Escolar Documentos
Profissional Documentos
Cultura Documentos
On
BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING
(2015-2016)
BY
ABIJIT GUDA
12C91A0301
ARUP MANDAL
12C91A0308
G SHRAVAN RAJ
12C91A0326
CERTIFICATE
This is to certify that the project DESIGN AND MODAL ANALYSIS OF
CRANKSHAFT is being submitted by the following students in partial fulfillment
of the requirements for the award of degree of BACHELOR OF TECHNOLOGY in
Mechanical Engineering from Jawaharlal Nehru Technological University,
Hyderabad is a bonafide work carried out during the academic year 2014-1015. The
result embodied in this project report has not been submitted to any other university or
institute for the award of any other degree.
ABIJIT GUDA
12C91A0301
ARUP MANDAL
12C91A0308
G SHRAVAN RAJ
12C91A0326
PROJECT GUIDE
H.O.D
Mr . G. Banu Prakash
External Examiner
ACKNOWLEDGEMENT
-Abijit Guda
-Arup Mandal
- G. Shravan
ABSTRACT
(i)
CONTENTS
Chapter1:Introductionofcrankshaft
Introduction
1 Combustionandinertiaforcesactingoncrankshaft
1.1.1Torsionalload
1.1.2Bendingload
2 Bendingmoment
3 Twistingmoment
4 Theoreticalanalysis
5 Application
Chapter2:Literaturereview
1 Recentdevelopments
2 Theoreticalanalysis
3 Designcalculationforcrankshaft
Chapter3:Methodology
3.1Procedureofmodalanalysis
3.1.1Systemrequirements
3.2CATIA
3.3HistoryofCATIA
3.3.1Releasehistory
3.4ANSYS
3.5ANSYSdata
3.6Materialproperties
Chapter4:Designandmodalanalysis
4.1DesignofcrankshaftinCATIAV5
4.2ModalanalysisofcrankshaftinANSYS
Chapter5:Resultanddiscussions.
Chapter6:ConclusionandFuturescope
References:
1. INTRODUCTION
Crank shaft is a large component with a complex geometry in the I.C engine, which
converts the reciprocating displacement of the piston to a rotary motion with a four bar link
mechanism. Crankshaft consisting of shaft parts, two journal bearings and one crankpin
bearing. The Shaft parts which revolve in the main bearings, the crank pins to which the big
end of the connecting rod are connected, the crank arms or webs which connect the crank
pins and shaft parts. In addition, the linear displacement of an engine is not smooth; as the
displacement is caused by the combustion chamber therefore the displacement has sudden
shocks.
The concept of using crankshaft is to change these sudden displacements to as smooth
rotary output, which is the input to many devices such as generators, pumps and compressors.
It should also be stated that the use of a flywheel helps in smoothing the shocks. Crankshaft
experiences large forces from gas combustion. This force is applied to the top of the piston
and since the connecting rod connects the piston to the crank shaft, the force will be
transmitted to the crankshaft. The magnitude of the forces depends on many factors which
consist of crank radius, connecting rod dimensions, and weight of the connecting rod, piston,
piston rings, and pin.
the torque axis, the resultant shear stress in this section is perpendicular to the radius. Note that
the highest shear stress occurs on the surface of the shaft, where the radius is maximum. High
stresses at the surface may be compounded by stress concentration such as rough spots. Thus,
shafts for use in high torsion are polished to a fine surface finish to reduce the maximum stress in
the shaft and increase their service life.
four cylinder 4- stroke diesel engine. It must be strong enough to take the downward force
during power stroke without excessive bending. So the reliability and life of internal
combustion engine depend on the strength of the crankshaft largely. And as the engine runs,
the power impulses hit the crankshaft in one place and then another.
The torsional vibration appears when a power impulse hits a crankpin toward the front of
the engine and the power stroke ends. If not controlled, it can break the crankshaft. Jian Meng
et al. analysed crankshaft model and crank throw were created by CATIA software and then
imported to ANSYS software.
The crankshaft deformation was mainly bending deformation under the lower frequency.
And the maximum deformation was located at the link between main bearing journal,
crankpin and crank cheeks. Gu Yingkui et al. Researched a three-dimensional model of a
diesel engine crankshaft was established by using PRO/E software. Using ANSYS analysis
tool, it shows that the high stress region mainly concentrates in the knuckles of the crank arm
& the main journal and the crank arm & connecting rod journal ,which is the area most easily
broken. Xiaorong Zhou et al. described the stress concentration in static analysis of the
crankshaft model.
1.5 Application
The stress concentration is mainly occurred in the fillet of spindle neck and the stress of
the crankpin fillet is also relatively large. Based on the stress analysis, calculating the fatigue
strength of the crankshaft will be able to achieve the design requirements. From the natural
frequencies values, it is known that the chance of crankshaft resonant is unlike. This paper
deals with the dynamic analysis of the whole crankshaft. Farzin H. Montazersadgh et al. [8]
investigated first dynamic load analysis of the crankshaft.
2. LITERATURE REVIEW
Rinkle garg and Sunil Baghl. have been analyzed crankshaft model and crank throw were
created by CatiaV5 Software and then imported to ANSYS software. The result shows that
the improvement in the strength of the crankshaft as the maximum limits of stress, total
deformation, and the strain is reduced. The weight of the crankshaft is reduced .There by,
reduces the inertia force. As the weight of the crankshaft is decreased this will decrease the
cost of the crankshaft and increase the I.C engine performance. Abhishekchoubey, and Jamin
Brahmbhatt have been analyzed crankshaft model and 3-dimentional model of the crankshaft
were created by CATIA Software and imported to ANSYS software. The crankshaft
maximum deformation appears at the centre of crankpin neck surface. The maximum stress
appears at the fillets between the crankshaft journals and crank cheeks and near the central
point journal. The edge of main journal is high stress area. R. J. Deshbhratar, and Y.R Suple.
have been analyzed 4- cylinder crankshaft and model of the crankshaft were created by
CATIA Software and then imported to ANSYS software
The maximum deformation appears at the centre of crankshaft surface. The maximum
stress appears at the fillets between the crankshaft journal and crank cheeks, and near the
central point. The edge of main journal is high stress area. The crankshaft deformation was
mainly bending deformation under the lower frequency. And the maximum deformation was
located at the link between main bearing journal and crankpin and crank cheeks. So this area
prones to appear the bending fatigue crack
C.M. Balamurugan et al has been studied the Computer aided Modelling and Optimization
of crankshaft and compare the fatigue performance of two competing manufacturing
technologies for automotive crankshafts, namely forged steel and ductile cast iron.
The Three dimensional model of crankshaft were created by solid edge software and then
imported to Ansys software. The optimisation process included geometry changes compatible
with the current engine, fillet rolling and results in increased fatigue strength and reduced
cost of the crankshaft, without changing connecting rod and engine block. Gu Yingkui, Zhou
Zhibo. have been discussed a three-Dimensional model of a diesel engine crankshaft were
established by using PRO/E software and analytical ANSYS Software tool, it shows that the
high stress region mainly concentrates in the knuckles of the crank arm & the main journal
and the crank arm & connecting rod journal ,which is the area most easily broken.
3. METHODOLOGY
3.1 Procedure of modal Analysis
1) First, I have Prepared Part design in catia V5 for crankshaft and Save as this part as .STP
for Exporting into Ansys Workbench Environment. Import .STP Model in ANSYS
Workbench Simulation Module.
2) Apply Material for Crank Shaft (structured steel).
Material Details
Material Type: - Structured Steel
Youngs Modulus 2E+11
Elongation (%):-13
Poisson ratio:-0.3
Bulk Modulus 1.6667E+11
Shear Modulus 7.6923+10
Requirement
Processor
Pentium (min)
RAM
2GB (min)
Hard Disk
60 GB (min)
Operating System
Windows based
3.2 CATIA
CATIA (Computer Aided Three-dimensional Interactive Application) is a multiplatform CAD/CAM/CAE commercial software suite developed by the French company
Assault Systems. Written in the C++ programming language, CATIA is the cornerstone of the
Assault Systems product lifecycle management software suite.
CATIA competes in the CAD/CAM/CAE market with Siemens NX, Pro/E, Autodesk
Inventor, and Solid Edge as well as many others.
Developer(s)
Stable release
Operating
system
Type
License
Website
Dassault Systems
V6R2011x / November 23,
2010
Unix / Windows
CAD software
Proprietary
WWW.3ds.com
Details of CATIA
versions of CATIA
3.4 ANSYS
ANSYS Workbench combines the strength of our core simulation tools with the tools
necessary to manage your projects. You will work with your ANSYS Workbench project on
the main project workspace, called the Project tab. The project is driven by a schematic
workflow, represented visually on a flowchart-like diagram called the Project Schematic. To
build an analysis, you add building blocks called systems to the Project Schematic; each
system is a block of one or more components called cells, which represent the sequential
steps necessary for the specific type of analysis. Once you have added your systems, you can
link them together to share and/or transfer data between systems.
The General Post Processor is mainly used to view the following Criterion.
Read Results
Plot Results
List Results
Query Results
Write Results
For Elemental Table
The Time History Post Processor consists of the following Menu Items
Variable Viewer
List Variables
List Extremes
Graph Variables
Math Operations
Table Operations
The structural analysis of the model mainly classified in to Static and Dynamic Analyses.
Each can be explained in detail below.
Static Analysis
The Analysis used the behaviour of structures under static loading can be analyzed by
employing different types of elements within ANSYS. The nature of the structure dictates the
type of elements utilized in the analysis. Discrete or framed Structures are suitable for
modelling with rod- and beam-type elements. However, the modelling of continuous
structures usually requires a three dimensional model with solid elements.
Dynamic Analysis
The analysis used for the behaviour of the structures under dynamic loading can be
analysed using Dynamic Analysis. It includes the determination of the Mode shapes, natural
frequencies and amplitudes of vibrations of the structural members. There are three
commonly used dynamic analysis types in ANSYS:
Modal Analysis.
Harmonic Analysis.
Transient Analysis.
Modal Analysis
If the structural vibration is of concern in the absence of time-dependent external loads,
a modal analysis is performed. It is is used to determine the natural frequencies and mode
shapes .The main steps involved in Modal Analysis are ,6
Harmonic Analysis
When a structure is subjected to cyclic loading, the resulting response is analyzed by
using Harmonic Analysis. It is used to determine the amplitude of vibrations of the structure.
The restrictions on a harmonic analysis are:
Transient Analysis
When a structure is subjected to non-cyclic transient loading , the resulting response can
be analyzed by using Transient Analysis. It is used to determine the Amplitudes of the
displacement at a particular node as a function of frequency under harmonic loading.
The main steps involved in Transient Analysis are
Durability.
1. Strength
Yield strength
Yield strength is the most common property that the designer will
need as it is the basis used for most of the rules given in design codes . In
European Standards for structural carbon steels, the primary designation
relates to the yield strength, e.g. S355 steel is a structural steel with a
specified minimum yield strength of 355 N/mm.
2. Toughness
It is in the nature of all materials to contain some imperfections. In
steel these imperfections take the form of very small cracks. If the steel is
insufficiently tough, the 'crack' can propagate rapidly, without plastic
deformation and result in a 'brittle fracture'. The risk of brittle fracture
increases with thickness, tensile stress, stress raisers and at colder
temperatures. The toughness of steel and its ability to resist brittle
fracture are dependent on a number of factors that should be considered
at the specification stage. A convenient measure of toughness is the
Charpy V-notch impact test
3.Ductility
Ductility is a measure of the degree to which a material can strain or elongate between the
onset of yield and eventual fracture under tensile loading
The designer relies on ductility for a number of aspects of design, including redistribution of
stress at the ultimate limit state, bolt group design, reduced risk of fatigue crack propagation
and in thefabrication processes of welding, bending and straightening.
4.Weldability
All structural steels are essentially weldable. However, welding involves locally melting
the steel, which subsequently cools. The cooling can be quite fast because the surrounding
material, e.g. the beam, offers a large 'heat sink' and the weld
is usually relatively small. This can lead to hardening of the 'heat affected zone' (HAZ) and to
reduced toughness. The greater the thickness of material, the greater the reduction
of toughness.
5.Durability
A further important property is that of corrosion prevention. Although special corrosion
resistant steels are available these are not normally used in building construction. The
exception to this is weathering steel .
The most common means of providing corrosion protection to construction steel is
by painting or galvanizing. The type and degree of coating protection required depends on the
degree of exposure, location, design life, etc.
STEP2:
select an axis plane then go to 2D plane by using sketch tool
STEP3 :
Draw two circles with required radius and draw lines from the smaller circle, then drop
them on the required horizontal line on the bigger circle.
STEP 4 :
By using corner tool we aquire the below shown image and to exit to 3d plane, we click
on exit to workbench tool.
STEP5 :
Add material to the image by using pad tool ,up to required thickness.
STEP6 :
Draw the circle on the required surface and add material to it by using pad tool.
STEP7:
draw a circle on the top of the surface with required dimensions, exactly opposite to the
previously drawn surface and add material using pad tool.
STEP8 :
By using reference plane tool, we draw a new plane and then by using the project 3d
tool we project the sketch 1 and add material by using pad.
STEP9 :
Draw a new plane then copy the sketch 2 and paste it on the new plane.
STEP 10 :
Now by using pad tool we add the material to the sketch.
STEP 11 :
Copy the sketch 1 and paste it on the new plane and now rotate the acquired image at
an angle of 180 degrees and add material to it by using pad tool.
STEP12 :
Now, copy the sketch 3 and paste it on the new plane and adjust it according to our
requirements and then add material using the pad tool.
STEP13 :
By using the project 3d tool project the sketch 4 on to the new plane and now rotate the
sketch by using the rotation tool at exactly 180 degrees.
STEP 14 :
Now draw a new plane and copy the sketch2 and paste it on to the plane with required
dimensions.
STEP 15 :
Now select all the pads mentioned on the specification tree.
STEP 16 :
Now by using the mirror tool and taking the new plane as the reference , the total image
on the left hand side will project on to the right hand side.
STEP 17 :
Select the sketch 2 and draw a small circle on it of required radius. Now exit to work
bench and the material in the circular shape is removed by using the pocket tool.
STEP 18 :
Now by using the circular pattern the required number of patterns can be drawn on
both the ends.
STEP 19 :
We apply the required material to the crankshaft by using the apply material tool.
STEP 20 :Below given picture/image shows all the views of the crankshaft.
STEP 5 :We now obtaim the maximum stress and the min stress on the crankshaft.
Sl no
1.
2.
3.
4.
5.
No of modes
total
deformation 1`
total
deformation 2
total
deformation 3
total
deformation 4
total
deformation 5
deformation
0.57786
Frequency
328.32
0.70438
550.03
0.44967
606.83
0.75806
873.61
0.54035
918.25
Above Results Shows the highest deformation and the point where there is
high frequency. The maximum deformation appears at the center of crankpin
neck surface. The maximum stress appears at the fillets between the
crankshaft journal and crank cheeks and near the central point Journal. The
same.
Moreover
the
critical
components
are
designed
taking
into
materials
apart
from
the
one
considered
in
this
dissertation.
4. By increasing the design size of crankshaft which is of four cylinder to
multi cylinder engine and by using the latest material used in design
we can understand more reliable.
5. The values that are generated by subjecting different loads are kept as
a reference and compare them with the different material, which may
give the researchers to achieve the optimum design in the future.
7. REFERENCES:1.C.M.Balamurugan.,R.Krishnaraj.,Dr.M.Sakthive.l,K.Kanthave.l ,DeepanMarudachalamM
.G.,R.Palani.,2011
Computer
Aided
Modeling
and
Optimization
of
Crankshaft,
International Journal of Scientific & Engineering Research Volume 2, Issue 8 ISSN 22295518
2. Yu Ding and Xiaobo Li.,2011, Crankshaft Strength Analysis of a Diesel Engine Using
Finite Element Method, Asia-Pacific Power and Energy Engineering Conference
3. Jian Meng., Yongqi Liu., Ruixiang Liu.,2011,Finite Element Analysis of 4-Cylinder
Diesel Crankshaft, I.J. Image, Graphics and Signal Processing, 5, 22-29
4. MENG Jian., LIU Yong-qi., LIU Rui-xiang., and ZHENG Bin.,2011,Intension Analysis
of 3-D Finite Element Analysis on 380 diesel crankshaft, International Conference on
Computational and Information Sciences
5. Yu Gongzh.i, Yu Hongliang., Duan Shulin., 2011, Crankshaft Dynamic Strength Analysis
for Marine Diesel Engine, Third International Conference on Measuring Technology and
Mechatronics Automation.
6.
PRO/E and ANSYS, Diesel Engine Crankshaft Based on PRO/E and ANSYS, and
Mechatronics Automation
7.
Xiaorong Zhou., Ganwei Cai., Zhuan Zhang. Zhongqing Cheng., 2009, Analysis on
Farzin H. Montazersadgh and Ali Fatemi., 2007,Dynamic Load and Stress Analysis of