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.
Failure of crankshaft in diesel locomotiveMdParwezAlam15
This project deals with the analysis about the various causes of
failures of the crankshaft of the diesel locomotive engine. It is found that
the cost for the crankshaft is very high whereas the lifecycle is not
satisfactory. The causes for the failure of the crankshaft and the possible
ways of minimising the failure effects were briefly studied from the past
failure specimen. The load bearing capacity of the crankshaft is
theoretically calculated and compared with the actual load acting on the
crankshaft. The suggestion were made for maximising the life of
crankshaft. Thus the lifecycle of the crankshaft is increased and the cost
for the maintenance is reduced.
Design and Analysis of Crankshaft for Internal Combustion Engineijtsrd
In this project design and analysis of the crankshaft for the combustion engine. These components have a large volume component with complex geometry and 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. Md. Hameed | Chova Deekshith | Gorge Bhanu Prasad | 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, URL: https://www.ijtsrd.com/papers/ijtsrd23531.pdf
Paper URL: https://www.ijtsrd.com/engineering/mechanical-engineering/23531/design-and-analysis-of-crankshaft-for-internal-combustion-engine/md-hameed
The document summarizes an in-plant training report at the KSRTC Regional Workshop in Mavelikkara, Kerala from June 28th to July 7th. It describes the various maintenance sections at the workshop including the engine assembly, gearbox, propeller shaft, small units like air brakes and clutches, front axle, differential, fuel injection, electrical, steering, suspension, and body building sections. The training provided hands-on experience of repairing and maintaining different parts of KSRTC buses. It was a valuable opportunity for the trainees to apply their engineering knowledge and gain practical skills relevant to their future careers.
The document discusses the design and validation process for a crankshaft. It begins with an overview of crankshafts and their function in converting linear piston motion to rotational motion in engines. It then outlines the 5 main steps in the design and validation process: 1) conceptual design, 2) process analysis and selection, 3) testing, 4) production, and 5) quality improvement. Key aspects of each step like dimensions, stresses, fatigue testing, and hardening processes are covered. The goal is to take an initial design concept and improve it using analysis, testing, manufacturing, and standards to validate the design.
Ksrtc central works INDUSTRIAL VISIT REPORTGeorge Jose
KSRTC Central Works is the main workshop for KSRTC that handles large-scale repairs and maintenance of buses. It has major departments like Workshop, Body Building, and others that focus on overhauling engines, transmissions, suspensions, and addressing other mechanical failures. The workshop dismantles vehicles, cleans and replaces worn parts, and performs tests before reassembly to ensure quality. The Body Building department handles interior and exterior assembly of new buses integrating mechanical components. The industrial visit provided students understanding of industry operations across different sections.
Detailed design report on design of upright and hubZubair Ahmed
The document describes the design process for an upright component in an automobile suspension system. It discusses 14 design parameters that were considered. Several design concepts and models were explored before settling on a final design (Design 4). The key points of the final design are that it is CNC milled from aluminum alloy 6351 T-6, weighs 760 grams, and addresses the weaknesses identified in previous designs. Loading scenarios analyzed include steering effort, braking forces, remote bump forces, and cornering forces. Finite element analysis was used to evaluate stresses and predict fatigue life under the different loading conditions.
DYNAMIC ANALYSIS OF ENGINE BLOCK FOR SELECTION OF SUITABLE MATERIAL FOR COST ...Ijripublishers Ijri
The Aim of this project is to design a combustion chamber using Pro-E and perform analysis using ANSYS software.
The analysis of the combustion chamber is done by using different materials. By conducting the above analysis on the
combustion chamber combustion rate, pressure and temperature gradient conditions are found and the best material
for the combustion chamber is suggested.
Thermal analysis is conducted to find heat dissipation rate in engine block with the variation of materials Structural
and fatigue analysis(dynamic) is conduct on engine block at working load conditions to evaluate and compare stress,
strain, deformation and fatigue life with the variation of materials.
Frequency analysis is conducted on engine block with the variation of materials to evaluate frequency,
Using these values material selection will be done, the value should be nearby previous one (cast iron) maximum accepted
variation value 65HZ.
The document discusses modules for marine engineering at the management level provided by Excellence and Competency Training Center Inc. It covers operating principles of ship power installations, analyzing diesel engine shop trial and sea trial data, procedures for engine performance testing and calculating specific fuel consumption. Key concepts discussed include indicated horsepower, brake horsepower, mechanical efficiency, thermal efficiency, fuel consumption, and the effects of ambient conditions on engine performance.
Failure of crankshaft in diesel locomotiveMdParwezAlam15
This project deals with the analysis about the various causes of
failures of the crankshaft of the diesel locomotive engine. It is found that
the cost for the crankshaft is very high whereas the lifecycle is not
satisfactory. The causes for the failure of the crankshaft and the possible
ways of minimising the failure effects were briefly studied from the past
failure specimen. The load bearing capacity of the crankshaft is
theoretically calculated and compared with the actual load acting on the
crankshaft. The suggestion were made for maximising the life of
crankshaft. Thus the lifecycle of the crankshaft is increased and the cost
for the maintenance is reduced.
Design and Analysis of Crankshaft for Internal Combustion Engineijtsrd
In this project design and analysis of the crankshaft for the combustion engine. These components have a large volume component with complex geometry and 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. Md. Hameed | Chova Deekshith | Gorge Bhanu Prasad | 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, URL: https://www.ijtsrd.com/papers/ijtsrd23531.pdf
Paper URL: https://www.ijtsrd.com/engineering/mechanical-engineering/23531/design-and-analysis-of-crankshaft-for-internal-combustion-engine/md-hameed
The document summarizes an in-plant training report at the KSRTC Regional Workshop in Mavelikkara, Kerala from June 28th to July 7th. It describes the various maintenance sections at the workshop including the engine assembly, gearbox, propeller shaft, small units like air brakes and clutches, front axle, differential, fuel injection, electrical, steering, suspension, and body building sections. The training provided hands-on experience of repairing and maintaining different parts of KSRTC buses. It was a valuable opportunity for the trainees to apply their engineering knowledge and gain practical skills relevant to their future careers.
The document discusses the design and validation process for a crankshaft. It begins with an overview of crankshafts and their function in converting linear piston motion to rotational motion in engines. It then outlines the 5 main steps in the design and validation process: 1) conceptual design, 2) process analysis and selection, 3) testing, 4) production, and 5) quality improvement. Key aspects of each step like dimensions, stresses, fatigue testing, and hardening processes are covered. The goal is to take an initial design concept and improve it using analysis, testing, manufacturing, and standards to validate the design.
Ksrtc central works INDUSTRIAL VISIT REPORTGeorge Jose
KSRTC Central Works is the main workshop for KSRTC that handles large-scale repairs and maintenance of buses. It has major departments like Workshop, Body Building, and others that focus on overhauling engines, transmissions, suspensions, and addressing other mechanical failures. The workshop dismantles vehicles, cleans and replaces worn parts, and performs tests before reassembly to ensure quality. The Body Building department handles interior and exterior assembly of new buses integrating mechanical components. The industrial visit provided students understanding of industry operations across different sections.
Detailed design report on design of upright and hubZubair Ahmed
The document describes the design process for an upright component in an automobile suspension system. It discusses 14 design parameters that were considered. Several design concepts and models were explored before settling on a final design (Design 4). The key points of the final design are that it is CNC milled from aluminum alloy 6351 T-6, weighs 760 grams, and addresses the weaknesses identified in previous designs. Loading scenarios analyzed include steering effort, braking forces, remote bump forces, and cornering forces. Finite element analysis was used to evaluate stresses and predict fatigue life under the different loading conditions.
DYNAMIC ANALYSIS OF ENGINE BLOCK FOR SELECTION OF SUITABLE MATERIAL FOR COST ...Ijripublishers Ijri
The Aim of this project is to design a combustion chamber using Pro-E and perform analysis using ANSYS software.
The analysis of the combustion chamber is done by using different materials. By conducting the above analysis on the
combustion chamber combustion rate, pressure and temperature gradient conditions are found and the best material
for the combustion chamber is suggested.
Thermal analysis is conducted to find heat dissipation rate in engine block with the variation of materials Structural
and fatigue analysis(dynamic) is conduct on engine block at working load conditions to evaluate and compare stress,
strain, deformation and fatigue life with the variation of materials.
Frequency analysis is conducted on engine block with the variation of materials to evaluate frequency,
Using these values material selection will be done, the value should be nearby previous one (cast iron) maximum accepted
variation value 65HZ.
The document discusses modules for marine engineering at the management level provided by Excellence and Competency Training Center Inc. It covers operating principles of ship power installations, analyzing diesel engine shop trial and sea trial data, procedures for engine performance testing and calculating specific fuel consumption. Key concepts discussed include indicated horsepower, brake horsepower, mechanical efficiency, thermal efficiency, fuel consumption, and the effects of ambient conditions on engine performance.
5)structural performance analysis of formula sae carAnkit Singh
This document summarizes the structural performance analysis of a Formula SAE race car chassis designed by engineering students. It describes:
1) How the chassis was modeled and analyzed using finite element analysis to study stress distributions and deformations under various static, dynamic, and frequency loads.
2) How load calculations were performed to estimate forces from acceleration, braking, and cornering. Loads from driver and components were also estimated.
3) Material selection for the chassis, with steel being chosen for its availability, cost, and mechanical properties like strength and stiffness.
4) Development process including modifying an existing 3D chassis model using CAD software while ensuring fit with an anthropometric driver model.
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.
IRJET- Analysis of Static Load Bearing Capacity of the Ball Bearing – A ReviewIRJET Journal
The document summarizes research analyzing the static load bearing capacity of ball bearings. It discusses using finite element analysis to determine capacity without destructive testing. The research found a linear relationship between the deviation of capacity results from finite element vs practical testing and the bearing size. A linear interpolation equation was developed relating deviation to bearing size. Laboratory testing on bearings of different sizes validated the relationship and showed deformation increasing with load. The research concludes the equation can be used to determine static capacity from bearing size.
Study on Automotive Engines & Design Analysis of Counter Shaft Bearing Affect...IRJET Journal
This document discusses a study on the design and analysis of counter shaft bearings in automotive engines. The study focuses on how factors like variable loads, speeds, vibrations, temperatures, lubricants, and water exposure can affect the life of counter shaft bearings. The researchers analyzed two vehicles - one operated under normal conditions and one under more stressful variable conditions. They found that the vehicle under more variable operation exhibited earlier failure of its counter shaft bearings, demonstrated by noise from the transmission. Maintaining proper operating conditions and using authorized maintenance can help increase the life of these critical components.
This document is an industrial training report submitted by Sumit Kumar from the Institute of Engineering & Management in Kolkata. It describes his 15-day summer training at the Carriage and Wagon Workshop of the Northeast Frontier Railway in New Bongaigaon, Assam. The report provides details about the workshop, including its history and activities. It also describes several shops within the workshop such as the wheel turning shop, roller bearing shop, machine shop, and others. In each shop, it outlines the key machines and operations.
Design and analysis of knuckle and hub of FSAE race carSangram Pisat
This document presents a project on the design and analysis of a knuckle and hub for an FSAE race car. It discusses sponsoring companies, introducing the purpose and problem definition. It outlines the methodology, which includes CAD modeling and ANSYS analysis. Expected outcomes are a lighter knuckle weighing 750g and 800g, and hub weighing 1.5kg. Material selection and design calculations are presented. Results show maximum stresses below limits. The project aims to reduce weight while maintaining stiffness for a better performance to weight ratio.
This is an Industrial visit report of BEST workshop, Mumbai conducted by the final year students of M H Saboo Siddik College of Engineering in the year 2015 for the subject Automobile Engineering.
This document provides an overview of Module 1 of a training program on marine engineering at the management level. It covers the objectives of the overall training program and then reviews the essential components of marine diesel engines, including the bedplate, crankshaft, cylinder liners, piston and rings, cylinder covers, bearing clearances, and shaft misalignment. Diagrams and descriptions are provided for each component, potential defects are discussed, and inspection procedures are described. The goal is to provide trainees with knowledge and proficiency in managing propulsion plant machinery at sea.
The document discusses the structural analysis of a rear dead axle using finite element analysis (FEA). It presents the background of the project, which involves analyzing the stresses, displacements, and frequencies on a rear axle model under working loads using ANSYS. The analysis will be conducted on models of the rear axle constructed from ductile cast iron and high-grade steel to determine which material would be more suitable. The results of the FEA, including stresses, deformations, and natural frequencies, will help evaluate the two materials.
The document provides information about the Carriage and Wagon workshop in Alambagh, Lucknow. It discusses the workshop's history and facilities. The workshop specializes in overhauling, repairing, and restoring coaches and wagons. It performs maintenance like wheel replacement, brake testing, and suspension oil changes. The document also describes different types of coaches and rolling stock, as well as the various levels of train maintenance.
GEOMETRIC OPTIMIZATION OF CRANK SHAFT FOR OPTIMUM DESIGN AND IMPROVEMENT OF LIFEIjripublishers Ijri
Crankshaft is a component in an engine which converts the reciprocating motion of the piston to the rotary motion. Design
of a crankshaft of Honda engine, it is assembled by the connecting rod and piston components in Pro engineering.
The designed model of engine crankshaft is analyzed in pro engineering by using its mechanism. Piston generates the
forces due to the combustion. These forces acting on the piston are analyzed by using their mechanisms with respect
to crank angle.
This document describes the design of a brake caliper for an all-terrain vehicle. It aims to reduce the size and weight of the caliper. The design process involves selecting aluminum 7075-T6 as the material for its strength and lightweight properties. Calculations are shown to determine the required clamping force and piston size. A floating caliper design is proposed, and the importance of the seal groove geometry for piston retraction is discussed. A CAD model of the designed caliper is presented. The conclusions discuss the importance of determining braking forces and selecting appropriate piston dimensions.
IRJET- Design and Steady-State Thermal Analysis of Disc BrakeIRJET Journal
This document analyzes and compares the thermal performance of disc brakes made from four materials: gray cast iron, stainless steel, silicon carbide composite, and titanium 550 alloy. A disc brake model is created in CATIA V5 and analyzed in ANSYS for equivalent stress, total deformation, and steady-state temperature distribution. Titanium 550 alloy performs the best with the lowest deformation and stress levels and temperature when subjected to simulated braking loads. In conclusion, titanium 550 alloy is identified as the best material for disc brakes based on the thermal and structural analysis results.
The document provides details about an internship report submitted by P. Thulasira Reddy at the Integral Coach Factory in Chennai, India from June 14-21, 2012. The Integral Coach Factory was established in 1952 and is the primary manufacturer of rail coaches for Indian Railways. It produces over 170 types of coaches and employs around 13,000 people, manufacturing around 6 coaches per day. The report then describes the various production shops at the factory, including sheet metal forming, side frame production, main assembly, furnishing, and painting.
IRJET- Design, Analysis and Optimization of Mounting and Dismounting Tool...IRJET Journal
This document describes the design, analysis, and optimization of mounting and dismounting tools for roller bearings. It begins with an introduction to bearings and some of the common issues with improper mounting and dismounting, such as premature failure. It then discusses the objectives of redesigning the tools to increase strength, develop a common tool for different bearings, and reduce weight, cost and cycle time. The document goes on to describe the existing mounting tool, a redesigned mounting tool made of stainless steel, and presents stress analysis results showing the design is safe. It also details the design of a new dismounting tool made of alloy steel, which uses a two-jaw mechanism to gradually remove the outer race of
The document summarizes the design of an off-road vehicle created by University of Texas at San Antonio students for the 2015 Baja SAE competition. It describes the design of the front and rear suspension systems, drivetrain, controls including steering and braking, and the frame. Analysis was conducted using software tools to optimize various components for performance over rough terrain while maintaining structural integrity. The vehicle was designed with a focus on safety, manufacturability, durability and performance given engineering and economic constraints.
Study on Hard Shifting of Gears in Transmission Box Assembly and Analysis of ...IRJET Journal
This document summarizes a study on hard shifting of gears and abnormal noise from the transmission box of four-wheeler vehicles under varying loads and speeds. The study found that hard shifting and a "kat-kat" noise were caused by worn synchronizer rings in the transmission. Replacing the synchronizer rings resolved the issues. Improper driving techniques like shifting gears at inappropriate times can accelerate wear and lead to transmission problems. Maintaining vehicles properly and avoiding water contact with the gear box can extend the life of the transmission components.
This document discusses crankshafts, balance shafts, and engine bearings. It describes the purpose and function of crankshafts, how they are constructed and balanced using counterweights. It also discusses the different types of crankshaft designs used in various engine configurations like V6, V8, inline 4 and 6 cylinder engines. Balance shafts are introduced as a way to reduce engine vibration.
design and analysis of an All Terrain VehicleNikhil kadasi
This document describes the design methodology for an All-Terrain Vehicle (ATV). It discusses selecting AISI 1018 carbon steel as the material for the roll cage due to its strength, weight, and weldability properties. Circular cross-sections are chosen for the roll cage members to maximize strength and torsional rigidity. The design process involves selecting cross-sections, defining frame parameters, designing the roll cage and its components, and specifying the suspension, steering, and braking systems. Finite element analysis will be performed to validate the design.
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.
5)structural performance analysis of formula sae carAnkit Singh
This document summarizes the structural performance analysis of a Formula SAE race car chassis designed by engineering students. It describes:
1) How the chassis was modeled and analyzed using finite element analysis to study stress distributions and deformations under various static, dynamic, and frequency loads.
2) How load calculations were performed to estimate forces from acceleration, braking, and cornering. Loads from driver and components were also estimated.
3) Material selection for the chassis, with steel being chosen for its availability, cost, and mechanical properties like strength and stiffness.
4) Development process including modifying an existing 3D chassis model using CAD software while ensuring fit with an anthropometric driver model.
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.
IRJET- Analysis of Static Load Bearing Capacity of the Ball Bearing – A ReviewIRJET Journal
The document summarizes research analyzing the static load bearing capacity of ball bearings. It discusses using finite element analysis to determine capacity without destructive testing. The research found a linear relationship between the deviation of capacity results from finite element vs practical testing and the bearing size. A linear interpolation equation was developed relating deviation to bearing size. Laboratory testing on bearings of different sizes validated the relationship and showed deformation increasing with load. The research concludes the equation can be used to determine static capacity from bearing size.
Study on Automotive Engines & Design Analysis of Counter Shaft Bearing Affect...IRJET Journal
This document discusses a study on the design and analysis of counter shaft bearings in automotive engines. The study focuses on how factors like variable loads, speeds, vibrations, temperatures, lubricants, and water exposure can affect the life of counter shaft bearings. The researchers analyzed two vehicles - one operated under normal conditions and one under more stressful variable conditions. They found that the vehicle under more variable operation exhibited earlier failure of its counter shaft bearings, demonstrated by noise from the transmission. Maintaining proper operating conditions and using authorized maintenance can help increase the life of these critical components.
This document is an industrial training report submitted by Sumit Kumar from the Institute of Engineering & Management in Kolkata. It describes his 15-day summer training at the Carriage and Wagon Workshop of the Northeast Frontier Railway in New Bongaigaon, Assam. The report provides details about the workshop, including its history and activities. It also describes several shops within the workshop such as the wheel turning shop, roller bearing shop, machine shop, and others. In each shop, it outlines the key machines and operations.
Design and analysis of knuckle and hub of FSAE race carSangram Pisat
This document presents a project on the design and analysis of a knuckle and hub for an FSAE race car. It discusses sponsoring companies, introducing the purpose and problem definition. It outlines the methodology, which includes CAD modeling and ANSYS analysis. Expected outcomes are a lighter knuckle weighing 750g and 800g, and hub weighing 1.5kg. Material selection and design calculations are presented. Results show maximum stresses below limits. The project aims to reduce weight while maintaining stiffness for a better performance to weight ratio.
This is an Industrial visit report of BEST workshop, Mumbai conducted by the final year students of M H Saboo Siddik College of Engineering in the year 2015 for the subject Automobile Engineering.
This document provides an overview of Module 1 of a training program on marine engineering at the management level. It covers the objectives of the overall training program and then reviews the essential components of marine diesel engines, including the bedplate, crankshaft, cylinder liners, piston and rings, cylinder covers, bearing clearances, and shaft misalignment. Diagrams and descriptions are provided for each component, potential defects are discussed, and inspection procedures are described. The goal is to provide trainees with knowledge and proficiency in managing propulsion plant machinery at sea.
The document discusses the structural analysis of a rear dead axle using finite element analysis (FEA). It presents the background of the project, which involves analyzing the stresses, displacements, and frequencies on a rear axle model under working loads using ANSYS. The analysis will be conducted on models of the rear axle constructed from ductile cast iron and high-grade steel to determine which material would be more suitable. The results of the FEA, including stresses, deformations, and natural frequencies, will help evaluate the two materials.
The document provides information about the Carriage and Wagon workshop in Alambagh, Lucknow. It discusses the workshop's history and facilities. The workshop specializes in overhauling, repairing, and restoring coaches and wagons. It performs maintenance like wheel replacement, brake testing, and suspension oil changes. The document also describes different types of coaches and rolling stock, as well as the various levels of train maintenance.
GEOMETRIC OPTIMIZATION OF CRANK SHAFT FOR OPTIMUM DESIGN AND IMPROVEMENT OF LIFEIjripublishers Ijri
Crankshaft is a component in an engine which converts the reciprocating motion of the piston to the rotary motion. Design
of a crankshaft of Honda engine, it is assembled by the connecting rod and piston components in Pro engineering.
The designed model of engine crankshaft is analyzed in pro engineering by using its mechanism. Piston generates the
forces due to the combustion. These forces acting on the piston are analyzed by using their mechanisms with respect
to crank angle.
This document describes the design of a brake caliper for an all-terrain vehicle. It aims to reduce the size and weight of the caliper. The design process involves selecting aluminum 7075-T6 as the material for its strength and lightweight properties. Calculations are shown to determine the required clamping force and piston size. A floating caliper design is proposed, and the importance of the seal groove geometry for piston retraction is discussed. A CAD model of the designed caliper is presented. The conclusions discuss the importance of determining braking forces and selecting appropriate piston dimensions.
IRJET- Design and Steady-State Thermal Analysis of Disc BrakeIRJET Journal
This document analyzes and compares the thermal performance of disc brakes made from four materials: gray cast iron, stainless steel, silicon carbide composite, and titanium 550 alloy. A disc brake model is created in CATIA V5 and analyzed in ANSYS for equivalent stress, total deformation, and steady-state temperature distribution. Titanium 550 alloy performs the best with the lowest deformation and stress levels and temperature when subjected to simulated braking loads. In conclusion, titanium 550 alloy is identified as the best material for disc brakes based on the thermal and structural analysis results.
The document provides details about an internship report submitted by P. Thulasira Reddy at the Integral Coach Factory in Chennai, India from June 14-21, 2012. The Integral Coach Factory was established in 1952 and is the primary manufacturer of rail coaches for Indian Railways. It produces over 170 types of coaches and employs around 13,000 people, manufacturing around 6 coaches per day. The report then describes the various production shops at the factory, including sheet metal forming, side frame production, main assembly, furnishing, and painting.
IRJET- Design, Analysis and Optimization of Mounting and Dismounting Tool...IRJET Journal
This document describes the design, analysis, and optimization of mounting and dismounting tools for roller bearings. It begins with an introduction to bearings and some of the common issues with improper mounting and dismounting, such as premature failure. It then discusses the objectives of redesigning the tools to increase strength, develop a common tool for different bearings, and reduce weight, cost and cycle time. The document goes on to describe the existing mounting tool, a redesigned mounting tool made of stainless steel, and presents stress analysis results showing the design is safe. It also details the design of a new dismounting tool made of alloy steel, which uses a two-jaw mechanism to gradually remove the outer race of
The document summarizes the design of an off-road vehicle created by University of Texas at San Antonio students for the 2015 Baja SAE competition. It describes the design of the front and rear suspension systems, drivetrain, controls including steering and braking, and the frame. Analysis was conducted using software tools to optimize various components for performance over rough terrain while maintaining structural integrity. The vehicle was designed with a focus on safety, manufacturability, durability and performance given engineering and economic constraints.
Study on Hard Shifting of Gears in Transmission Box Assembly and Analysis of ...IRJET Journal
This document summarizes a study on hard shifting of gears and abnormal noise from the transmission box of four-wheeler vehicles under varying loads and speeds. The study found that hard shifting and a "kat-kat" noise were caused by worn synchronizer rings in the transmission. Replacing the synchronizer rings resolved the issues. Improper driving techniques like shifting gears at inappropriate times can accelerate wear and lead to transmission problems. Maintaining vehicles properly and avoiding water contact with the gear box can extend the life of the transmission components.
This document discusses crankshafts, balance shafts, and engine bearings. It describes the purpose and function of crankshafts, how they are constructed and balanced using counterweights. It also discusses the different types of crankshaft designs used in various engine configurations like V6, V8, inline 4 and 6 cylinder engines. Balance shafts are introduced as a way to reduce engine vibration.
design and analysis of an All Terrain VehicleNikhil kadasi
This document describes the design methodology for an All-Terrain Vehicle (ATV). It discusses selecting AISI 1018 carbon steel as the material for the roll cage due to its strength, weight, and weldability properties. Circular cross-sections are chosen for the roll cage members to maximize strength and torsional rigidity. The design process involves selecting cross-sections, defining frame parameters, designing the roll cage and its components, and specifying the suspension, steering, and braking systems. Finite element analysis will be performed to validate the design.
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
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round shafts with various diameters and lengths have been analyzed. The additional effects like angle of
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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.
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.
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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.
International Journal of Engineering Research and Development (IJERD)IJERD Editor
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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.
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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.
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A Study of Crankpin Failure in I.C. Engine
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
3
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
6. Mechanical Engineering: An International Journal ( MEIJ), Vol. 1, No. 3, November 2014
6
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
7
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
8
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
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10,605-616.
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Engine, ASM International
[3] Osam Asi (2006), Failure Analysis of a Crankshaft from Ductile cast iron, Elsevier,Engineering
Failure Analysis, 13,1260-1267.
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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,
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[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.