Study on failure analysis of crankshaft using Finite Element Analysis

The present project is focused on constructing a 90° L-twin cylinder crankshaft model and conducting the failure analysis of specific crankshaft using finite element analysis (FEA) software. The stress distribution, fatigue behavior and fatigue life of the crankshaft will be analyzed.

Crankshaft is one of the crucial parts for the internal combustion engine (ICE) which required effective and precise working. Failure of the crankshaft can make the engine unusable which requires costly purchases and replacements to fix and repair. In this study, the main objective of the research is to identify the stress distribution and fatigue behavior of the crankshaft with the aid of finite element analysis (FEA). The 3D model of the crankshaft model was designed and developed using SolidWorks. FEA was performed using ANSYS 2019 R3 under static and dynamic conditions to determine the maximum equivalent stress and total deformation at critical locations of the crankshaft. Two different boundary conditions were formulated to determine the actual response of crankshaft under dynamic loading conditions. The fatigue assessment of the crankshaft was carried out and identified the critical locations for both of the load cases. The modal analysis was carried out to identify the natural frequencies of the crankshaft at different mode. The harmonic response of the crankshaft was evaluated and compared with natural frequencies to examine the resonance effect. The results obtained had indicated that the crankshaft has obvious fatigue crack which was belongs to fatigue fracture. The crack on the crankshaft was found initiated from the fillet region of the lubrication hole because it was a high bending stress concentration location. The high bending stress is the root cause of the failure analyzed in this work. The crankshaft subjected to fluctuating and cyclic loads were influenced with vibration which could harm the mountings and may produce high wear and tear. The crankshaft is safe for both static and fatigue loadings. In dynamic analysis, the critical frequency obtained in the frequency response curve should be avoided which it may cause failure of the crankshaft.

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