Optimization of the crankshaft using finite element analysis approach

Abstract

Crankshaft is one of the most critical components for effective and precise working of the internal combustion engine. In this paper, a static structural and dynamic analysis was conducted on a single cylinder four-stroke diesel engine crankshaft. A solid model of the crankshaft was created using higher-end computer-aided design software, i.e., Pro/Engineer software according to the dimensional details drawing of the existing crankshaft. Finite element analysis was performed using ANSYS software under the static and dynamic condition to obtain the variation of stresses at different critical locations of the crankshaft. Boundary conditions were applied on finite element model in accordance with engine specification chart and engine mounting conditions. Optimization of the crankshaft was studied in the area of geometry and shape on the existing crankshaft; however especially working on geometry and shape optimization, the optimized crankshaft design should be replaced with existing crankshaft, without changes in the engine block and cylinder head. The optimized crankshaft helps to improve the performance of the engine and causes reduction in weight. This optimization study of the crankshaft helps to reduce 4.37% of the weight in the original crankshaft.