International Journal of Research and Innovation (IJRI)

International Journal of Research and Innovation (IJRI)

1401-1402

GEOMETRIC OPTIMIZATION AND MANUFACTURING PROCESS OF SIX CYLINDER

DIESEL ENGINE CRANK SHAFT USED IN AUTOMOBILE USING FEA

Karnati Sreedhar 1,Gandhi Perumallapalli2, D.sreeramprasad

1 Research Scholar, Department Of Mechanical Engineering, Sri Venkateswara Engineering College, Amaravadi Nagar, Suryapet,India
2 Assistant professor , Department Of Mechanical Engineering, Sri Venkateswara Engineering College, Amaravadi Nagar, Suryapet,India
3 Associate Professor , Department Of Mechanical Engineering, Sri Venkateswara Engineering College, Amaravadi Nagar, Suryapet,India

Abstract
The crankshaft is that part of an engine which translates reciprocating linear piston motion into rotation. To convert the
reciprocating motion into rotation, the crankshaft has "crank" or "crankpins", additional bearing surfaces whose axis is
offset from that of the crank, to which the "big ends" of the connecting rods from each cylinder attach.
The aim of the project work is to optimize the geometry shape of 6-cylinder diesel engine crank shaft to reduce the failures and to reduce the weight. And also this project work will provide the brief explanation of manufacturing process.
Initially literature survey and data collection will be done to understand methodology.
Design calculations will be done to get parameters of object for drafting.
3D model will be prepared according to the obtained parameters.
Analysis will be conducted on crank shaft to rectify failures by optimizing geometric shape. Also best material will be
suggested by analyzing and comparing results with the variation of materials.
Mold tool design will be done and assembly will be prepared according to that.
Cnc program will be prepared for die set using cam
*Corresponding Author:
Karnati Sreedhar,
Research Scholar, Department Of Mechanical Engineering,
Sri Venkateswara Engineering College,
Amaravadi Nagar, Suryapet,India
Published: May 20, 2015
Review Type: peer reviewed
Volume: II, Issue : II

Citation: Karnati Sreedhar, Research Scholar (2015)

GEOMETRIC OPTIMIZATION AND MANUFACTURING PROCESS

OF SIX CYLINDER DIESEL ENGINE CRANK SHAFT USED IN
AUTOMOBILE USING FEA

Problem Description
When observing 6 cylinder automobiles like busses
having frequent break downs due to engine failures.
Millage is also become one of the most important
thing in those days if we can reduce the mechanical
efficiency.
Commonly crank shafts are made with low carbon
steels and casting along with milling is used to the
produce object.It causes low production rate and
high cost.
Methodology
This is an attempt to reduce weight, improve life
time and to improve production rate by implementing geometric optimization we can reduce failure
and by introducing new materials we can reduce
weight as well as we switch manufacturing process.
By implementing metal injection system we can improve production rate.

Introduction
The crankshaft, sometimes casually abbreviated
to crank, is the part of an engine which translates
reciprocating linear piston motion into rotation. To
convert the reciprocating motion into rotation, the
crankshaft has "crank throws" or "crankpins", additional bearing surfaces whose axis is offset from
that of the crank, to which the "big ends" of the connecting rods from each cylinder attach.
It typically connects to a flywheel, to reduce the pulsation characteristic of the four-stroke cycle, and
sometimes a torsional or vibrational damper at the
opposite end, to reduce the torsion vibrations often
caused along the length of the crankshaft by the
cylinders farthest from the output end acting on the
torsional elasticity of the metal.
Stress on crankshafts
The shaft is subjected to various forces but generally needs to be analysed in two positions. Firstly,
failure may occur at the position of maximum bending; this may be at the centre of the crank or at
either end. In such a condition the failure is due to
bending and the pressure in the cylinder is maximal. Second, the crank may fail due to twisting, so
the conrod needs to be checked for shear at the position of maximal twisting. The pressure at this position is the maximal pressure, but only a fraction
of maximal pressure.
A crankshaft contains two or more centrally-located
coaxial cylindrical ("main") journals and one or more
offset cylindrical crankpin ("rod") journals. The two108

International Journal of Research and Innovation (IJRI)

plane v8 crankshaft pictured in figure 1 has five

main journals and four rod journals, each spaced
90 from its neigbors.

The crankshaft main journals rotate in a set of supporting bearings ("main bearings"), causing the offset rod journals to rotate in a circular path around
the main journal centers, the diameter of which is
twice the offset of the rod journals. The diameter
of that path is the engine "stroke": the distance
the piston moves up and down in its cylinder. The
big ends of the connecting rods ("conrods") contain
bearings ("rod bearings") which ride on the offset
rod journals.

is becoming increasingly significant because of the

feasibility and ease of adding new functions to the
existing commercial products, apart form products
made completely from nanomaterials through the
bulk, which is relatively difficult. Nanomaterials are
usually characterized by a feature size of less than
100 nm at least in one dimension.
Recently in april 2010, us epa has announced a new
working definition of nanomaterials as an ingredient that contains particles that have been intentionally produced to have at least one dimension that
measures between approximately 1 and 100 nanometers in order to facilitate the implementation
of regulations on use of nanomaterials in commercial products.
Introduction to cad
Throughout the history of our industrial society,
many inventions have been patented and
Whole new technologies have evolved. Perhaps the
single development that has impacted
Manufacturing more quickly and significantly than
any previous technology is the digital computer.

Crankshaft materials
The steel alloys typically used in high strength
crankshafts have been selected for what each designer perceives as the most desirable combination
of properties. Figure 6 shows the nominal chemistries of the crankshaft alloys discussed here.
Medium-carbon steel alloys are composed of predominantly the element iron, and contain a small
percentage of carbon (0.25% To 0.45%, Described
as 25 to 45 points of carbon), along with combinations of several alloying elements, the mix of which
has been carefully designed in order to produce
specific qualities in the target alloy, including hardenability, nitridability, surface and core hardness,
ultimate tensile strength, yield strength, endurance
limit (fatigue strength), ductility, impact resistance,
corrosion resistance, and temper-embrittlement
resistance. The alloying elements typically used in
these carbon steels are manganese, chromium, molybdenum, nickel, silicon, cobalt, vanadium, and
sometimes aluminium and titanium. Each of those
elements adds specific properties in a given material. The carbon content is the main determinant of
the ultimate strength and hardness to which such
an alloy can be heat treated.

Introduction to pro/engineer
Pro/engineer is the industrys standard 3d mechanical design suit. It is the worlds leading cad/cam /
cae software, gives a broad range of integrated solutions to cover all aspects of product design and
manufacturing.
Advantages of pro/engineer
1.It is much faster and more accurate. Once a design is completed. 2D and 3d views are readily obtainable.
2.The ability to incorporate changes in the design
process is possible.
3.It provides a very accurate representation of model specifying all other dimensions hidden geometry
etc.
4.It provides a greater flexibility for change. For example if we like to change the dimensions of our
model, all the related dimensions in design assembly, manufacturing etc. Will automatically change.
5.It provides clear 3d models, which are easy to
visualize and understand.
6.Pro/e provides easy assembly of the individual
parts or models created it also decreases the time
required for the assembly to a large extent.
Design of multi cylinder engine crank shaft (diesel engine) specifications

Nanomaterials
The role of nanomaterials in modern technologies
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International Journal of Research and Innovation (IJRI)

Pressure calculations
Engine type: air cooled 4-stroke
(Agco sisu power 66cta bus)
Number of cylinders
=6
Bore diameter (d)
= 108 mm
Stroke length (l)
= 120mm
Maximum combustion pressure=10.466N/mm2
Displacement
=6600cc
Compression ratio
=23:1
Density of diesel
= 874.6081Kg/m3 at 15c
T =288.855K
Mass
= density volume

= 0.00000087460816600000

= 5.77Kg
Molecular weight for diesel is 200 g/mole
Pv = mrt

Assume that the length of the main bearings to be

equal, i.E.,
C1 = c2 = c / 2.
We know that due to the weight of the flywheel
acting downwards, there will be two vertical reactions v2 and v3 at bearings 2 and 3 respectively,
such that

Model of crank shaft

We know that force on the piston i, e: gas load

In order to find the thrust in connecting rod we

should find out angle of inclination of connecting
rod with line of stroke (i,e: angle ) (lies between 30
to 40)

Assume that the distance (b) between the bearings 1

and 2 is equal to twice the piston diameter (d).
B = 2d = 2 108 =216mm
Due to this piston gas load (fp) acting horizontally,
there will be two horizontal reactions h1and h2 at
bearings 1 and 2 respectively, such that
B1 = b2= 108mm

The above image shows total sections

2D drafting crankshaft

Powder metallurgy
Powder metallurgy is a forming and fabrication
technique consisting of three major processing stages. First, the primary material is physically powdered, divided into many small individual particles.
Next, the powder is injected into a mold or passed
through a die to produce a weakly cohesive structure (via cold welding) very near the dimensions of
the object ultimately to be manufactured. Pressures
of 10-50 tons per square inch are commonly used.
Also, to attain the same compression ratio across
more complex pieces, it is often necessary to use
lower punches as well as an upper punch. Finally,
the end part is formed by applying pressure, high
temperature, long setting times (during which self110

International Journal of Research and Innovation (IJRI)

welding occurs), or any combination thereof.

Cad/cam in die design
In the die casting scenario the advent of digital computers has facilitated the improvement of productivity and elimination of costly rework. Here before
the physical realization of the die, the design can be
redefined and the parameters can be decided which
would yield good results. Variety of feed systems
and combination of ideas can be selected. This is
an analytic approach to estimate the validity of the
design. Thus it gives enormous confidence to the
designer even before the tool is manufactured.
Core & cavity design with pro/engineer
Core cavity preparation

Create parting surface

The above image shows exploded view of complete die

Introduction to manufacturing
The manufacturing of various products is done at
different scales ranging from humble domestic production of say candlesticks to the manufacturing of
huge machines including ships, aeroplanes and so
forth. The word manufacturing technology is mainly
used for the latter range of the spectrum of manufacturing, and refers to the commercial industrial
production of goods for sale and consumption with
the help of gadgets and advanced machine tools.
Industrial production lines involve changing the
shape, form and/or composition of the initial products known as raw materials into products fit for
final use known as finished products.
Procedure of manufacturing
Cavity
Roughing

Create work piece

With workpiece

The above image shows cavity 1

The above image shows total die assembly

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International Journal of Research and Innovation (IJRI)

Cutting tool

Playpath

By the early 70's, fea was limited to expensive mainframe computers generally owned by the aeronautics, automotive, defense, and nuclear industries.
Since the rapid decline in the cost of computers and
the phenomenal increase in computing power, fea
has been developed to an incredible precision. Present day supercomputers are now able to produce
accurate results for all kinds of parameters.
Fea consists of a computer model of a material or
design that is stressed and analyzed for specific results. It is used in new product design, and existing
product refinement. A company is able to verify a
proposed design will be able to perform to the client's specifications prior to manufacturing or construction. Modifying an existing product or structure is utilized to qualify the product or structure
for a new service condition.In case of structural failure, fea may be used to help determine the design
modifications to meet the new condition.
Introduction to ansys

Vericut

Ansys is general-purpose finite element analysis

(fea) software package. Finite element analysis is
a numerical method of deconstructing a complex
system into very small pieces (of user-designated
size) called elements. The software implements
equations that govern the behaviour of these elements and solves them all; creating a comprehensive explanation of how the system acts as a whole.
These results then can be presented in tabulated,
or graphical forms. This type of analysis is typically
used for the design and optimization of a system far
too complex to analyze by hand. Systems that may
fit into this category are too complex due to their
geometry, scale, or governing equations.
Material properties and boundary
Conditions
Material properties :carbon steel

Roughing program
%
G71
O0001
(\Roughing.Ncl.1)
(04/30/15-12:13:46)
N0010t1m06
S1500m03
G01g43x-377.072Y-157.018Z2.F500.H01m08
Z-2.F150.
Introduction to fea
Finite element analysis (fea) was first developed in
1943 by r. Courant, who utilized the ritz method of
numerical analysis and minimization of variational
calculus to obtain approximate solutions to vibration systems. Shortly thereafter, a paper published
in 1956 by m. J. Turner, r. W. Clough, h. C. Martin, and l. J. Topp established a broader definition
of numerical analysis. The paper centered on the
"stiffness and deflection of complex structures".
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International Journal of Research and Innovation (IJRI)

Boundary conditions
Constrained at crankshaft both ends
Pressure on shaft

Dynamic analysis of crankshaft

Existing model

Structural analysis of crankshaft

Existing model
Material: carbon steel

The above image shows total deformation mode 1

The above image shows total deformation

The above image shows total deformation mode 2

Fatigue analysis of crankshaft existing model

The above image shows stress

The above image shows strain

The above image shows life

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International Journal of Research and Innovation (IJRI)

The above image shows safety factor

The above image shows biaxiality indication

Structural analysis of crankshaft

Existing model
Material: nano material

The above image shows total deformation

The above image shows stress

The above image shows strain

Dynamic analysis of crankshaft

Existing model

The above image shows total deformation mode 1

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International Journal of Research and Innovation (IJRI)

Modified model

2D drafting

The above image shows total deformation mode 2

Fatigue analysis of crankshaft existing model

Structural analysis of crankshaft

Modified model
Material: carbon steel

The above image shows life

The above image shows total deformation

The above image shows safety factor

The above image shows stress

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International Journal of Research and Innovation (IJRI)

Fatigue analysis

The above image shows safety factor

Results Table
The above image shows strain

STRUCTURAL ANALYSIS
Existing model

Modified model

carbon
steel

Nano
material

carbon
steel

Nano
material

Total deformation

0.00679

0.012065

0.0059

0.0104887

Stress

12.626

12.348

10.955

10.711

Strain

5.9963e-5

0.000106

5.1513e-5

9.1435e-5

Results and graphs

Structural analysis

Dynamic analysis

The above image shows total deformation graph

The above image shows stress graph

Existing model

Modified model

carbon
steel

Nano
material

carbon
steel

Nano
material

Total deformation mode

1HZ

65.455

54.36

66.017

54.827

Total deformation mode

2 HZ

67.961

56.441

68.569

56.946

Total deformation mode

3 HZ

179.08

148.73

180.71

150.08

Total deformation mode

4 HZ

187.09

155.38

188.54

156.58

Total deformation mode

5 HZ

248.42

206.31

254.31

211.2

FATIGUE ANALYSIS
Existing model

Modified model

carbon
steel

Nano
material

carbon
steel

Nano
material

LIFE

1e6

1e6

1e6

1e6

Damage

1000

1000

1000

1000

Safety
factor

3.416

3.4903

3.9344

4.0238

Biaxiality
indication

0.99856

0.99856

0.99907

0.99907

Alternating stress

25.252

24.697

21.909

21.422

The above image shows strain graph

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International Journal of Research and Innovation (IJRI)

Conclusion
This project works deals with geometric optimization and manufacturing process of six cylinder diesel engine crank shaft used in automobile using fea
Initially literature survey and data collection was
done to understand methodology.
Crank shaft parameters are calculated using empirical formals for 6 cylinder engine.
3D model is prepared according to the obtained
valve from calculation,
Static, fatigue and dynamic analysis is done on
crankshaft using low carbon steel (existing).Same
as been done using steel nano material and to find
out the failure locations and to evaluate results for
new material.
Geometric modifications are done on crank shaft
model to reduce stress concentration by implementing stress reliving holes on web.
As per the static, fatigue and dynamic analysis results, existing model is up to the mark only. Implementation of nano material will increase life by
2%, while appling stress reliving holes, life will be
increased by 17.8% And also weight can be reduced
by 22%due to low density for nano steel alloy. Also
material is removed from the crank web. So better
to use modified model with nano material.
In the next step manufacturing is described and for
the nano materials better to go with metal injection
process.
Mould parts are prepared and assembly, which contains ejectors, retainers, spacer housing and pins.
Cnc codes are generated using cam in pro/engineer.
This project concludes that modified model with
nano material increases the life and also weight will
be reduced up to 35% which interns increases the
mechanical efficiency. Metal injection process is the
most efficient way to manufacture crankshaft with
nano material and also it increase the production
rate
References
1.Dynamic stress analysis of a multi cylinder two-stage compressor crankshaft Research journal of engineering sciences

Authour

Karnati sreedhar
Research scholar, department of mechanical
engineering,sri venkateswara engineering college,
Amaravadi nagar, suryapet - 508213.Nalgonada
(dt), india.

Gandhi perumallapalli
Assistant professor in mechanical engineering
Sri venkateswara engineering college,
Amaravadi nagar, suryapet - 508213.Nalgonada
(dt),india.

D.Sreeramprasad
Associate professor in mechanical engineering
Sri venkateswara engineering college,
8 Years industrial, 18 years teaching+ years

2.Design and analysis of crankshaft for single cylinder 4-stroke

deisel engine Crankshaft design and optimization- a review
National conference on recent trends in engineering & technology
3.Theoretical and experimental analysis of torsional and bending effect on four cylinders engine crankshafts by using finite
element approach International journal of engineering research
4.Fatigue strength and residual stress analysis of deep rolled
crankshafts International journal of engineering and technology
(ijet)
5.Finite element analysis of 4-cylinder diesel crankshaft
6.Crankshaft strength analysis using finite element method
International journal of engineering research
7.Concept and manufacture of a crankshaft production tool
8.Elastic multi body simulation of a multi-cylinder engine
The open mechanical engineering journal,

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