Crankshaft

CONTENTS Page No:

NOMENCLATURE 04
Abstract 05
Chapter 1. Introduction 06
1.1 Engine 06
1.2 Internal combustion engine 07
1.3 Parts of an engine 07
1.4 Engine cycle 10
1.5 Operation 11

Chapter 2. Crankshaft 12
2.1 Crank (mechanism) 12
2.2 Crank Construction 13
2.3 Crankshaft Geometry 14

Chapter 3. Designing of crank shaft using pro/e 19

3.1 Overview of Solid Modeling 19
3.2 Advantages of Solid Modeling 19
3.3 Features 20
3.4 Blending and Chamfering 20
3.5 Advanced Modeling Operations 20
3.6 General Operations 21
3.7 Introduction to Drafting 22
3.8 Assembly Concepts 24
Chapter 4. Finite Element Method 28
4.1 Introduction 28
4.2 Available Software Packages For FEM 31
4.3 Basic Steps Involved In FEA 32
4.4View of Structural Static Analysis 34
4.4 Notes on Ansys Element Manual 36
4.5 Theories Of Failures 42

Chapter 5. Ansys 46
5.1 Performing A Typical Ansys Analysis 47
5.2 Pre-Processor 48
5.3 Solution Processor 49
5.4 Post-Processor 49
5.5 Review the Results 50
5.6 Meshing 51
5.7 Structural Static Analysis 52

Chapter 6. Introduction to Solid 92 Element 53

Chapter 7. Analysis of Crankshaft 56

7.1 Mesh in the Critical Regions 60
7.2 Boundary Conditions 62
7.3Constraints on Shaft 63

Chapter 8. Results and Conclusion 82

8.1 Comparison Table 82
8.2 Conclusion 85
Bibliography 86
 NOMENCLATURE

A Crank angle (rad)

a Piston pin acceleration (inches/rad2)

l Rod length (inches)

r Crank radius (inches)

x Piston Pin position (inches)

v Piston pin velocity (inches/rad)

 Crank angular velocity (rad/s)

Psi Pound square inch

lb Pounds
 ABSTRACT

In this project we designed and analyzed a crankshaft of 4-stroke S.I engine

using “Ansys”, which is software, which works on the basis of finite element method.

Firstly, we created a solid model of the crankshaft using designing software

“PRO/E”. Then the model is imported into Ansys and analyzed by applying necessary
conditions, which were considered in designing it and then checked for the strength and
life. The specifications required for the design are taken from the drafted design.

The results were found in the analysis of the crankshaft, the design is found out to
produce more stresses and some modifications were done to the design and again it is
analyzed and the stresses developed were lesser when compared to the previous design.

The engine, which is used, is a four-stroke S.I engine. It is a twin cylinder multi
utility engine. It is a horizontal shaft engine. The cylinder volume of the engine is 196cc
and it is used in cold countries for snow cutting purpose. It is also used for grass cutting.
 1.INTRODUCTION

1.1ENGINE:

An engine is something that produces an effect from a given input. The origin of
engineering was the working of engines. There is an overlap in english between two
meanings of the word "engineer": 'those who operate engines' and 'those who design and
Internal combustion engine.

There is a wide range of internal combustion engines corresponding to their many

varied applications. Likewise there is a wide range of ways to classify internal-
combustion engines, some of which are listed below.

Although the terms sometimes cause confusion, there is no real difference between
an "engine" and a "motor." At one time, the word "engine" (from Latin, via old french,
ingenium, "ability") meant any piece of machinery. A "motor" (from Latin motor,
"mover") is any machine that produces mechanical power. Traditionally, electric motors
are not referred to as "engines," but combustion engines are often referred to as "motors."
(An electric engine refers to locomotive operated by electricity).With that said, one must
understand that common usage does often dictate definitions. Many individuals consider
engines as those things which generate their power from within, and motors as requiring
an outside source of energy to perform their work. Evidently, the roots of the words seem
to actually indicate a real difference. Further, as in many definitions, the root word only
explains the beginnings of the word, rather than the current usage. It can certainly be
argued that such is the case with the words motor and engine.

1.2INTERNAL COMBUSTION ENGINE:

The internal combustion engine is an engine in which the burning of a fuel occurs
in a confined space called a combustion chamber. This exothermic reaction of a fuel with
an oxidizer creates gases of high temperature and pressure, which are permitted to
expand. The defining feature of an internal combustion engine is that useful work is
performed by the expanding hot gases acting directly to cause movement, for example by
acting on pistons, rotors, or even by pressing on and moving the entire engine itself.

This contrasts with external combustion engines, such as steam engines, which use
the combustion process to heat a separate working fluid, typically water or steam, which
then in turn does work, for example by pressing on a steam actuated piston.

The term Internal Combustion Engine (ICE) is almost always used to refer
specifically to reciprocating engines, Wankel engines and similar designs in which
combustion is intermittent. However, continuous combustion engines, such as Jet
engines, most rockets and many gas turbines are also internal combustion engines.

1.3PARTS OF AN ENGINE:

Components of a typical, four stroke cycle engine. (E) Exhaust camshaft, (I)
Intake camshaft, (S) Spark plug, (V) Valves, (P) Piston, (R) Connecting rod, (C)
Crankshaft, (W) Water jacket for coolant flow.

An illustration of several key components in a four-stroke typical engine the parts

of an engine vary depending on the engine's type. For a four-stroke engine, key parts of
the engine include the crankshaft (purple), one or more camshaft (red and blue) and
valves. For a two-stroke engine, there may simply be an exhaust outlet and fuel inlet
instead of a valve system. In both types of engines, there are one or more cylinders (grey
and green) and for each cylinder there is a spark plug (darker-grey), a piston (yellow) and
a crank (purple). A single sweep of the cylinder by the piston in an upward or downward
motion is known as a stroke and the downward stroke that occurs directly after the air-
fuel mix in the cylinder is ignited is known as a power stroke.
Cylinder:
As the name implies it is a cylindrical vessel or space in which the piston makes
the reciprocating motion. The clyinder is supported in the clyinder block.

Piston:
It is a clyindrical component fitted into the clyinder forming the moving boundary
of the combustion system. It forms the first link in transmitting the gas forces to the
output shaft.

Combustion chamber:
The space enclosed in the upper part of the clyinder head and the piston top during
the combustion process, is called the combustion chamber.

Inlet and Exhaust valves:

They are provided either on the cylinder head or on the side of the cylinder for
regulating the charge coming in to the cylinder and for discharging the products of
combustion from the cylinder.
Spark plug:
It is a component to initiate the combustion process in S.I.engines and is usually
located on the cylinder head.

Connecting Rod:
It interconnects the piston and the crankshaft and transmits the gas forces from the
piston to the crankshaft.

Crankshaft:
It converts the reciprocating motion of the piston in to useful rotary motion of the
output shaft. The crankshaft is enclosed in a crankcase.

Gudgeon Pin:
It forms the link between small end of the connecting rod and the piston.

Camshaft:
The camshaft and its associated parts control the opening and closing of two
valves. The camshaft is driven by the crankshaft through timing gears.

Cams:
These are made as integral parts of the camshaft and are designed in such a way to
open valves at the correct timing and to keep them open for the necessary duration.

1.4ENGINE CYCLE:
1.4.1FOUR-STROKE:

Engines based on the four-stroke cycle or Otto cycle have one power stroke for
every four strokes (up-down-up-down) and are used in cars, larger boats and many light
aircraft. They are generally quieter, more efficient and larger than their two-stroke
counterparts. There are a number of variations of these cycles, most notably the Atkinson
and Miller cycles. Most truck and automotive Diesel engines use a four-stroke cycle, but
with a compression heating ignition system. This variation is called the diesel cycle.

The four strokes of the S.I. engine are:

I. Suction or Intake stroke

II. Compression stroke
III. Expansion or Power stroke
IV. Exhaust stroke

I. Suction or Intake stroke:

It starts when the piston is at TDC and about to move downwards. The inlet valve
is open and exhaust valve is closed. Due to suction created by piston, the charge
consisting of fuel-air mixture is drawn into the cylinder. When the piston reaches the
BDC the suction stroke ends and inlet valve closes.

II. Compression stroke:

 The charge taken into the cylinder during the suction stroke is compressed by the
return stroke of the piston. During this stroke both inlet and exhaust valves are in closed
position. The mixture which fills the entire cylinder volume is now compressed into the
clearence volume. At the end of compression stroke the mixture is ignited with the help
of an electric spark between the elecrodes of a spark plug located on the cylinder head.

III. Expansion or Power stroke:

The high-pressure of the burned gases forces the piston towards the BDC,with
both inlet and exhaust valves remaining closed. Thus, power is obtained during this
stroke.

IV. Exhaust stroke:

At the end of the expansion stroke the exhaust valve opens and the inlet valve
remains closed. The piston moves from the BDC to TDC and sweeps the burnt gases
from the cylinder almost at atmospheric pressure. The exhaust valve closes at the end of
exhaust stroke.

1.5OPERATION:

All internal combustion engines depend on the exothermic chemical process of

combustion,the reaction of a fuel, typically with air, although other oxidizers such as
nitrous oxide may be employed.

2. CRANKSHAFT

The crankshaft, sometimes casually abbreviated to crank, is the part of an engine which
translates reciprocating linear piston motion into rotation. 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. The crankshaft was invented by the
inventor Al-Jazari in the 12th century.

2.1CRANK (MECHANISM):

A crank is a bent portion of an axle, or shaft, or an arm keyed at right angles to

the end of a shaft, by which motion is imparted to or received from it; also used to change
circular into reciprocating motion, or reciprocating into circular motion. Familiar
examples of a crank for manual use include the crank on a manual pencil sharpener and
the crank set that drives a bicycle via the pedals.

Cranks were formerly common on some machines in the early 20th century; for
example almost all phonographs before the 1930swere powered by clockwork motors
wound with cranks, and internal combustion engines of automobiles were usually started
with cranks before electric starters came into general use.

2.2CONSTRUCTION OF CRANKSHAFT:
 Crankshafts can be forged or cast from iron. They can be machined out of a single
billet of forged steel. A disadvantage to billet crankshafts is that the grain structure is uni-
directional. The only real advantage to billet crankshafts is its capability to produce very
low amounts of custom designed crankshafts. Untreated mild steel is only used for
engines in models or other such applications, where the engine runs but does not supply
high power. Cast crankshafts are usually found in low cost production engines, where as
now more and more automotive manufacturers are using forged crankshafts in need of its
durability for todays high powered engines (not just high performance cars, but mid-
ranged vehicles). The rough casting or forging is machined to size and shape, the holes
are drilled, the main and connecting rod bearing journals are precision ground and
casehardened, and the appropriate holes are threaded.

2.3CRANKSHAFT GEOMETRY:
Diagram showing geometric layout of piston pin, crank pin and crank center

DEFINITIONS:
l = rod length (distance between piston pin and crank pin)
r = crank radius (distance between crank pin and crank center, half stroke)
A = crank angle (from cylinder bore centerline at TDC)
x = piston pin position (upward from crank center along cylinder bore centerline)
v = piston pin velocity (upward from crank center along cylinder bore centerline)
a = piston pin acceleration (upward from crank center along cylinder bore centerline)
ω = crank angular velocity in rad/s