FAILURE INVESTIGATION OF 4 STROKE ENGINE HEAT TRANSFER ANALYSES IN CRANK SHAFT SURFACE

Mechanical engineering

The Computer aided modeling and analysis of connecting rod is to study was to evaluate and compare the thermal friction performance of two competing manufacturing technologies for automotive connecting rod, namely EN8 and Automotive alumina. In this study a static simulation analysis and thermal analysis was conducted on two crank, EN8 and automotive alumina, since similar single cylinder four stroke engines. Finite element analyses were performed to obtain the deviation of stress magnitude at critical settings. The Static analysis with thermal transient was done analytically and was verified by simulations in ANSYS. Results achieved from after mentioned analysis was used in optimization of the forged steel connecting crank. Geometry, material and manufacturing processes were optimized allowing for different constraints, manufacturing practicability and cost. The optimization Process included geometry changes compatible with the current engine and consequences in in- creased fatigue strength and abridged cost of the connecting rod, without changing crank shaft and engine block The Thermal stress analysis with static structural analysis of a 4-cylinder crankshaft is discussed using finite element method in this paper. Reports an investigation that was carrying out on two damaged crankshafts. They were four stock petrol engine crankshafts that were sent to be ground, after a life of about 300,000 km each. Some journals were damaged on every crankshaft. After grinding, and assembling on the connecting pin, the crankshafts lasted about 1000 km each, and the journals were spoiled again. The crankshafts were then sent to be investigating. Different laboratory tests were carrying out in order to discover what could have been the cause of the damage. Different typical crankshaft failures were assessed, and will be discussing in this paper. The cause of the damaged journals was found to be a erroneous grinding process that created minor thermal fatigue cracks at the centre of the journals, on both crankshafts. These virtually invisible cracks, with shrill edges, acted as knives originating a very quick damaging of the journal bearings, and as significance spoiled find it. After the process The Computer aided modeling and analysis of connecting crank is to study was to evaluate and compare the thermal friction performance of two competing manufacturing technologies for automotive connecting crank, namely EN8 and Automotive alumina. In this study a static simulation analysis and thermal analysis was conducted on two crank, EN8 and automotive alumina, from similar single cylinder four stroke engines. Finite element analyses remained performs to attain the variation of stress magnitude at critical locations. The Static analysis with thermal transient was done analytically and was verified by simulations in ANSYS. Results achieved from after mentioned analysis was used in optimization of the forged steel connecting crank. Geometry, material and manufacturing progressions were optimized allowing for different restrictions, manufacturing possibility and cost. The optimization Process involved geometry changes compatible with the current engine, surface thermal with results in-creased fatigue strength and reduced cost of the connecting rod, without changing crank shaft and engine block.

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