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.

1. 21 st March 2011 Sakib Sarker Darlington Midrange Technical Operations (MTO)

2. “ Take the best that exists and make it better. When it does not exist, design it.” - Sir Henry Royce

3. Design and Validation of a Crankshaft

4. Design and Validation of a Crankshaft

5. Crankshaft can be found in any kind of reciprocating engine that translates linear piston motion into rotation. i.e. Engines of Heavy duty truck, cars, racing car, bus, mini car, aircraft. Design and Validation of a Crankshaft

6. Conceptual design Major functions are fixed Setting of Structural relationships of the principal components Sufficient details to provide approximate costs, weights Assured overall dimensions and feasibility of crank Major crankshaft dimensions must be chosen early in the engine design process as they affect overall engine dimensions. Design and Validation of a Crankshaft

7. Process analysis and selection crank stress integrity of the joints impact of the crank on the block stress and deformation Design and Validation of a Crankshaft

8. The virtual procedure of analysis: Run full crank reduced model (dynamic) to calculate reactions and torques. Model entire crankshaft with FEM Constrain the model at the flywheel end Run analysis applying all possible loads Scale and sum up the FE results for each crank angle Design and Validation of a Crankshaft

9. Design and Validation of a Crankshaft

10. Test fatigue through the crank web. fatigue through the pin journal, with the crack initiation starting at the oil hole. run calibration curve, calculate test strain levels, set control parameters, run test and inspect the specimen surface. Design and Validation of a Crankshaft

11. Production Forging Casting Billet Design and Validation of a Crankshaft

12. Quality improvement Hardening- using induction hardened bearing surfaces Fatigue strength- increased by using a radius at the ends of each main and crankpin bearing Counterweights-helps to negate the flexing of the crank Design and Validation of a Crankshaft

13. Supportive materials through Design and Validation: Six Sigma ISO 9001: 2000 BS 7000 Health and Safety Executive (HSE) Design and Validation of a Crankshaft

14. Step 1- conceptual design Step 2- process analysis and selection Step 3- test Step 4- production Step 5- improvement Design and Validation of a Crankshaft

15. Any questions? Design and Validation of a Crankshaft