ISSN 2319-8885

Vol.04,Issue.07,
March-2015,
Pages:1393-1398
www.ijsetr.com

Design and Static Structural Analysis of Crank Shaft

SUJATA SATISH SHENKAR1, NAGRAJ BIRADAR2
1
Professor, Dept of Mechanical Engineering, Pune University, JSPM, ICOER, Wagholi, Pune, MH, India,
E-mail: [email protected].
2
HOD, Dept of Mechanical Engineering, Pune University, JSPM, ICOER, Wagholi, Pune, MH, India,
E-mail: [email protected].

Abstract: The stress analyses of a single-cylinder crankshaft are discussed using finite element method in this paper. Three-
dimension models of single crankshaft and crank throw were created using Pro/ENGINEER software The finite element
analysis (FEM) software ANSYS was used to analyze the distortion and stress status of the crank throw. The maximum
deformation, maximum stress point and dangerous areas are found by the stress analysis of crank throw. The results would
provide a valuable theoretical foundation for the optimization and improvement of engine design.

Keywords: Crankshaft, Finite Element Analysis, Modal Analysis, Stress Analysis.

I. INTRODUCTION In contemporary racing crankshaft design, the requirements
Crankshaft (i.e. a shaft with a crank) is a central component for bending and torsional stiffness (see the Stiffness vs.
of any internal combustion engine and is used to convert Strength sidebar) compete with the need for low mass
reciprocating motion of the piston into rotatory motion or moment of inertia (MMOI). Several crankshaft experts
vice versa.. The crankshaft main journals rotate in a set of emphasized the fact that exotic metallurgy is no substitute
supporting bearings ("main bearings"), causing the offset for proper design, and there's little point in switching to
rod journals to rotate in a circular path around the main exotics if there is no fatigue problem to be solved. High
journal centers, the diameter of which is twice the offset of stiffness is a benefit because it increases the torsional
the rod journals. The diameter of that path is the engine resonant frequency of the crankshaft, and because it reduces
“stroke": the distance the piston moves up and down in its bending deflection of the bearing journals. Journal
cylinder as shown in Fig.1. The big ends of the connecting Deflection can cause increased friction by disturbing the
rods ("conrods") contain bearings ("rod bearings") which hydrodynamic film at critical points, and can cause loss of
ride on the offset rod journals. With the development of lubrication because of increased leakage through the greater
computer, more and more design of crankshaft has been radial clearances that occur when a journal's axis is not
utilized finite element method (FME) to calculate the stress parallel to the bearing axis The crankshaft, depending upon
of crankshaft. The application of numerical simulation for the position of crank, may be divided into the following two
the designing crankshaft helped engineers to efficiently types:1. Side crankshaft or overhung crankshaft, as shown in
improve the process development avoiding the cost and Fig 2.(a), and 2. Centre crankshaft, as shown in Fig.2 (b).
limitations of compiling a database of real world parts.

Fig.1. Crankshaft Nomenclature.

Fig.2. Position of Crankshaft.

Copyright @ 2015 IJSETR. All rights reserved.

 SUJATA SATISH SHENKAR, NAGRAJ BIRADAR
The crankshafts are subjected to shock and fatigue loads. vanadium, and sometimes aluminum and titanium. Each of
Thus material of the crankshaft should be tough and fatigue those elements adds specific properties in a given material.
resistant. The crankshafts are generally made of carbon The carbon content is the main determinant of the ultimate
steel, special steel or special cast iron. The crankshafts are strength and hardness to which such an alloy can be heat
made by drop forging or casting process but the former treated. In converting the linear motion of the piston into
method is more common. The surface of the crankpin is rotational motion, crankshafts operate under high loads and
hardened by case carburizing, nitriding or induction require high strength.
hardening. In this report we will be concentrating upon the
design of crankshaft used in Atul Shakti Limited for Mini Crankshafts require the following characteristics,
Tempo. The engine runs on Single cylinders. The detailed  High strength and stiffness to withstand the high
parameters of the engine are mentioned in design chapter. loads in modern engines, and to offer opportunities
for downsizing and weight reduction.
II. DESIGN OF CRANK SHAFT  Resistance to fatigue in torsion and bending.
A. Forces Imposed On A Crankshaft  Low vibration.
We have selected engine is Combustion Ignition Diesel  Resistance to wear in the bearing areas.
Engine. The obvious source of forces applied to a crankshaft
is the product of combustion chamber pressure acting on the Thus the forged steel crankshafts offer higher strength
top of the piston. High-performance, contemporary high- and stiffness and the other material characteristics than the
performance Compression-Ignition (CI) engines can see cast iron alternative.
combustion pressures in excess of 200 bar (2900 psi) which
will produce a force of 16529 Kg acting on a small 4.00 inch C. Chemical Composition of Crankshft
diameter piston. This kind of huge force exerted onto a The material selected for Atul Shakti Engine single
crankshaft rod journal which produces substantial bending cylinder crankshaft is 40Cr4Mo3. The detailed composition
and torsional moments and the resulting tensile, compressive of material is as below mentioned in Table II,
and shear stresses. However, there is another major source
of forces imposed on a crankshaft, namely Piston TABLE I: Chemical Composition
Acceleration. The combined weight of the piston, ring
package, wristpin, retainers, the con-rod small end and a
small amount of oil are being continuously accelerated from
rest to very high velocity and back to rest twice each
crankshaft revolution. Since the force it takes to accelerate
an object is proportional to the weight of the object times the
acceleration (as long as the mass of the object is constant),
many of the significant forces exerted on those reciprocating
components, as well as on the con-rod beam and big-end,
crankshaft, crankshaft, bearings, and engine block are
directly related to piston acceleration. Combustion forces
and piston acceleration are also the main source of external
vibration produced by an engine. In addition to these
reciprocating forces and the resulting moments, there is a
rotating mass associated with each crankpin, which must be
counteracted. The rotating mass consists of the weight of the
con-rod big end(s), conrod bearing(s), some amount of oil,
and the mass of the crankshaft structure comprising the
crankpin and cheeks. These rotating forces are counteracted
by counterweight masses located in appropriate angular Mechanical Properties:
locations opposing the rod journals Hardenability : 1.5mm – 56 to 63 HRC
5mm – 45 to 55 HRC
B. Material Selection 30mm – 20-29 HRC
Medium-carbon steel alloys are composed of
predominantly the element iron, and contain a small Tensile Strength : 83 Kg/mm2
percentage of carbon (0.25% to 0.45%, described as „25 to
Yield Strength : 55 Kg/mm2
45 points‟ of carbon), along with combinations of several
alloying elements, the mix of which has been carefully % Elongation : 14 % Min
designed in order to produce specific qualities in the target
alloy, including hardenability, nitridability, surface and core Micro-Structure: Uniform tempered martensite with
hardness, ultimate tensile strength, yield strength, endurance transferred ferrite content up to 10% Max. at core.
limit(fatigue strength), ductility, impact resistance, corrosion
resistance, and temper-embrittlement resistance. The D. Design Parameters Assumed
alloying elements typically used in these carbon steels are Refer below specification in Table II details taken from
manganese, chromium, molybdenum, nickel, silicon, cobalt, Atul Shakti Ltd website to design crank shaft.
International Journal of Scientific Engineering and Technology Research
Volume.04, IssueNo.07, March-2015, Pages: 1393-1398
 Design and Static Structural Analysis of Crank Shaft
TABLE II: Crank Shaft Specification In the scenario we have not consider bearing reaction
calculation at 3. We have given more focus for bearing
reaction at 1 and 2 since true data is not available to
calculate the reaction.

Now force on Piston,

Fp = Area of the bore x Max. Combustion pressure

= π/4 x D2 x Pmax

(Where Pmax = 25 bar = 2.5N/mm2)

= π/4 x (86)2 x 2.5

Fp = 14.52KN

Assuming the distance between the bearing 1 & 2 as

b = 2D = 2*69.6 = 13902 mm

b1 = b2 = b/2 = 69.6
E. Design Procedure
Based on the chemical composition of the material we We know that due to piston gas load, there will be two equal
will now design the crankshaft dimensions. Thus the design horizontal reactions H1 & H2 at bearings 1 & 2
of crankshaft is to be made by considering the two position respectively..i.e
of crank. When the crank is at dead center (or when the
crankshaft is subjected to maximum bending moment. When H1 = Fp/2 = 167.66/2 = 83.83 kN= H2
the crank angle is at which twisting moment is maximum.
Assuming that the length of bearing to be equali.e.
When Crank Is At Dead Center: At this point of crank, c1=c2=c/2
the maximum gas pressure on the piston will transmit
maximum force on the crankpin in the plane of the crank F. Design of Crank Pin
causing only bending of the shaft. The crankpin as we as Crankpin is also subjected to shear stress due to twisting
ends of the crankshaft will only be subjected to bending moment. Thus we can calculate bending moment at centre of
moment. Thus, when crank is at dead center, the bending crankpin and twisting moment on crank pin and the resultant
moment on the shaft is maximum and twisting moment is moment.
zero. The various forces that are acting on the crankshaft are
indicated as below Fig.3. This engine crankshaft is a single Let,
throw and two bearing shaft is located 1 and 2. We can
calculate the various forces acting on the crankshaft, dc = Diameter of crank pin in mm
connecting rod (Fp), Horizontal and vertical reaction on the
lc = length of crank pin in mm
shaft, and the resultant force at bearing 1 & 2 by below
formulae. σallow = allowable bearing stress for crank pin = 83kg/mm2

Bending moment at the centre of crank pin is,

Mc = H1 * b2 = 83.83 * 69.6 = 5834.53 KN.mm

We know that

Mc = π/32 * (dc)3 *σb

5834.56 x 103 = π/32 * (dc)3* 83dc

= 89.46 mm say 90 mm

Now, the length of crank pin lc = Fp/(dc*pb)

= 167.67 x 103 / (90 * 10) -- (say pb =10)

= 186.28 mm
Fig.3. Crank at dead centre.
International Journal of Scientific Engineering and Technology Research
Volume.04, IssueNo.07, March-2015, Pages: 1393-1398
 SUJATA SATISH SHENKAR, NAGRAJ BIRADAR
G. Design of Left Hand Crank Web M =4275.33 KN.mm
The crank web is designed for eccentric loading. There
will be two stresses acting on the crank web, one is direct Section Modulus
compressive stress and the other is bending stress due to
piston gas load (Fp). The crank web is subjected to the Z = 1/6 * w * t2
following stresses:
= 1/6 * 68 *13.2^2
 Bending stresses in two planes normal to each other
 Direct compressive stress and Z = 1974.72 mm^3
 Torsional stress
Bending Stress όb = M/Z
We know that the thickness of crank web is
όb= 2.165 KN/mm2
t = 0.65 *dc + 6.35
The compressive stress acting on crank web are
= 0.65* 90 + 6.35
όc = H1/(w * t)
= 64.85 = say 65 mm
= 83.33/(68* 13.2)
Also width of crank web is,
= .0939 KN/mm2
w = 1.125 * dc +12.7
The total stress on crank web is less than allowable
= 1.125 * 90 +12.7 bending stress of 83 N/mm2.
= 113.95 = say 115 mm Hence, Design is safe
The maximum bending moment on crank web is H. Design of Right Hand Crank Web
From balancing point of view, the dimension of right
Mmax = H1 (b2 – lc/2 - t/2) hand crank web i.e. thickness and width are made equal to
the dimension of the left hand crank web. When the crank is
= 83.83 (69.6- 186.28/2-65/2)
at an angle of maximum twisting moment; the twisting
= - 4697.83 kN mm moment on the crankshaft will be maximum when the
tangential force on the crank (FT) is maximum. The
The bending moment is negative; hence the design is not maximum value of tangential force lies when the crank is at
safe. Thus the dimensions are on higher side. angle 30º to 40º for constant pressure combustion engines
(i.e. diesel engines). When the crank is at angle at which the
Now let‟s assume, twisting moment is maximum, the shaft is subjected to
twisting moment from energy or force stored by flywheel.
dc = 45 mm The above design parameters can be cross checked for the
factor of safety while designing by considering the
Hence, lc = 372.57 mm crankshaft at an angle of maximum twisting moment. If the
factor of safety is more than 1 then the design is safe.
This is very high, which will require huge length of Considering this, we have to various forces acting on
crankshaft. To have optimum dimension of crankshaft; lets crankshaft at different twisting angles.
assume length of crank web as,
III. CRANKSHAFT MODELLING AND ANALYSIS
Lc = 24mm and check whether these dimension are suitable A. Crankshaft Drawing/Model
for the load exerted by the piston and other forces, As per calculation, we have created the Proe model of
the crankshaft. The final dimensions of the crankshaft are as
Now,
given below Fig.4,
T = 35.6 &

W = 63.32 = say 68 mm

This thickness is also on higher side, let‟s assume

thickness of crank web as

T =13.23 mm

As compared to width of crank web thickness is more

Bending moment,
(a)
International Journal of Scientific Engineering and Technology Research
Volume.04, IssueNo.07, March-2015, Pages: 1393-1398
 Design and Static Structural Analysis of Crank Shaft
Loading on Crankshaft:

Below are radial Loads (Fy) = 10.68N (Load is applied at

Modes of geometry)

(b)
Fig.4. 2D&3D of Crankshafts.

B. Crankshaft FEA Static Structural Analysis

Below are Tangential Loads (Fz) = 10.05N
Introduction: For FEA analysis we have used ANSYS
workbench as shown in Fig.5.

Input for FEA: Pro-e Solid model OR Parasol file of

Crankshaft.

Material properties:

Material Type: Forged Steel

Designation: 40CrMo4

Yield strength (MPa): 680

Ultimate tensile strength (MPa): 850

Fig.6. Radial load & Tangential load.
Elongation (%):13
Radial load & Tangential load is as shown in Fig.6.
Poisson ratio:0.3
FEA Results: Represent two views of crankshaft in order to
Pre-processor: Meshing Details of the Crankshaft. view magnitude of stress (Fig. 7).
Mesh Statics:

Type of Element: Tetrahedrons

Number of Nodes: 56279

Number of Elements: 44106

Fig.7. FEA Results: Magnitude of stress.

Interpretation:
 Max stress occurs at the joints besides the bearing
region.
 Introducing a fillet will help reduce the stresses.

IV. CONCLUSION
The stresses are well below the YS of the material – safe
to use the component. Refer below table for stress analysis
Fig.5. FEA analysis of crankshaft. results of analytical and FEA method.
International Journal of Scientific Engineering and Technology Research
Volume.04, IssueNo.07, March-2015, Pages: 1393-1398
 SUJATA SATISH SHENKAR, NAGRAJ BIRADAR
TABLE III: FEA Results

Above Results Shows that FEA Results matches with the

theoretical calculation so we can say that FEA is a good tool
to reduce time consuming theoretical Work. 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 edge of main journal is high stress area.
The Value of Von-Misses Stresses that comes out from the
analysis is far less than material yield stress so our design is
safe and we should go for optimization to reduce the
material and cost.

V. ACKNOWLEDGMENT
This research authors would like thanks to “Imperial
College of Engineering, JSPM ,Wagholi ,Pune”. For
providing better resources.

VI. REFERENCES
[1] Atul Shakti Engine Limited; http://www .atulauto.co .in/
site/vehicle/atul-shakti- smart/pickup-van-standard.html.
[2] C.Gaier and H.Dannbauer – “A Multi axial fatigue
analysis method for Ductile, semiductile and brittle
materials” The Arabian Journal for Science and
Engineering, Volume 33, Number 1B - 18 March 2006.
[3] M.Zoroufi and Fatemi– “A Literature review on
durability evaluation of Crankshafts including comparisons
of competing manufacturing Processes” Vol. 12, pp. 38-53.
[4] 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.
[5] Machine Design by Sri R S Khurmi and Sri. J K Gupta,
Chapter-32 Internal Combustion Engine parts.
[6] http://knol.google.com].

International Journal of Scientific Engineering and Technology Research

Volume.04, IssueNo.07, March-2015, Pages: 1393-1398