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Crankshaft Design and Analysis: April 10, 2014
Crankshaft Design and Analysis: April 10, 2014
,
_
,
_
,
_
x
y
n
n
y
x
n
x
y
T
T
P
P
1
1
,
_
sin arcsin
b
r
-iston displa*e'ent
( ) ( ) ( ) ( ) r b b r s + cos cos
-iston area
( )
4
2
Bore
A
p
,
_
4 4 1
A Stroke
A
V
V
V
V V
V
V
p
nt displaceme
TDC
TDC
nt displaceme TDC
TDC
tot
,
_
+ Stroke
Stroke
A V
p tot
4
Cylinder 1olu'e
( ) ( )
p tot
A s V V
&ntake 1olu'e
( )
p tot
A s V V 1A0
int
&ntake pressure
kPa P D2
int
&ntake te'perature
K T B22
int
-ressure during *o'pression
( )
( )
int
int
P
V
V
P
n
comp
,
_
,
_
Co'bustion te'perature
The a'ia+atic (lame temperat)re o( gasoline -octane. is 22C2 ;* The engine ma9
temperat)re is +ase' on 20H o( the a'ia+atic (lame temperat)re o( gasoline*
( )( ) 20BC 22C2 2 * 0 K T
AFT
-re2*o'bustion pressure
( )
int
int
BDD
P
V
V
P
n
comb pre
,
_
-re2*o'bustion te'perature
( )
int
1
int
BDD
T
V
V
T
n
comb pre
,
_
Co'bustion pressure
comb pre
comb pre
AFT
comb
P
T
T
P
,
_
,
_
)
(
k
P
a
)
Gas for*e
( ) ( ) ( )
atm p as
P P A F
Gas Force, Fgas()
-2000.00
0.00
2000.00
4000.00
6000.00
8000.00
10000.00
12000.00
14000.00
0 100 200 300 400 500 600 700 800
crankshaft angle, (degrees)
g
a
s
f
o
r
c
e
,
F
g
a
s
(
)
(
N
)
-iston displa*e'ent
( ) ( )
2 2 2
. sin- cos r b r ! +
-iston 1elo*ity
2 2 2
2
. sin-
. cos- . sin- 2
. sin- 2 . -
r b
r
r V
p
-iston a**eleration
( )
( )
( )
2 2 2
2 2 2 4
B
2 2 2
2
2
2 2
. sin-
. cos- . sin- 4
. sin-
. cos- . sin- 4
. cos- 4 . -
r b
r
r b
r
r a
p
-iston body for*e
( )
p p p body
a m F
,
.or*e on *rankshaft due to gas and piston body for*es
( ) . cos-
r c
F F
0or/ue on *rankshaft due to gas and piston body for*es
( ) . cos- . cos- r F T
p
Conne*ting 3od .or*es
3od 42position
( ) . sin- 1
2 1
1
r
L L
L
x
r
,
_
+
3od 421elo*ity
( ) . cos- 1 2
2 1
1
,
r
L L
L
V
x r
,
_
+
3od 42a**eleration
( ) . sin- 1 4
2 2
2 1
1
,
r
L L
L
a
x r
,
_
+
3od y2position
( ) ( )
2 2 2
2 1
1
. sin- cos r b
L L
L
r y
r
,
_
+
+
3od y21elo*ity
( )
2 2 2
2 1
2
1
,
. sin- . -
. sin- . cos- 2
. sin- 2
r b L L
r L
r V
y r
+
3od y2a**eleration
( )
( )
( )
( )
,
_
,
_
+
+
2 2 2
2 2 2 2 2
2
B
2 2 2
2 2 2 2
2 1
1 2 2
,
. sin-
cos . sin- 4
. sin-
. sin- . cos- 4
. cos- 4
r b
r
r b
r
L L
L
r a
y r
3od e/ui1alent 'ass
r e"#i$ r
m
L L
L
m
,
_
2 1
1
,
Body 42for*e
( )
e"#i$ r x r x
m a F
, ,
Body y2for*e
( )
e"#i$ r x r y
m a F
, ,
0or/ue on *rankshaft due to rod body for*es
( ) ( ) ( ) sin cos r F r F T
y x r
.or*e on *rankshaft due to rod body for*es
( ) ( ) ( ) sin cos
, x y r body
F F F +
0hrow .or*es
Centripetal for*e
2
,
C0
2
,
_
cm throw throw centrip
X m F
0otal .or*es
0or/ue
( )
p r as
T T T T + +
Body for*e on 'ain shaft
( )
throw centrip r body p body body
F F F F
, , ,
+ +
.or*e of one *ylinder
( )
as body cyl
F F F +
Force of One Cylinder, Fcyl()
-6,000
-4,000
-2,000
0
2,000
4,000
6,000
8,000
10,000
12,000
14,000
16,000
0
2
5
5
0
7
5
1
0
0
1
2
5
1
5
0
1
7
5
2
0
0
2
2
5
2
5
0
2
7
5
3
0
0
3
2
5
3
5
0
3
7
5
4
0
0
4
2
5
4
5
0
4
7
5
5
0
0
5
2
5
5
5
0
5
7
5
6
0
0
6
2
5
6
5
0
6
7
5
7
0
0
crankshaft angle, (degrees)
f
o
r
c
e
(
N
)
cylinder force, Fcyl() body force, Fbody() gas force Fgas()
D* ST"ESS A6AF#SS
d +earing 'iameter
Area
4
2
d
A
)o'ent of inertia
C4
4
d
&
0orsion
%
Td
torsion
2
. -
( )
c
F
Bearing rea*tion for*es
( ) ( ) ( ) ( )
1
]
1
+
b a
a
F ' F '
c B c A
1
( )
( )
b a
a F
'
c
B
+
Shear for*e
( ) ( )
A
' V
0rans1erse shear stress
A
V
trans$erse
B
4
. -
0otal shear stress
( )
torsion trans$erse
+
Bending 'o'ent
( )
entration StressConc A
X ' (
( )
B
'
( )
A
'
Stress Concentration
Total Shear Stress on Output earing, !() and ending "o#ent, "()
-6
-4
-2
0
2
4
6
8
10
12
14
0 50 100 150 200 250 300 350 400 450 500 550 600 650 700
crankshaft angle, (degrees)
t
o
t
a
l
s
h
e
a
r
s
t
r
e
s
s
,
!
(
)
(
"
P
a
)
-1,500
-1,000
-500
0
500
1,000
1,500
2,000
$
e
d
n
i
n
g
#
o
#
e
n
t
,
"
(
)
(
N
#
)
sear s!ress, "() bending #o#en!, $()
Bending stress
( )
&
(d
bend
2
Total Shear Stress, !() and ending Stress, %$end()
-60
-40
-20
0
20
40
60
80
100
0
2
0
4
0
6
0
8
0
1
0
0
1
2
0
1
4
0
1
6
0
1
8
0
2
0
0
2
2
0
2
4
0
2
6
0
2
8
0
3
0
0
3
2
0
3
4
0
3
6
0
3
8
0
4
0
0
4
2
0
4
4
0
4
6
0
4
8
0
5
0
0
5
2
0
5
4
0
5
6
0
5
8
0
6
0
0
6
2
0
6
4
0
6
6
0
6
8
0
7
0
0
7
2
0
crankshaft angle, (degrees)
s
t
r
e
s
s
(
"
P
a
)
sear s!ress, "() bending s!ress, %bend()
54pe*ted fatigue life
$e ass)me that the cran&sha(t %ill +e e9pecte' to last (or aro)n' 200000 miles at an
average spee' o( C0 miles per ho)r at an average o( B000 revol)tions per min)te*
cycles e
re$
ho#r miles
ho#r
miles cycles crank
A
C
min 1
B000
1
min C0
C0
1
. 000 , 200 - I
,
_
,
_
,
_
Bending stress
>rom o)r sprea'sheet 'ata
(Pa
(Pa
b
b
BA * 4
11D
min ,
ma9 ,
(Pa (Pa
(Pa (Pa
nom m
nom a
B * C1
2
BA * 4 11D
D4
2
BA * 4 11D
,
,*
,
_
,
_
Stress Con*entration
(illet ra'i)s r J 1*DA4D mm, ' J DA mm, D J 4C mm,
B1 * 1
d
D
,
0024B * 0
d
r
>rom >ig)re E12 -all ta+les an' (ig)res (rom 6orton3s Machine DesignG An ntegrate'
Approach.
A J 0*2C0, + J 10*2B1
Stati* stress *on*entration fa*tor
21 * 2
DA
DA4D * 1
. 2C0 * 0 - . -
2B1 *
,
_
,
_
b
t
d
r
A K
>rom Ta+le C*C (or
kpsi S
#t
AC
044 * 0 I K a n#mber s )e#ber
6ot*h sensiti1ity
D14 * 0
00C2D * 0
044 * 0
1
1
1
1
,
_
r
a
"
.atigue stress *on*entration fa*tor
CB * 1 . 1 21 * 2 .- D14 * 0 - 1 . 1 - 1 + +
t *
K " K
Since
(Pa S (Pa (Pa K
y nom *
424 1A4 . 11D - CB * 1
ma9,
<
CB * 1
* *m
K K
(Pa (Pa K
(Pa (Pa K
nom m *m m
nom a * a
4 * 22 . B * C1 .- CB * 1 -
0 * AA . D4 .- CB * 1 -
,
,
Shear stress *on*entration fa*tor
Since
(Pa S (Pa (Pa K
y nom *
B42 4 * 12 . C0 * 4 - CB * 1
ma9,
<
CB * 1
* *m
K K
(Pa (Pa K
(Pa (Pa K
nom m *m m
nom a * a
DD * B . 1A * 2 .- CB * 1 -
A0 * A . 41 * D .- CB * 1 -
,
,
Von )ises stress
(Pa
(Pa
m xy m y m x m y m x m
a xy a y a x a y a x a
2 * 22 . DD * B .- B - . 0 .- 4 * 22 - . 0 - . 4 * 22 - B
0 * A2 . A0 * A .- B - . 0 .- 4 * A4 - . 0 - . 4 * A4 - B
2 2 2 2
, , ,
2
,
2
,
K
2 2 2 2
, , ,
2
,
2
,
K
+ + + +
+ + + +
C* 6TE"6AF >AT<UE A6AF#SS
Since the cran&sha(t is e9pecte' to last over a million cycles, %e ass)me in(inite li(e (or
(atig)e analysis*
7n*orre*ted enduran*e li'it
( ) ( ) (Pa (Pa S S
#t e
B4B 44D D * 0 D * 0
K
(or steel,
(Pa (Pa S
#t
1400 44D <
Corre*tion fa*tors
1
load
C
(or primarily +en'ing
>or a rotating soli' sha(t
A02 * 0 . DA - 1A2 * 1 . - 1A2 * 1
024 * 0 024 * 0
d C
si+e
>rom >ig)re C*2C (or polishe'
2 * 0
s#r*
C
>or C T
4D0
1
temp
C
4DB * 0 H 2 * 22 L
y reliabilit
C
1
en$
C
S
e
C
load
C
size
C
reliab
C
surf
C
temp
C
env
S
e
'
(Pa (Pa S
e
202 . B42 .- 1 .- 1 .- 2 * 0 .- 4DB * 0 .- A02 * 0 .- 1 -
.a*tor of safety
Ass)ming that
m
a
'
K
K
J constant
44 * 1
. 202 .- 2 * 22 - . 44D .- A2 -
. 44D .- 202 -
. .- - . .- -
. .- -
K K
+
,
_
,
_
d
C
l
d
n
P
,
d a$e
)
min
2
1
d
h
C
( )( )
( )
( )( )
rps
m
m -
mm
mm
s Pa -
Pa -
d
h
l
d
,
P
n
)
a$e
4 * A4
A2 * 0 1 0DA * 0
C 4D * D 2
2D
DA
B0 M B 1D
C 02 * C
. 1 -
2
2 2
2
min
2
K
,
_
,
_
,
_
,
_
,
_
,
_
rpm
rps n
D * 1
C0
4 * A4
C0
K
min
3od Bearing
)a4i'u' for*e on rod bearing fro' spreadsheet data
k) F
rod
BC * 2
ma9 ,
A1erage oil pressure
( )( )
(Pa
m m
k)
ld
F
P
cyl
a$e
A0 * 4
04A * 0 02D * 0
BC * 2
ma9 ,
!il 1is*osity
=il viscosity (or SAE B0$ engine oil L
1A0 T F
s mPa cP M 1D 1D
)ini'u' 3-) for full2fil' lubri*ation
( )( )
( )
( )( )
rps
m
m -
mm
mm
s Pa -
(Pa
d
h
l
d
,
P
n
)
a$e
11B
A2 * 0 1 04A * 0
C 4D * D 2
2D
4A
B0 M B 1D
A0 * 4
. 1 -
2
2 2
2
min
2
K
,
_
,
_
,
_
,
_
,
_
,
_
rpm
rps n
A2 * 1
C0
11B
C0
K
min
The minim)m "0M is (ar +elo% i'le spee' o( aro)n' 200 "0M*
A* C=6CFUS=6
The cran&sha(t can %ithstan' the (orces applie' %ith a minim)m (actor o( sa(ety o( 1*44*
>)ll (ilm l)+rication is maintaine' in the +earings (rom 1*A2 "0M thro)gh re'line* The
()ll1(ilm l)+rication is accomplishe' only %hen the p)mp can provi'e a'e8)ate press)re*
"ealistically, the p)mp cannot provi'e s)((icient press)re )ntil appro9imately i'le spee'*
There(ore, ()ll1(ilm l)+rication li&ely occ)rs at aro)n' i'le spee'*
2* "E>E"E6CES
&'ngine For#(la.& 4-)!ro*e. 'ngineers 'dge. + ,ec. 2005
-!!./00111.engineersedge.co#0engine2for#(la2a(!o#o!i3e.!#4.
5or!on, 6ober! 7. $acine ,esign, an 8n!egra!ed 9..roac. 3rd ed. / :orces!er ;ol(!ecnic
8ns!i!(!e, 2005.
6ollins, $i*e. &:a! is !e ).eed of a ;is!on 1i! an offse! cran*saf!<.& 13 $ay. 2006.
-!!./00111.1f(.ed(0=rollins0.is!on0offse!04.