A PROJECT REPORT ON

Analysis of Crankshaft on Catia V5 and Ansys

Software

Submitted in partial fulfillment for the award of the degree of

Bachelor of Technology
In

Mechanical Engineering
From

Dr.A.P.J. Abdul Kalam Technical University

2016-2020

Guided by Submitted By
Mr. Rahul Sharma Shivam Swami
(Assistant Prof.) Sagar Mal
(Mechanical department) Sangram Singh
Lovish Kumar
Moral
Sanshay Tawra

Submitted to.
Department of Mechanical Engineering.
MEERUT INSTITUTE OF ENGINEERING AND TECHNOLOGY,
MEERUT
 DECLARATION

We hereby declare that the project work entitled “Analysis of Crankshaft

on Catia V5 and Ansys Software” submitted to the MIET, Meerut, is a record of
an original work done by our group under the guidance of Mr. Rahul Sharma
(Assistant prof.) , Department of Mechanical Engineering, Meerut Institute of
Engineering and Technology, Meerut and this project work is submitted in the
partial fulfillment of the requirements for the award of the degree of Bachelor of
Technology in Mechanical Engineering . The result embodied in the report have
not been submitted to any other University or Institute for the award of any degree
or diploma.

Date: Declare by:

Shivam Swami

Sagar Mal

Sangram Singh

Lovish Kumar Moral

Sanshay Tawra
 ACKNOWLEDGEMENT

We have taken efforts in this project. However, it would not have been possible
without the kind support and help of our guide and college. we would like to
extend our sincere thanks to them.
We are highly indebted to Mr. Rahul Sharma (Assistant Prof.) for their guidance
and constant supervision as well as for providing necessary information regarding
the project & also for their support in completing the project.
We would like to express our gratitude towards our parents & member of (Meerut
Institute of Engineering and Technology, Meerut) for their kind co-operation
and encouragement which help us in completion of this project.

Our thank and appreciations also go to our colleague in developing the project and
people who have willingly helped us out with their abilities.

Acknowledge by:

Shivam Swami

Sagar Mal

Sangram Singh

Lovish Kumar Moral

Sanshay Tawra
 CONTENT

 INTRODUCTION

 OBJECTIVE

 MODELING AND MESHING OF CRANKSHAFT

 INTRODUCTION TO FEA AND ANSYS

 ANALYSIS

 RESULT AND DISCUSSION OF CAST IRON

CRANK SHAFT

 RESULT AND DISCUSSION OF ALUMINIUM

ALLOY CRANK SHAFT

 COMPARISON OF RESULT

 CONCLUSION
 ABSTRACT:

Crankshaft is large volume production component with a complex

geometry in the Internal Combustion (I.C) Engine. This converts the
reciprocating displacement of the piston in to a rotary motion of the
crank. An attempt is made in this paper to study the Static analysis on a
crankshaft from a single cylinder 4-stroke I.C Engine. The modeling of
the crankshaft is created using CATIA-V5 Software. Finite element
analysis (FEA) is performed to obtain the variation of stress at critical
locations of the crank shaft using the ANSYS software and applying the
boundary conditions. Then the results are drawn Von-misses stress
induced in the crankshaft is 16.315Mpa and shear stress is induced in the
crankshaft is 8.3428Mpa. The Theoretical results are obtained von-
misses stress is 19.6Mpa, shear stress is 9.28Mpa. The validation of
model is compared with the Theoretical and FEA results of Von-misses
stress and shear stress are within the limits. Further it can be extended
for the different materials and dynamic analysis of crank shaft.
I. INTRODUCTION:
Crank shaft is a large component with a complex geometry in the I.C engine,
which converts the reciprocating displacement of the piston to a rotary motion with
a four bar link mechanism. Crankshaft consisting of shaft parts, two journal
bearings and one crankpin bearing. 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. In addition,
the linear displacement of an engine is not smooth; as the displacement is caused
by the combustion chamber therefore the displacement has sudden shocks. The
concept of using crankshaft is to change these sudden displacements to as smooth
rotary output, which is the input to many devices such as generators, pumps and
compressors. It should also be stated that the use of a flywheel helps in smoothing
the shocks. Crankshaft experiences large forces from gas combustion. This force is
applied to the top of the piston and since the connecting rod connects the piston to
the crank shaft, the force will be transmitted to the crankshaft. The magnitude of
the forces depends on many factors which consist of crank radius, connecting rod
dimensions, weight of the connecting rod, piston, piston rings, and pin.
Combustion and inertia forces acting on the crankshaft. 1. Torsional load 2.
Bending load. Crankshaft must be strong enough to take the downward force of the
power stroke without excessive bending so the reliability and life of the internal
combustion engine depend on the strength of the crankshaft largely. The crank pin
is like a built in beam with a distributed load along its length that varies with crank
positions. Each web is like a cantilever beam subjected to bending and twisting. 1.
Bending moment which causes tensile and compressive stresses. 2. Twisting
moment causes shear stress. There are many sources of failure in the engine one of
the most common crankshaft failure is fatigue at the fillet areas due to the bending
load causes by the combustion. The moment of combustion the load from the
piston is transmitted to the crankpin, causing a large bending moment on the entire
geometry of the crankshaft. At the root of the fillet areas stress concentrations exist
and these high stress range locations are the points where cyclic loads could cause
fatigue crank initiation leading to fracture.
III. OBJECTIVE:

An attempt in this paper, the crankshaft is modeled by using CATIA-V5 software,

and static analysis is done by using ANSYS Workbench software. To evaluate the
von-misses stress and shear stress.

MODELING AND MESHING OF THE CRANKSHAFT

Figure: - 1.1. Model of the crankshaft and meshing

 Figure: - 1.2. Mesh detail of the crankshaft using ANSYS

Introduction to FEA: The basis of FEA relies on the decomposition of the

domain into a finite number of sub-domains (elements) for which the systematic
approximate solution is constructed by applying the variational or weighted
residual methods. In effect, FEA reduces problem to that of a finite number of
unknowns by dividing the domain into elements and by expressing the unknown
field variable in terms of the assumed approximating functions within each
element. These functions (also called interpolation functions) are defined in terms
of the values of the field variables at specific points, referred to as nodes. The finite
element method is a numerical procedure that can be used to obtain solutions to a
large class of engineering problems involving stress analysis, heat transfer, electro-
magnetism, and fluid flow.
Introduction to ANSYS Software:
ANSYS is general-purpose Finite Element Analysis (FEA) software package.
Finite Element Analysis is a numerical method of deconstructing a complex system
into very small pieces (of user designed size) called elements. The software
implements equations that govern the behavior of these elements and solves them
all; creating a comprehensive explanation of how the system acts as a whole. The
ANSYS Workbench environment is an intuitive up-front finite element analysis
tool that is used in conjunction with CAD systems and/or Design Model. ANSYS
Workbench is a software environment for performing structural, thermal, and
electromagnetic analyses. The Workbench focuses on attaching existing geometry,
setting up the finite element model, solving, and reviewing results.
Static Analysis on Cast Iron Crankshaft:
Used to determine displacements, Stresses, Strain, Deformation etc. under static
loading conditions in both linear and nonlinear static analysis. Nonlinearities
include plasticity, stress stiffening, large deflection, large strain, hyper elasticity,
contact surfaces, and creep.

Apply Material for crankshaft (cast iron).

Material Type: cast iron
Young modulus: 1.78e+005Mpa
Poisson’s ratio: 0.3
Density: 7.197e-006kg/mm³
RESULTS AND DISCUSSION:
Analysis of crankshaft-cast Iron

Figure: - 2.1 Apply Boundary condition the crankshaft

The two ends of the crankshaft are to be fixed, the load 3.5 Mpa is applied on the top of the crankpin surface.
 Figure: - 2.2 crankshaft voin-misses stress
The maximum stress induced in the crankshaft is 16.315 Mpa at the crankpin neck surface. Minimum stress
1.1026e-10 Mpa.

Figure: - 2.3 Maximum stress induced in the crankpin area

Maximum stress induced in the Crankshaft is 16.315 Mpa at the fillet areas.

Figure:-2.4 crankshaft shear stress

The Maximum shear stress induced in the crankshaft is 8.3428 Mpa, Minimum stress induced is 6.1033e-11Mpa.
 Figure: - 2.5 crankshaft (cast Iron) elastic strain Maximum Strain in the crankshaft is 8.1576e-5.

Figure: - 2.6 crankshaft total deformation

VIII. CONCLUSION:-
Validated Results:-
S.No. Type of stress Theoretical ANSYS results
1 Von-misses stress(N/mm²) 19.6 16.315
2 Shear stresses (N/mm²) 9.28 8.3428

 The maximum deformation appears at the centre of the crankpin neck surface.
 The maximum stress appears at the fillet areas between the crankshaft journal and crank cheeks
and near the central point journal.
 The value of von-misses stresses that comes out from the analysis is far less than material yield
stress so our design is safe.
Static Analysis on Aluminum Alloy Crankshaft:
Used to determine displacements, Stresses, Strain, Deformation etc. under static
loading conditions in both linear and nonlinear static analysis. Nonlinearities
include plasticity, stress stiffening, large deflection, large strain, hyper elasticity,
contact surfaces, and creep.

Apply Material for crankshaft (Aluminum Alloy).

Material Type: Aluminum Alloy
Young modulus: 71000 Mpa
Poisson’s ratio: 0.33
Density: 2770 kg/mm³

RESULTS AND DISCUSSION

Analysis of crankshaft- Aluminum Alloy

The two ends of the crankshaft are to be fixed, the load 3.5 Mpa is applied on the
top of the crankpin surface.

Figure: - 3.1 crankshaft voin-misses stress (Aluminum Alloy)

The maximum stress induced in the crankshaft is 18.42 Mpa at the crankpin neck surface.
Minimum stress 1.4862e-10 Mpa.
 Figure: - 3.2 Maximum stress induced in the crankpin area
Maximum stress induced in the Crankshaft (Aluminum Alloy) is 18.42 Mpa at the fillet areas.

Figure:-3.3 crankshaft shear stress (Aluminum Alloy)

The Maximum shear stress induced in the crankshaft (Aluminum Alloy) is 9.3135 Mpa, Minimum stress induced is
8.2268e-11Mpa.
 Figure: - 3.4 crankshaft (Aluminum Alloy) elastic strain Maximum Strain in the crankshaft is 2.5944e-4.

Figure: - 3.5 crankshaft (Aluminum Alloy) total deformation

Comparison of Analysis Results

The 3D models generate for each of crankshaft corresponding to each different
material are imported into Ansys to estimate the Deformation and Equivalent Von-
Mises stress for each of the material alternatives with the aid of [18]. Thereafter a
comparative analysis is conducted to assess the suitability of each the alternative
i.e. Cast Iron and Aluminum alloy compared to conventional forged steel crank
shaft.
Deformation

Deformation (mm)
0.012

0.01

0.008

0.006
Deformation
0.004

0.002

0
CAST IRON AL. ALLOY
Figure: - 4.1 Graphical representation of deformation

Von misses Stress (MPa)

Von mises stress (MPa)
19
18.5
18
17.5
17
von mises stress
16.5
16
15.5
15
Cast Iron Aluminum Alloy
Figure: - 4.2 Graphical representation of Von Misses Stress
Shear Stress (MPa)
Shear Stress
9.4
9.2
9
8.8
8.6
Shear Stress
8.4
8.2
8
7.8
Cast Iron Aluminum Alloy
Figure: - 4.3 Graphical representation of Shear Stress

Optimum Material Selection

Thus Aluminum Alloy provides a greater weight reduction and a lighter design as
compared to cast iron as shown in fig 4.4
Relative Mass
5

2 Relative Mass

0
Cast Iron Aluminum Alloy

Figure: - 4.4 Graphical representation of Relative Mass

Figure: - 4.5 Material comparison between cast iron and aluminum alloy using ANSYS