77201942

International Journal of Research in Advent Technology, Vol.7, No.7, July 2019
E-ISSN: 2321-9637
Available online at www.ijrat.org
21
doi: 10.32622/ijrat.77201942

Abstract— Crankshaft is one of the large components with a
complex geometry in internal combustion engine which
converts the reciprocating displacement of the piston into a
rotary motion. The study was undertaken with the objective
of analysis of single cylinder four stroke engine of Super
Splendor Crankshaft using ANSYS Software for different
materials and optimize the best materials for crankshaft. The
three materials used were Structural Steel, Aluminum Alloy
and Nickel Chromium Molybdenum Steel. The measurement
of crankshaft of bike engine was taken from bike workshop
and model was generated in SolidWorks which was finally
imported in ANSYS for Analysis. The stress analysis and
total deformation was criteria for optimization of crankshaft
materials. The comparative study was done by comparing
both analytical as well as software generated results. The
value of von-misses stresses of analysis is less than the
material yield stress so this design is safe. From this work, the
maximum stress appears at the area between crank journal
and crank cheeks. By comparing von-misses stress values,
Aluminum Alloy has higher strength and shows lower stress
value (146.28 MPa) than other materials. Because of the
more strength, Aluminum Alloy crankshaft can withstand
load and is best materials for crankshaft among three.
Index Terms— Crankshaft, SolidWorks, ANSYS, Stress
Analysis, Super Splendor
I. INTRODUCTION
Crankshaft is one of the critical components of IC engine
with complex geometry that converts the reciprocating
displacement of piston into a rotatory motion [4]. Crankshaft
consists of different parts like journal bearing, crank pin,
crank web and shaft parts. 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 [1]. Ismail al-Jazari
was the first Arabic mechanical engineer to invent crankshaft
[2] . The crankshaft is subjected to the function of bending
torsional loads by the centrifugal force, periodic change of
inertial force and reciprocating inertial force of the rotational
Manuscript revised on August 6, 2019 and published on August 20, 2019
Santosh Kumar Yadav, PG Student Department of Mechanical Engineerin,
Sam Higginbottom University of Agriculture, Technology & Sciences,
Allahabad (Prayagraj), Uttar Pradesh, India
Dr. Earnest Vinay Praksh, Assistant Professor Department of Mechanical
Engineering, Sam Higginbottom University of Agriculture, Technology &
Sciences, Allahabad (Prayagraj), Uttar Pradesh, India
mass [6]. Therefore, the crankshaft must have sufficient
strength and stiffness, the surface of the shaft neck need to
wear, work evenly, and good balance. The reliability and life
of internal combustion engine mainly depend on the strength
of the crankshaft [5]. A large value of the coefficient of
thermal expansion can be a problem when choosing materials
for crankshafts. Ductile iron, forged steel, and titanium are
commonly used as materials for manufacturing shafts like in
the Prosche GT3 RS. Crankshafts made of aluminum
composites reinforced with SiC and graphite are in the
development stage [7].
II. OBJECTIVES
i. To model single cylinder crankshaft using modeling
Software SolidWorks.
ii. To analyze a single cylinder engine crankshaft using
ANSYS Software.
iii. To analyze the crankshaft with different materials for
crank web and crankpin
iv. To optimize the existing crankshaft and provide
optimum design.
Fig 1. Typical Crankshaft of hero Splendor taken from
Workshop
III. DESIGN CALCULATION FOR CRANKSHAFT
The Design calculation of single cylinder petrol engine
crankshaft with specific two wheeler Hero Super Splendor
124.7 CC bike. The engine specification and dimension are
given below in tabulated form:
Design and Analysis of Crankshaft of Single Cylinder Four
Stroke Engine Using ANSYS Software
Santosh Kumar Yadav, Earnest Vinay Prakash

E-ISSN: 2321-9637
22
doi: 10.32622/ijrat.77201942
Table 1. Engine Specification
Table 2. Engine Dimension
Mathematical derivation of Von misses stress and total
deformation using formulas are given below:
 Pressure Calculation
Density of petrol (CgH18):
ρ = 750 kg / m3
Molecular mass of petrol:
M = 114.228 × 10-3
kg / mole
= 750 × 10-9 kg / mm3
Operating Temperature:
T = 20 0
C
= 20 + 273.15
= 293.15 0
k
Gas constant for petrol:
R = 72.7868 × 103
J / kg / mo l K
Mass of displacement:
m = ρ × V
= (750 × 10-9
) × (124.7 × 103
)
= 0.0935 kg Where,
ρ = Density
V= Volume
We know that PV = mRT
P × 124.7 × 103
= 0.0935 × 72.7868 × 103
× 293.15
P=
P=16.003 MPa
 Design Calculation for Gas force
Design of crankshaft when the crank angle is at the
angle of maximum bending moment
Gas force (Fp) =?
We have
Fp = P X A
=16.003X (
=16.003X (0.7854X52.4X52.4)
=34.51 KN
Distance between two bearings is given by
b = 2D = 2X52.4= 104.8 mm
b1=b2=52.4 mm
Due to the piston gas load (Fp) acting horizontally there
will be the two horizontal reactions H1 and H2 at the
bearings 1 and 2 respectively, such that
H1 = H2 = Fp/2 = 17.255 KN
 Design of crankpin
Moment on crankpin =
M max = X
= 17.255X103
X 20
= 345.1X103
Nmm
Torque obtained at Max. Power of hero splendor
P =
11.2X103
=
T= 14.26 Nmm
Von- misses stress
Where,
von = Meq = Equivalent bending moment
So, Equivalent bending moment is given by
Meq = [(Kb X Mmax)2
+ (Kt X T)2
Here, Kb = Combined shock and fatigue for bending = 1
Kt = Combined shock and fatigue for torsional = 1
Mmax = Bending moment
Meq = [(1X345.1X103
)2
+ (1X14.26X103
)2
Meq = 345.32X103
Nmm
Section modulus of crankpin
Z= X dc X dc X d
=0.098175X 28X28X28
=2155.132 mm3
Now,
von =
= 160.227 MPa
Equivalent twisting moment
Teq = ( Mmax
2
+ T2
Teq = [ (345.1X103
)2
+ (14.26X103
)2
Teq = 345.48X103
Nmm
Now,
Teq =
Parameter Value
Engine Type 4 Cycle, 1 Cylinder, Air Cooled
Valve System OHC, 2 VALVE
Cylinder Bore 52.4 mm
Stroke 57.8 mm
Displacement 124.7 cm3
Compression ratio 10:1
Maximum Power 11.20 PS @ 7500 rpm
Maximum Torque 11 NM @ 6500 rpm
Symbol Parameter Value
D Piston Diameter 52.4 mm
lc Length of crankpin 40 mm
dc Diameter of crankpin 28 mm
L Stroke 57.8mm
ds Shaft Diameter 22 mm
T Thickness of crank web 30 mm
W Width of crank web 30 mm
R Shaft center to web center 29 mm

E-ISSN: 2321-9637
23
doi: 10.32622/ijrat.77201942
345.48X103
=
= 80.15 N/ mm2
Stain for Structural Steel Stain for Aluminum Alloy
ε = ε =
= =
=0.00225 =0.00225
Strain for Nickel Chromium Molybdenum Steel
ε =
=
= 0.00080113
IV. DESIGN METHODOLOGY
A. Procedure for Static Analysis
First, we modeled the crankshaft in SolidWorks and saved it
as .IGES file format for Analysis of crankshaft in ANSYS
software. The imported .IGES model is simulated in ANSYS
Workbench.
The dimension of crankshaft taken from workshop is
modelled in SolidWorks software. The modeled assembly of
crankshaft is shown below:
Fig 2. Crankshaft assembly modeled in SolidWorks
B. Loading and boundary condition
Boundary condition play important role in FEA[9]. Here we
have taken fixed support at both bearing. The given below
illustrate the boundary condition of crankshaft. The force of
34.51 KN is applied in Crankpin of crankshaft. The blue
colour mark illustrate fixed support and red coulur illustrate
application of gas force as given in fig. 3
C. Meshing of crankshaft
Meshing is the most important part in any of the computer
simulations, because it can show drastic changes in results
you get. Tetrahedral meshing is done because the tetrahedral
meshing methodology is utilized for the cross section of the
strong district geometry and meshing delivers fantastic cross
section for boundary representation of solid auxiliary model.
Method: Tetrahedrons
Number of nodes: 16625
Numbers of elements: 9148
Fig 3 Application of Load and Gas Force
Fig 4. Meshing of crankshaft in ANSYS
D. Application of Materials for Analysis
There are total three materials are used for this solid
model structural steel, aluminum alloy and nickel
chromium molybdenum steel. The material properties of
the crankshaft is given below:
I. Structural Steel
Density=7850 Kg/m3
Yield Tensile Strength= 250 MPa
Poison Ratio= 0.3
Modulus of Elasticity= 200 GPa
II. Aluminum Alloy
Density=2770 Kg/m3
Yield Tensile Strength=280Mpa
Ultimate Tensile Strength=310Mpa
Poison Ratio=0.33
Modulus of Elasticity=71 Gpa

E-ISSN: 2321-9637
24
doi: 10.32622/ijrat.77201942
III. Nickel Chromium Molybdenum Steel
Density=7850 Kg/m3
Yield Tensile Strength= 550 MPa
Ultimate Tensile Strength= 620 MPa
Poison Ratio= 0.285
Modulus of Elasticity= 200 GPa
E. Linear Static Analysis of Crankshaft
After the application of boundary condition and force, the
next step is to perform static analysis in ANSYS software.
We are mainly concern with the von mises stress and total
deformation. The crankshaft is checked for von-misses stress
and analytical calculation with different three materials for
the validation of work.
Fig 5 Von- misses stress for Structural steel
Fig 6 Von- misses stress for Aluminum alloy
Fig 7 Von- misses stress for NCM steel
Since crankshaft consists of different parts like crank web,
journal shaft, crankpin and main shaft. The crankpin is the
important part of crankshaft assembly as gas force is
indirectly applied to crankpin through connecting rod. So we
have carried out our analysis by taking one material for
crankpin and other materials for rest part of crankshaft
assembly among three used materials for best result out of
these combination.
Fig 8. Web made of structural steel & crankpin made
of NCM steel
Fig 9. Web made of NCM steel & crankpin made of
Structural steel
Fig 10. Web made of structural steel & crankpin made of
Aluminum Alloy

E-ISSN: 2321-9637
25
doi: 10.32622/ijrat.77201942
Fig 11. Web made of Aluminum alloy& crankpin
made of structural steel
Fig 12. Web made of Aluminum alloy & crankpin
made of NCM steel
Fig 13. Web made of NCM steel & crankpin
The software result obtained with different materials for Von
Misses stress in different condition of web and crankpin
materials are given below:
Table 3. Von misses stress value for different materials
S.N. Materials Condition Von misses
stress
1 Only Structural Steel 148.95
2 Only Aluminum Alloy 146.28
3 Only Nickel Chromium
Molybdenum Steel
150.21
4 Webs made of Structural steel and
crankpin as Aluminum alloy
301.42
5 Webs made of Aluminum Alloy and
crankpin as structural steel
166.51
6 Webs made of NCMS and crankpin
as aluminum alloy
302.66
7 Webs made of aluminum alloy and
crankpin as NCMS
167
8 Webs made of NCMS and crankpin
as structural steel
150.28
9 Webs made of structural steel and
crankpin as NCMS
148.89
The total deformation obtained for different materials of
crankshaft using ANSYS software are given below:
Fig 14. Total deformation for structural steel
Fig 15. Total deformation for Aluminum Alloy
Fig 16. Total deformation for NCM steel

E-ISSN: 2321-9637
26
doi: 10.32622/ijrat.77201942
Table 4. Total deformation for different materials
S.N Materials Type Software Results (m)
1 For Structural Steel 9.27E-6
2 For Aluminum Alloy 2.624E-5
3 For Nickel Chromium Molybdenum Steel 9.244E-6
V. RESULT AND DISCUSSION
From above analysis we can see that there is total three
materials used for analysis and got the different result with
different parameters, from analysis it is found that the
Aluminum alloy is best of them. Usually crankshaft is made
from steel by using casting or forging but we can use
aluminum alloy as a material for crankshaft making. We can
see that crankshaft is made of combination of different parts
like crank webs, crankpin, bearing supports, etc. among them
crank webs and crankpin are important parts. Crank webs are
used for weight balancing and crankpin are components were
Pressure of gas is applied and is responsible for conversion of
reciprocating motion into rotatory.
Thus we have used different materials for overall design of
crankshaft as crankpin is made of one material and rest part
are made of another one to check the von misses stress and
total deformation under same condition of loading. From this
analysis we get Webs made of structural steel and crankpin
made from nickel chromium molybdenum steel is the second
best combination for crankshaft design. Von misses stress for
aluminum alloy is 146.28 MPa. The crankshaft chosen for
this project is Hero Super Splendor 124.7 CC. Comparing
chat of three materials is as below:
Table 5. Comparative table for Stress analysis
S.N. Materials Condition Analytical value (MPa) Von misses stress
1 Only Structural Steel 160.227 148.95
2 Only Aluminum Alloy 160.227 146.28
3 Only Nickel Chromium Molybdenum Steel 160.227 150.21
4 Webs made of Structural steel and crankpin as Aluminum alloy 160.227 301.42
5 Webs made of Aluminum Alloy and crankpin as structural steel 160.227 166.51
6 Webs made of NCMS and crankpin as aluminum alloy 160.227 302.66
7 Webs made of aluminum alloy and crankpin as NCMS 160.227 167
8 Webs made of NCMS and crankpin as structural steel 160.227 150.28
9 Webs made of structural steel and crankpin as NCMS 160.227 148.89
Table 5. Comparative table for total deformation
S.N. Materials Types Analytical results
(mm)
Software analysis Results
(mm)
1 For Structural Steel 8.0113E-4
9.27E-6
2 For Aluminum Alloy 2.257E-3
2.624E-5
3 For NCM Steel 8.0113E-4
9.244E-6

E-ISSN: 2321-9637
27
doi: 10.32622/ijrat.77201942
VI. CONCLUSION
The following conclusion can be drawn from the result of
crankshaft analysis
a. Three different materials were used for the analysis of
crankshaft as structural steel, aluminum alloy and Nickel
Chromium molybdenum steel
b. The maximum stress appears at the area between crank
journal and crank cheeks
c. The value of von-misses stresses of analysis is less than
the material yield stress so this design is safe.
d. Crankshaft made of aluminum alloy has highest strength
and show minimum value of von misses stress (146.28
Mpa)
e. Crankshaft is made of combination of different parts like
crank webs, crankpin, bearing supports, etc. among them
crank webs and crankpin are important parts.
f. Since, force is directly applied at the crankpin of
crankshaft so a different combination of materials in
same crankshaft is used to find best materials. we
obtained Webs made of structural steel and crankpin
made from nickel chromium molybdenum steel has least
value of von misses stress (148.89 Mpa)
VII. FUTURE SCOPE
The analysis of crankshaft can be done in various way beside
follows in this works. The design analysis can be explained
by taking different constraints other static analysis and with
different simulation software. The future scope of this works
can be tabulated below:-
a. Analysis can be done with other materials of higher
strength and low weight materials.
b. Vibration and fatigue analysis can be done to estimate life
of crankshaft
c. Economic analysis for different combination of materials
in single crankshaft can be in future.
VIII. AKNOWLEDGEMENT
I would like convey my deep sense appreciation to prof. (dr.)
Anshuka Srivasatava, Prof. (Dr.) S.C. Moses, Er. Rahul
Francis Charles for their guidance and care in each and every
step of preparing the research. I am grateful to Er. Rajesh
Ranjan Mishara, Er. Rupesh Shah, Er. Avinash Singh and
pursuing engineer Mr. Shuvam Shingh for their timely help
without whom support this paper could not touch the final
layout.
REFERENCES
[1] D. Harshada, J. Ashwini, L. Madhura and P.Yadav .‖ Design, Analysis &
Optimization of Crankshaft Using CAE‖, IIJME, Vol 4,Issue 4 ,2016
[2] J. Joshi and D.M. Patel, ―Design and failure analysis of single cylinder
petrol engine crankshaft usisng ANSYS software‖, International
journal of engineering science and computing, Vol. 7 Issue No. 4,2017
[3] S.Bhagya Lakshmi ., Sudheer Kumar V, Ch. Nagara ju ―Dynamic
Analysis of Honda Engine Crankshaft‖, International Journal of
Engineering and Innovative Technology ,Vol. 2, Issue 1, pp. 174-178),
2012.
[4] R. K. Rajput, ―A Textbook of Internal Combustion Engines‖, Laxmi
Publication (P) Ltd. (2009)., ch 2 , pp 20-22.
[5] P. N. Rohini, S. Nagu ―Design and Optimization of IC Engine
Crankshaft‖, International Journal of Engineering Sciences & Research
Technology ISSN: 2277-9655, pp 931-937, 2014.
[6] R. G .Dubensky,. ―Crankshaft Concept Design Flowchart for Product
Optimization‖, SAE Technical Paper No. 2002-01-0770, Society of
Automotive Engineers, 2002.
135
140
145
150
155
160
165
structural steel aluminumalloy Nickel Chromium Molybdenum
steel
stressinMpa
materialstype
Comparative Chart
analytical Results (Mpa) Software Results (Mpa)
Chart 1. Von Misses Stress for different materials of Crankshaft

E-ISSN: 2321-9637
28
doi: 10.32622/ijrat.77201942
[7] A .Hallal, A .Elmarakbi, A .Shaito, & H. El-Hage, Overview of
Composite Materials and their Automotive Applications. Advanced
Composite Materials for Automotive Applications, 1–28. 2013.
[8] H .Farzin. Montazersadgh and A. Fatemi ―Stress Analysis and
Optimization of Crankshafts Subjected to Dynamic Loading‖, AISI,
2007.
[9] G.H. Farrahi, S.M. H-Gangaraj, M. Sakhaei, S. Abolhassani F. Hemmati
―Failure Analysis of a Four Cylinder Diesel Engine Crankshaft Made
From Nodular Cast Iron‖, the Journal of Engine Research/Vol. 22 /
Springer,2014.
[10] R. Gligorijevic, J .Jevtic, G. Vidanovic, and N .Radojevic, ―Fatigue
Strength of Nodular Iron Crankshafts‖, SAE Technical Paper No.
2001-01-3412, Society of Automotive Engineers, 2001.
AUTHORS PROFILE
Santosh Kumar Yadav has completed BE from
Paschimancahl Engineering Campus (TU, Nepal) and
M. Tech from SHUATS India in Mechanical
Engineering. His area of interest is Automobile and
Production Engineering. Santosh was awarded
Scholarship for M tech by Gov. of India. He has
attended many Seminar and Conferences relating
mechanical engineering. He has excellent
understanding in Modeling and Simulation Software
like AutoCAD, SolidWorks and ANSYS. He has
organized various Workshop in SolidWorks as a Trainer in
College.
Email- santosh.rhythm341@gmail.com
Dr. Earnest Vinay Prakash has accomplished BE
from R.G.T.U. Jabalpur, M tech and PhD from
SHUATS Prayagraj and presently working as Assistant
Professor at SHUATS. He has published many
research paper in National and International journals.
Dr. Vinay has attended many Seminars and
Conferences.
Email- earnest.prakash@shiats.edu.in

77201942

More Related Content

77201942