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2nd Review

The document describes the design and analysis of a crankshaft for a W12 engine. It discusses modeling the crankshaft in Solidworks and optimizing stress concentration areas. Two new materials, spheroidal graphite cast iron and nitriding coated steel, are selected for analysis in ANSYS. The stresses induced in the crankshaft are compared between the typical and new materials.

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133 views29 pages

2nd Review

The document describes the design and analysis of a crankshaft for a W12 engine. It discusses modeling the crankshaft in Solidworks and optimizing stress concentration areas. Two new materials, spheroidal graphite cast iron and nitriding coated steel, are selected for analysis in ANSYS. The stresses induced in the crankshaft are compared between the typical and new materials.

Uploaded by

retech
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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DESIGN AND ANALYSIS OF W12

ENGINE CRANK SHAFT

• By
• Yash Chaubey [RA1611002010394] Project Guide
• Abhinay Animireddi [RA1611002010895] Mr Ann Joachim Martin R
ABSTRACT
In heavy engines more than one cylinder is seen which requires
separate crank to run, so multiple crankshaft is designed to run W12 en­
gine. As the W12 engine is subjected to higher load at high speed many
analyses done to the components to check their failure properties. Many
analyses are done according to the components function and mostly
thermal analysis is done to all the models because of the heat the
released by the engine is affected to them, but static structural analysis
is done to all the compo­nents. These analyses will give the results which
are evaluated and required changes can be done to them to reach the
customer requirements. This paper focus on the design and static
structural analysis of the crankshaft of W12 engine.
INTRODUCTION
A crankshaft is a rotating shaft which (in conjunction with the connecting rods)
converts reciprocating motion of the pistons into rotational motion.
Crankshafts are commonly used in internal combustion engines and consist of a series
of cranks and crankpins to which the connecting rods are attached.
The crankshaft rotates within the engine block through use of main bearings, and the
crankpins rotate within the connecting rods using rod bearings.
Crankshafts are usually made from metal, with most modern crankshafts being
constructed using forged steel.
PROBLEM STATEMENT
• W12 engine and its crankshaft are one of the most under studied
machines
• Key problem in this crankshaft are the huge amount of various
stresses in the typical design
• Material used to manufacture isn’t optimum
• High production cost all over
OBJECTIVES
• To reduce the stress induced in the existing W12 engine crankshaft by
optimizing the stress concentration areas
• To use new materials like SG 600/3 & NITRIDING COATED EN19 STEEL
in crankshaft design and structural analysis is done in ANYSYS.
• The results are taken and evaluated for choosing the best material for
manufacturing the crankshaft which is suitable for the desired
operation
S.no
LITERATURE SURVEY
Title of the journal Author(S) Points noted
1. Dynamic stress analysis of a multi Lakshman N, Saravanan 1) Manufacturing material was
cylinder crankshaft K changed from typical EN-19
FORGED STEEL to SPHEROIDAL
GRAPHITE CAST IRON (SG
600/3)
2) Thus less manufacturing cost
3) No drastic improvement in
stress sustaining but low
manufacturing cost
2. Determination of the engine Aleksander Milasinovic 1) Crankshaft’s angular velocity
torque based on HARMONIC fluctuation is due to cylinder
ANALYSIS of crankshaft angular pressure variation , engine friction.
velocity
2) Lumped mass model is created
to correctly analyse crankshaft
dynamics

3) New methodology was designed


to determine cylinder pressure
variation using crankshaft angular
velocity
S.no Title of the journal AUTHOR Points noted
3. Failure analysis of multi Ms.Shweta 1) Stress concentration areas in a crankshaft
cylinder crankshaft using Ambadas Naik were found out
FEA 2) CRANK PIN
3) NEAREST CRANKPIN TO FLYWHEEL
4) FILLET OF SPINDLE
4. Analysis of multicylinder Anand S & 1) Material changed from EN19 STEEL to
crankshaft of an IC Engine Parthasarathy C Nitriding coated EN19 steel
2) Improvement in sustaining torsional and
bending load were observed
METHODOLOGY
• Modelling the crankshaft in SOLIDWORKS 2016, and optimising the profile referring
from journal 3
• Areas such as crank pin, nearest crankpin to flywheel and fillet of spindle are
concentrated for optimization
• Additional counterweight and a crankpins are added to reduce the stress
• Finalizing on the profile and converting into IGES form
• Analysis of typical material crankshaft are found out in ANSYS
• Selecting new materials for the crankshaft manufacture such as SPHEROIDAL
GRAPHITE CAST IRON (SG 600/3) & Nitriding coated EN 19 STEEL
• Plot the goodman diagram for the materials used
• Compare the induced stresses and various parameters
DRAWING OF W12 CRANKSHAFT
FRONT VIEW OF W12 CRANKSHAFT
TOP VIEW OF W12 CRANKSHAFT
DESIGN PROCEDURE

BASE CRANK SKETCH IS CREATED USING 2D COMMANDS


BASE CRANK BODY IS CREATED
USING EXTRUDE TOOL
2D SKETCH OF CRANK IS DRAWN ON
THE BASE
EXTRUDE COMMAND IS USED TO
CREATE CRANK
MIRROR COMMAND IS USED TO
PRODUCE CRANK FOR TWO CYLINDER
MOVE COMMAND IS USED TO
PRODUCE CRANK FOR TWO CYLINDER
FILLET COMMAND IS USED TO CREATE
BLUNT EDGES
PATTERN COMMAND IS USED TO W12
CRANKSHAFT
MOVE COMMAND IS USED TO PLACE
THE CRANK AT RESPECTIVE POSITION
HOLE WIZARD COMMAND IS USED TO MAKE
HOLES ON CRANKSHAFT
3D MODEL OF W12 CRANKSHAFT
ANSYS WORKBENCH 16.0
• ANSYS, Inc. is an engineering simulation software (computer-aided
engineering, or CAE) developer headquartered south of Pittsburgh in
the South pointe business park in Cecil Township, Pennsylvania,
United States.
• One of its most significant products is ANSYS CFD, a
proprietary Computational Fluid Dynamics (CFD) program.
STRUCTURAL ANALYSIS
• Structural analysis is the determination of the effects of loads on
physical structures and their components.
• Structures subject to this type of analysis include all that must withstand loads,
such as buildings, bridges, vehicles, furniture, attire, soil strata, prostheses and
biological tissue.
• Structural analysis employs the fields of applied mechanics, materials
science and applied mathematics to compute a structure's deformations,
internal forces, stresses, support reactions, accelerations, and stability.
• The results of the analysis are used to verify a structure's fitness for use, often
precluding physical tests.
• Structural analysis is thus a key part of the engineering design of structures
MODELLED W12 CRANKSHAFT IS
IMPORTED IN ANSYS
MESHING
• Meshing is an integral part of the computer-aided engineering (CAE)
simulation process.
• The mesh influences the accuracy, convergence and speed of the solution.
• Furthermore, the time it takes to create a mesh model is often a
significant portion of the time it takes to get results from a CAE solution.
• Therefore, the better and more automated the meshing tools, the better
the solution.
• From easy, automatic meshing, to a highly crafted mesh, ANSYS, provides
the ultimate solution.
FINE MESHING OF W12 CRANKSHAFT
IN ANSYS
GANTT CHART
THANK YOU

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