Failure Analysis of Ductile Iron Crankshaft in Four-Cylinder Diesel Engine

Aliakbari, Karim

doi:10.1007/s40962-020-00550-y

Cited by 13 publications

(7 citation statements)

References 55 publications

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“…The differential equations are derived from the equations of motion and taken into account the dynamic behavior of the crankshaft including its mass, damping, and stiffness properties. The governing equation for modal analysis of a twin cylinder crankshaft can be written in the form of a partial differential equation is given in equation (2).…”

Section: Geometry Analysis and Fea Modal Analysismentioning

confidence: 99%

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Fatigue failure prediction through factor of safety and stress concentration in a malfunctioned AISI 4140 automotive crankshaft

Mylsamy,

Subramanyan

2023

Mater. Res. Express

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The performance and safety of any vehicle relies on proper design of crankshaft. Crankshaft failure occurs mainly due to the combination of imbalance and minor deflections when the materials is subjected to combined bending and twisting. Failure analysis is crucial to identify the causes and modes of failure, in order to improve the service life of automotive crankshafts and prevent accidents. This research analyses the root cause of failure by testing a failed crankshaft of a twin cylinder diesel engine used in mini commercial vehicle runs around 80000 km. The important research gap identified as that there is no fool-proof techniques and validation procedures are followed in the service stations during its life cycle period. This investigation of a failed crankshaft provides detailed composition of material, its micro structure and mechanical properties. Further, rotary analysis, experimental modal analysis and mechanical testing of materials are helpful in characterizing proper materials to be selected and analyzing the root cause of failure. The experimental setup helps to test a crankshaft and its specimen as per ASTM testing procedures and the results are correlated with numerical analysis using ANSYS software. The objective of this investigation is to provide insights through failure analysis to the designers and manufacturers, thereby improve the reliability and safety of automotive crankshafts, ensure safe operation of the vehicle, and eventually minimize financial losses.

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Section: Geometry Analysis and Fea Modal Analysismentioning

confidence: 99%

“…Aliakbari investigated to find the failure of a truck crankshaft is due to improper heat treatment. The author found that the hardness of the quenched layer is lesser than the requirement [2]. The high stress concentration in the web crankpin fillet region is another cause of failure of the crankshaft.…”

Section: Introductionmentioning

confidence: 99%

Fatigue failure prediction through factor of safety and stress concentration in a malfunctioned AISI 4140 automotive crankshaft

Mylsamy,

Subramanyan

2023

Mater. Res. Express

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“…Another research work reported that the major cause of engine failure is the dysfunctionality of the crankshaft [8].…”

Section: Journal Of Applied Engineering and Technologymentioning

confidence: 99%

Failure Analysis of a Diesel Engine Crankshaft based on Finite Element Modeling

Solangi,

Memon,

Memon

et al. 2023

JAET

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The crankshaft is one of the essential components of an internal combustion engine that converts the piston's linear motion into the crank's rotary motion. This research has been carried out to study the failure analysis of diesel engine crankshafts, and forged steel material is selected. A crankshaft's geometry is relatively complex compared to other parts; its working conditions are critical, and the stress concentration areas are very complicated. While considering all these phenomena, it is significant that a crankshaft's fatigue strength, stiffness, durability, and wear resistance should be checked and analyzed properly. Firstly, a 3D model of the crankshaft is designed using SolidWorks 2022 software. After that, the Model is imported to ANSYS software 2022 R2 student version. However, using ANSYS (finite element method) is carried out on the crankshaft’s Model. This research aims to obtain the variation in stress magnitude at critical locations of the crankshaft by applying variable loads and boundary conditions. Simulation techniques were conducted for both static and dynamic analysis. The total deformation observed at the critical area of the crank pin is 1.3488e-8. The corresponding equivalent stress is 318.37, and the crankshaft's safety factor is 15.

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“…Infante conducted several kinds of standard tests on the broken crankshaft applied on a helicopter engine, the main conclusions carried out from these tests was that the failure reason of this component was not from the part itself, but the from damaged shell bearings assembled at the main journal [ 10 ]. Karim also conducted different experiments and tests to analyze the failure mechanism of the chosen ductile iron crankshaft, the results showed that the low crankpin hardness and the low nodularity of the material are the two main reasons for the failure of the part [ 11 ]. Tian analyzed the fracture crankshaft from a sport utility vehicle and discovered that the density of inclusions was great enough to act as the initiation of cracks [ 12 ].…”

Section: Introductionmentioning

confidence: 99%

Research of the crankshaft high cycle bending fatigue experiment design method based on the modified unscented Kalman filtering algorithm and the SAFL approach

Rui,

Jiang,

Sun

et al. 2023

PLoS ONE

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In modern engineering application, enough high cycle bending fatigue strength is the necessary factor to provide the basic safety security for the application of the crankshaft in automobile engines (both diesel and gasoline types). At present, this parameter is usually obtained through the standard bending fatigue experiment process, which is time consuming and expensive. In this paper, a new accelerated crankshaft bending fatigue experiment was proposed step by step. First the loading procedure was quickened through the prediction of the residual fatigue life based on the UKF (unscented Kalman filtering algorithm). Then the accuracy of the predictions was improved based on the modified sampling range and the theory of fracture mechanics. Finally the statistical analysis method of the fatigue limit load was performed based on the above predictions. The main conclusion of this paper is that the proposed accelerated bending fatigue experiment can save more than 30% of the bending fatigue experiment period and provide nearly the same fatigue limit load analysis result. In addition, compared with the particle filtering algorithm method, the modified UKF can provide much higher accuracy in predicting the residual bending fatigue life of the crankshaft, which makes this method more superior to be applied in actual engineering.

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Failure Analysis of Ductile Iron Crankshaft in Four-Cylinder Diesel Engine

Cited by 13 publications

References 55 publications

Fatigue failure prediction through factor of safety and stress concentration in a malfunctioned AISI 4140 automotive crankshaft

Fatigue failure prediction through factor of safety and stress concentration in a malfunctioned AISI 4140 automotive crankshaft

Failure Analysis of a Diesel Engine Crankshaft based on Finite Element Modeling

Research of the crankshaft high cycle bending fatigue experiment design method based on the modified unscented Kalman filtering algorithm and the SAFL approach

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