology. Minitab software is used for canalization. The data are tabulated and kept for future reference. Noise effect
due to the gradual torsional load performed in the gear box and other rotating components is also studied for healthy working environment. The nature and characteristics of material also be explained by this noise analysis.
Micro-structural and Tribological Behaviour of AA6063/12SiC-5Gr Hybrid Compos...ijsrd.com
In this paper the friction and wear behavior of aluminium matrix reinforced with silicon carbide and graphite is investigated. A pin on disc type apparatus is used to measure the sliding wear rate (WR), the frictional force (F) and the coefficient of friction (μ). Friction and wear behavior of the hybrid metal matrix composites (HMMC) have been investigated at various loads, sliding velocity and constant sliding distance. The applied loads are 20N, 40N, 60N and 80 N respectively, sliding speeds are 1.5 m/sec and 3 m/sec and the sliding distance is 1500 m. The aluminium based MMC has been produced by stir casting technique. AA6063 with 12SiC-5Gr composite is machined to the required size. Optical microscope is used for investigating the microstructure and surface properties of the specimen. The addition of graphite and silicon carbide reinforcement to AA 6063 alloy increases the wear resistance and hardness of the composites.
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Microstructure and Hardness of Aluminium Alloy- Fused Silica Particulate Comp...AM Publications
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Experimental Study of Wear Rate Coefficient of Aluminium Hybrid Composites Ma...AM Publications
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IRJET- Strength Evaluation of Spur Gear Made up of Polymer Composite Mate...IRJET Journal
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INVESTIGATION OF COMPOSITE TORSION SHAFT USING MATERIAL MATRIX IN FEAIjripublishers Ijri
have found application in many areas of daily life for quite some time. Often it is not realized that the application makes
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Research Inventy : International Journal of Engineering and Scienceinventy
Research Inventy : International Journal of Engineering and Science is published by the group of young academic and industrial researchers with 12 Issues per year. It is an online as well as print version open access journal that provides rapid publication (monthly) of articles in all areas of the subject such as: civil, mechanical, chemical, electronic and computer engineering as well as production and information technology. The Journal welcomes the submission of manuscripts that meet the general criteria of significance and scientific excellence. Papers will be published by rapid process within 20 days after acceptance and peer review process takes only 7 days. All articles published in Research Inventy will be peer-reviewed.
MODELING, ANALYZING AND SAFETY ASPECTS OF TORSION AND NOISE EFFECTS ON ROUND ...msejjournal
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Modeling, Analyzing and Safety Aspects of Torsion and Noise Effects on Round ...msejjournal
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torsion etc. It is important to study and analyze these behaviors before selecting a material for an
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rotation, rpm and duration also considered to find the optimum predicted value. The data observed by
various experiments are analyzed by design of experiments especially by response surface methodology.
Minitab software is used for canalization. The data are tabulated and kept for future reference. Noise effect
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International Journal of Engineering Research and Development (IJERD)IJERD Editor
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yahoo journals, bing journals, International Journal of Engineering Research and Development, google journals, hard copy of journal
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Regression analysis of shot peening process for performance characteristics o...IJMER
International Journal of Modern Engineering Research (IJMER) is Peer reviewed, online Journal. It serves as an international archival forum of scholarly research related to engineering and science education.
This document summarizes the failure analysis of a helical gear used in a steel mill reducer gearbox. Visual examination found two broken teeth with pitting on the contact side. Investigation found the gear material was a low alloy steel and fractography showed brittle fracture from excessive contact stress. The failure was caused by replacing the original motor with a more powerful one, increasing stress over 3 times higher than allowable for the gear material and leading to pitting, crack initiation and growth, and final fracture.
Stress analysis and optimization of crankshaft under dynamic loading 2IAEME Publication
This document summarizes a study that optimized the design of a forged steel crankshaft through finite element analysis and stress modeling. The analysis found the crankshaft experiences maximum stress at location 2. Geometry optimization focused on removing non-critical material while maintaining dynamic balance. Optimization included increasing hole diameters, deepening holes, and modifying crank web geometry. The goal was reducing weight and cost while not exceeding the original design's stress levels. Material choices and compressive rolling were also evaluated for increasing fatigue strength.
An Overview of Design and Analysis of Rocker ArmIRJET Journal
This document summarizes research on the design and analysis of rocker arms. It discusses how rocker arms are used to transfer motion from camshafts to engine valves. Finite element analysis is used to model rocker arms and analyze stresses. Different materials are analyzed to reduce stresses and increase durability, including steel, aluminum, composites, and polymers. Studies analyzed stresses on rocker arms made of various materials and identified optimal materials to increase strength while reducing weight. Composite materials showed potential to reduce stresses compared to steel.
1. The document describes an experimental study that aims to determine the effect of varying load, sliding velocity, and number of cycles on the depth of wear of CuPb24Sn4 metal-lined bush bearings used in automobile engines.
2. Tests were conducted using a single cylinder engine mounted on a dynamometer test bed, with bush samples subjected to varying load and speed cycles over time periods ranging from 300-1000 minutes.
3. Preliminary results found that depth of wear in the bush lining increases with time, followed by effects from velocity and load. Further analysis of test data aimed to establish relationships between depth of wear and changing operational parameters.
This document discusses failure analysis of bearing cups in drive shaft assemblies. It aims to find a cost-effective solution to eliminate bearing cup cracking during assembly of universal joints. Various heat treatment processes are considered and carbonitriding is identified as the optimal process. It reduces bearing cup failure and manufacturing costs compared to other options like case hardening. A systematic methodology is applied, including understanding the current problem, analysis using wear testing and FEA, and implementing and confirming the effects of carbonitriding as a corrective measure.
The document analyzes the breakage of an elevator chain wheel shaft made of normalized C45 steel. Macroscopic, mechanical, chemical, and microstructural analyses show characteristics of fatigue failure originating from indentation of the soft ferrite surface by the keyway edge. While the steel composition met standards, the normalized microstructure and soft surface were insufficient. Surface hardening is proposed to increase surface hardness and prevent future failures from external stresses exceeding the ferrite's critical shear stress.
Finite element analysis of single cylinder engineLaukik Raut
This paper deals with, the problem occurred in single cylinder engine crank shaft. It consist of static structural
and fatigue analysis of single cylinder engine crank shaft. It identifies and solves the problem by using the
modeling and simulation techniques. The topic was chosen because of increasing interest in higher payloads,
lower weight, higher efficiency and shorter load cycles in crankshaft. The main work was to model the crank
shaft with dimensions and then simulate the crank shaft for static structural and fatigue analysis. The modeling
software used is PRO-E wildfire 4.0 for modeling the crank shaft. The analysis software ANSYS will be used for
structural and fatigue analysis of crank shaft for future work. The material for crank shaft is EN9 and other
alternate materials on which analysis will be done are SAE 1045, SAE 1137, SAE 3140, and Nickel Cast Iron.
The objectives involves modeling and analysis of crank shaft, so as to identify the effect of stresses on crank
shaft, to compare various materials and to provide possible solution.
Review of shaft failure in Coil Car AssemblyIRJET Journal
This document summarizes a study on failures of shafts in coil car assemblies. The researchers investigated a failed coil car shaft and found that reversed bending fatigue caused it to fracture, occasionally due to misalignment. They calculated loads on the existing shaft theoretically and analytically and found the stresses exceeded permissible levels, indicating it was prone to failure. To improve shaft design, they examined increasing diameter and using fillets/chamfers to disperse stresses. A literature review showed other shaft failures were due to low radius of curvature, incorrect chamfer size increasing stress concentration, and vibrations from imbalance.
This document summarizes a research paper that analyzed and optimized the design of a connecting rod for a diesel engine. The researchers performed finite element analysis on the connecting rod to determine stress distributions under different loads. They then optimized the connecting rod design through parametric modeling and reducing mass while maintaining sufficient strength and safety factors. Key goals were improving weight and cost while meeting fatigue life requirements. The optimized connecting rod design eliminated the central oil hole and reduced the cross-sectional size to lower weight. Force calculations using ADAMS software simulated dynamic loads on the connecting rod to inform the optimization study.
This document summarizes a study that investigated gas tungsten arc welding (GTAW) of pure titanium sheets. Commercially pure titanium sheets were welded using GTAW. Tensile, flexural, and microhardness tests were conducted on the welded samples. Microstructural analysis found coarser grains in the weld zone compared to the base metal. Tensile and flexural strengths of the GTA welded samples were lower than the base metal but higher than samples welded with other methods. Microhardness was also higher in the weld zone. The study concluded that GTAW is suitable for welding pure titanium sheets when proper parameters are used.
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1. Mechanical Engineering: An International Journal ( MEIJ), Vol. 1, No. 3, November 2014
1
A Study of Crankpin Failure in I.C. Engine
M. Senthil kumar1
, Dr.S.Ragunathan2
, M.Suresh3
, V.R.Srinivashan4
1
Asst.Professor, Dept. of Mechanical Engg.,Sona College of Technology, Salem.
2
Principal, Jayalakshmi Institute of Technology, Thoppur.
3
PG Student,Sona College of Technology,Salem.
4
PG Student,Jayalakshmi Institute of Technology, Thoppur
Abstract
A detailed study was carried out on crankshafts used in two wheeler made from C45 (EN 8/AISI 1042)
steel. Undesirable noise was heard in crankshaft when the engine is in running. This was stated as failure
of crankshaft. Material has been peeled off and seemed to be scraped at the central portion of the crankpin.
It was the bearing seating place where oil hole also provided. Under analysis the crankpin was identified
as tempered. Chemical composition, micro-hardness and microstructure were studied and compared with
the specified properties of the crankpin material. Reason for failure is identified as wear due to lower
hardness, improper lubrication and high operating oil temperature.
Keywords
crankshaft, crankpin, chemical analysis, micro hardness, finite element analysis,hardening.
1. INTRODUCTION
Crankshaft is the heart of an Internal Combustion Engine [2]. The reciprocating motion of Piston
is converted into rotary motion by crankshaft. Crankshafts are generally subjected to torsional
stress and bending stress due to self-weight or weights of components or possible misalignment
between journal bearings. Crankshaft failures may be resulted from by several causes which are
oil absence, defective lubrication on journals, high operating oil temperature, misalignments,
improper journal bearings or improper clearance between journals and bearings, vibration, high
stress concentrations, improper grinding, high surface roughness, and straightening operations.
The crankshaft faults caused high cost of maintenance in automotive industry [3].
Reasons for failure of crankshaft assembly and crankpin may be
A)Shaft misalignment
B) Vibration cause by bearings application
C) Incorrect geometry (stress concentration)
D) Improper lubrication
E) High engine temperature
F) Overloading
G) Crankpin material & its chemical composition
2. Mechanical Engineering: An International Journal ( MEIJ), Vol. 1, No. 3, November 2014
2
H) Pressure acting on piston
Osam asi et al [3] have conducted failure analysis of a diesel engine crankshaft used in truck
made of ductile cast iron. The crankshaft was found to break into 2 pieces at the crankpin portion
before completion of the warranty period. The crankshaft was induction hardened. Failure
analysis including visual examination, photo documentation, chemical analysis, micro-hardness
measurement, tensile testing and metallographic examination were conducted. Test results
showed that the material was EN-GJS-700-2 ductile cast iron as induction hardened and tempered
condition. The failure zones were examined using Scanning Electron Microscope with EDX
facility. They identified that the absence of hardened case in fillet region caused fatigue initiation
and this was the cause of premature failure.
B.Kareem [4] ,has studied mechanical crankshaft failure for automobile .This was done using
data gathered by oral interviews and questionnaire on mechanical failure of crankshafts. He has
done research using Nissan, Datsun and other Japanese cars. Finally he has concluded that the
failure of crankshaft in automobile came as a result of oil leakages in engines, overloading,
misalignment, poor surface finishing, misassembling, poor reconditioning of thrust bearing and
adultered engine oil. And the failure can be reduced by production of crankshafts with locally
sourced materials, improvement on the local roads, right mechanical maintenance practice and
educating the users.
Jian meng et al,[5] have done stress analysis and model analysis of four cylinder engine
crankshaft using FEM .The three dimensional model of diesel engine crankshaft was created by
pro-e and also they analysed the vibration model , the distortion and stress status of crank throw
and they found the dangerous areas by stress analysis. The relationship between the frequency
and the vibration modal was examined by the modal and harmonic analysis of crankshaft using
ANSYS. They concluded that the maximum deformation appeared at the centre of crankpin neck
surface. The maximum stress appeared at the fillets between the crankshaft journal and crank
cheeks, and near the central point journal. The edge of main journal was high stress area. The
failure was due to bending fatigue.
S.M.Sorte et al, [6] have analysed the stress and design optimization of a single cylinder crankpin
of TVS Scooty Pep crankshaft assembly. Three-dimension models of crankshaft and crankpin
forces were created using Pro/ENGINEER software and software ANSYS was used to analyze
the stress status on the crankpin. The maximum deformation, maximum stress point and
dangerous areas are found by the stress analysis.
R.K.Pandey[7],investigated the failure of diesel engine crankshaft used in tractor made from C45
steel.Premature failure was reported in the web region of the crankshaft. The crankshafts were
forged, normalized and partly induction hardened. The investigation included determination of
chemical composition,microstructural examination, evaluation of tensile properties and charpy
toughness as well as hardness determination. The fracture toughness was estimated from the
charpy energy data. The failure zones in various crankshafts were examined using the scanning
electron microscope (SEM) and the micro mechanism of failure in the crankshafts was studied.
Fractographic studies indicated fatigue as the dominant mechanism of failure of crankshafts. The
studies indicated that fatigue initiation from the crankpin-web fillet region necessitated a stress
level of about 175 MPa. To avoid recurrence of failure, machining and final grinding has to be
done carefully to prevent formation of discontinuities or crack-like defects in the fillet region and
induction hardening of the fillet is desirable. Also, the fillet radius needs to be increased.
3. Mechanical Engineering: An International Journal ( MEIJ), Vol. 1, No. 3, November 2014
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Changli Wang et al, [8] have conducted a test run for only 20 min and a crankshaft cracked in a
strange manner. The crankshaft is made of 40CrMnMo alloy steel. Four cracks were found on the
edge of the oil hole. Using mechanical analysis, microstructure and metallurgy the reason of this
event has been revealed. Force of friction caused by improper crankshaft repair and assembling is
main factor of the failure. Why friction occurs, how the crack initiates and expands and what the
process of failure were studied. They concluded that the crankshaft cracked by shearing stresses,
caused by unusual friction between surface of shaft and the main bush, due to improper repairing
and assembling and Friction can cause slip on the surface of friction boundary, especially when
the temperature goes up to a critical level. To 40CrMnMo 300–500°C is a special temperature
which may lead to temper brittleness. Finally they stated that it is possible that molten copper
from the bearing shell caused liquid metal embrittlement in the crankshaft journal.
Ali Keskin et al, [9] have gone for failure analysis of nodular graphite cast iron crankshaft used in
petrol engine. They tested mechanical and metallurgical properties of the crankshaft including
chemical composition, micro-hardness, tensile properties and roughness and were compared with
the specified properties of the crankshaft materials. In the comparison, there were no
metallurgical defects apart from slightly higher carbon content. All other measured values were
within the specified values. The reason identified for the failure was the thermal fatigue because
of contact of journal and bearing surface. This condition led to the formation and growth of
fatigue cracks. The contact was resulted from defective lubrication or high operating oil
temperature.
A failed crankshaft was analyzed for the cause of failure. When the crankshaft was taken from
engine, it was found that crank pin was worn out severely and looked like material has been
peeled off and scraped at the centre of the crankpin.
Item
Specif
ication
Number
of Cylinder
Single
Cycle
4
stroke
Stroke(m
m)
49.5
Bore(mm) 50
Displace
ment(cc)
97.2
Compress
ion ratio
9:1
Maximum
power
5.5
kW at
8000rpm
Maximum
Torque
7.95
Nm at
8000rpm
4. Mechanical Engineering: An International Journal ( MEIJ), Vol. 1, No. 3, November 2014
4
Table.1. Engine Specifications
2. Finite Element Analysis
Fig.1. Pro-e Model of the crankshaft
There are two critical locations identified as cause of crankpin failure and it is compared with
FEA results.
Fig.2. Stress concentration on fillet area
The original image of failed crankpin shows that the wear is maximum at the fillet region where
the crank web contacts with the crankpin. And this region is considered as one of the critical
locations. The same is validated in finite element analysis.
5. Mechanical Engineering: An International Journal ( MEIJ), Vol. 1, No. 3, November 2014
5
Fig.3. Stress concentration on oil hole
The original image of failed crankpin shows that the oil hole provided at the centre of crankpin
for lubrication of connecting rod and connecting rod big end bearing. And this region is
considered as one of the critical locations where the stress concentration will be more. The same
is validated in FEA
The stress level of the failed crankshaft is analyzed by finite element method.Fig.4-7 gives the
finite element model of crankshaft and shows us the stress results at the crankpin location.
Crankshaft assembly and crank pin are analyzed separately.
Fig.4.Meshing
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Design calculation
Single Cylinder Engine
SweptVolume,
V = ∏/4xD2
xL.
= ∏/4x502
x49.5
= 97.19x103
mm3
Meaneffectivepressure = (Px60xn)/(Nxv)
= (60x2x5500)/(97.19x103
)
= 0.85MPa
F = ∏/4xd2
xP
F = 1.669kN
Fig.5.Boundary conditions
7. Mechanical Engineering: An International Journal ( MEIJ), Vol. 1, No. 3, November 2014
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Fig.6.Finite element stress analysis of the crankshaft
Fig.7.Finite element stress analysis of the crankpin
The model was imported to ANSYS. The finite element mesh is generated with SOLID 185
element and meshed using tetrahedra freemesh.The node numbers are 19329 and number of
Elements are 94584.
Bearings are assumed as boundary conditions and their displacement is assumed zero. Force is
applied from the crankpin bearing location for 120˚angle of contact [12]. Vonmises stress in the
failure location and fillet radius are higher and hence they are considered as critical location for
the analysis.
3. EXPERIMENTAL METHODS
A. Chemical analysis
Fig.8.Crankpin
The crankpin was cut perpendicular to its axis to find out the chemical composition.Table.1 and 2
gives the specified chemical composition of crankpin material. In the same table the chemical
composition of the material from the failed shaft and crankpin is reported by using Optical
Emission Spectroscope (OES) analyzer. Analysis revealed that the crankpin material is SCM 420
and crankshaft material is EN 8 of BS 970(C45 steel).It is observed that the chemical composition
of crankpin is within the specified range.
8. Mechanical Engineering: An International Journal ( MEIJ), Vol. 1, No. 3, November 2014
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Fig.9.Failed crankpin
Com
position
W
t.% as
Specified
W
t.%
based
on
analysis
Carbo
n
0.
18-0.23
0
.18
Mang
anese
0.
6-0.85
0
.79
Silico
n
0.
15-0.35
0
.31
Sulph
ur
M
ax 0.03
0
.006
Phosp
horus
M
ax 0.03
0
.005
Chro
mium
0.
9-1.2
0
.958
Moly
bdenum
0.
15-0.3
0
.15
9. Mechanical Engineering: An International Journal ( MEIJ), Vol. 1, No. 3, November 2014
9
Table 2.Chemical composition of crankpin material
Pro
perties
V
alues
Yo
ung’s
modulus
1
90-
210GPa
De
nsity
7
.9^3
kg/m3
Poi
sson ratio
0
.3
Yie
ld stress
4
34MPa
Ten
sile stress
7
15Mpa
Elo
ngation
1
5%
Table 3.Material properties of crankpin.
B.Hardness Measurement
Hardness of crankpin was tested using Vickers micro hardness tester. The test load was 1kg and
three locations in cross section were tested [10].
Hardness of the failed crank pin and a new crank pin was tested at both cross section side and
centre of the crankpin around the circumference at different points by using Vickers micro
hardness tester. The mean hardness value at the three locations (Fig.9) is listed in Table.4 and
Table.5.
Table.4.Vickers micro hardness results (HV1) of failed crankpin
Table.5. Vickers micro hardness results (HV1) of new crankpin
10. Mechanical Engineering: An International Journal ( MEIJ), Vol. 1, No. 3, November 2014
10
Hardness result shows that the failed region (centre of crankpin) has lower hardness than cross
section sides and hence the wear was initiated earlier due to friction and it propogated due to
improper lubrication with oil temperature.
C. Microsturcture analysis
The crankpin was tesred using METSCOPE (Metallurgical microscope).The image of 500X
magnification shows that fine tempered martensite structure is throughout the matrix [3] .Tthe
microstructure is not the cause for the failure.
Fig.10 .Microsructure of the crankpin cross section With 500X
The macro etched crank pin doesn’t show any crack. Hence, the failure is only due to friction
occurred by improper lubrication.
4. Solution
Then the crankpin central portion was subjected to selective induction hardening to the depth of
3mm followed by salt bath quenching [11]. The hardness measured after hardening is listed in
table 6.
Table.6. Vickers micro hardness results (HV1) of new crankpin after Induction Hardening
11. Mechanical Engineering: An International Journal ( MEIJ), Vol. 1, No. 3, November 2014
11
The measured value shows that there is increase in
Hardness value after induction hardening. Due to this life of the crankpin can be increased.
5. Results and discussion
It is found that the chemical composition of the crankpin is within the range of the technical
specifications and no manufacturing and machining defects were found. The crankpin was not
case hardened except tempering followed by general hardening.
However the hardness value at the failure region was lower (699 HV1) than other locations (716
HV1) and it is the cause for the rapid wear of the crankpin at the contact region. This initiation of
failure is consequently propogated by improper lubrication. Hence the stress and wear at this
region becomes more.
6. Conclusion
1. The crankpin wears at the centre and caused failure. The lower value of hardness increases the
wear between contacts.
2. Two critical locations have been identified and Finite Element Analysis result confirmed that
the highly stressed regions are the contact region with the web and centre of crank pin where oil
hole is provided.
3. Improper lubrication increases the wear rapidly and hence noise is heard when the engine is in
running. Hence, the life of crankshaft becomes shorter.
7. Future work
In Case Hardening, Nitriding process will improve hardness in better way and this process has
been used to increase hardness of crankpin in many crankshaft applications. But due to the size
insufficiency in our crankpin it was not possible to do. In future, we will try for Nitriding and
optimize the hardening process to give the maximum hardness at the surface area of crankpin to
increase the life of the crankshaft.
Another possibility we are going to try is giving a Nano coating over the surface area to reduce
the wear of crankpin. Here also, we will go for optimization of parameters like depth of coating,
processing time etc.
REFERENCES
[1] Silva.F.S. (2003), Analysis of a vehicle Crankshaft Failure, Pergamon, Engineering Failure Analysis,
10,605-616.
[2] Xue-qin Hou et al (2010), Fracture Failure Analysis of Ductile Cast Iron Crankshaft in a Vehicle
Engine, ASM International
[3] Osam Asi (2006), Failure Analysis of a Crankshaft from Ductile cast iron, Elsevier,Engineering
Failure Analysis, 13,1260-1267.
12. Mechanical Engineering: An International Journal ( MEIJ), Vol. 1, No. 3, November 2014
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[4] Kareem.B (2007), A Survey of Failure in Mechanical Crankshafts of Automobile, Journal of
Engineering and Applied Sciences, 2(7):1165-1168.
[5] Jian meng et al (2011) , Finite Element Analysis of 4- Cylinder Diesel Crankshaft , I.J.Image ,
Graphics and Signal Processing , 5, 22-29.
[6] Sorte. S.M. et al (2013), Stress Analysis and Design Optimization of Crankpin , International Journal
of science and Modern Engineering , Vol 1 , Issue 4 .
[7] Pandey. P.K. (2003), Failure of Diesel-Engine Crankshafts, Pregamon, Engineering Failure Analysis,
10, 165-175.
[8] Changli Wang et al (2005), Analysis of an Unusual Crankshaft Failure, Elsevier, Engineering Failure
Analysis, 12 465-473.
[9] Ali KESKIN et al (2010), Crack Analysis of a Gasoline Engine Crankshaft, Gazi University Journal
of science, 23 (4): 487-492.
[10] Bayrakceken.H. et al (2007), Failure of Single Cylinder Diesel Engine Crankshafts, Elsevier,
Engineering Failure Analysis, 14,725-730.
[11] Paswan.M.K and Goel.A.K(2008),Fatigue Testing Procedure of 6 cylinder Diesel Engine
Crankshaft,ARISER vol.4 No.3,144-151.
[12] Jonathan Williams et al(2007),Fatigue Performance Comparison and Life predictions of Forged steel
and Ductile cast iron crankshafts,Final project report.