Crank Shaft Research Articles

The torsional vibration simulation of the diesel engine crankshaft system based on multi-body dynamic model

In order to analyze the torsional vibration of the crankshaft system, a three-dimensional model of the crankshaft system is established, consisted of the piston, connected rod, crank shaft, flywheel and silicone oil damper. Use by multi-body dynamics simulation software ADAMS, created the multi-body dynamics model of the multiple degrees of freedom consisting of rigid hybrid engine system, to do the torsional vibration response simulation, analysis of the torsional vibration on the crankshaft. Through the torsional vibration test of the diesel engine crankshaft system, the accuracy of the simulation calculation results have been verified. This simulation result has higher accuracy, and this calculation method has certain engineering application value.

Optimization of tank engine crank shaft material properties

Metals and coating materials, with best material properties are highly desired in the field of engineering to control the stresses and strains, that play important role in design strategies. The crankshaft, an important part of tank engine, depends on the cranking mechanism in the internal combustion engine. The function of the crankshaft is to convert the sliding motion of the piston into rotary motion. Since most industrial mechanisms and processes make more efficient use of rotary motions rather than displacements, the function of crankshaft becomes very vital. To understand the reason behind the fatigue and heavy load cycles, a mathematical model is simulated. The complex geometry of crankshaft is developed in a numerical solver. The model is simulated relative to several material properties to mimic the resulting fatigue. The numerical data was optimized using the python Bayesian optimization tools, to forecast the threshold values relative to longer duration. In the recent literature, different nano-composites are acquiring at- tention as the coating materials, to tackle with the friction load. The hybrid modeling approach used during this research can help to simulate the stresses, resulting from dif- ferent nanocomposite coatings.

Strength analysis of the TWS 600 plunger pump body in Solid Works Simulation

Introduction. The relevance of the presented paper is due to the widespread use of plunger pumps in industrial practice, in particular, in gas and oil production. The quality of working operations and the efficiency of further well operation depend largely on their reliability. The improvement of plunger pumps involves increasing their reliability, increasing their service life, efficiency, downsizing, reduction in weight, labor intensity of installation and repair work. The modernization of the mechanism includes its power study since the found forces are used for subsequent strength calculations. Before the appearance of programs for the numerical analysis of solid objects, the analytical solution to the problem of strength calculation of the high-pressure pump drive frame was a very time-consuming and expensive procedure. The situation has changed with the development of computer technologies and the inclusion of the finite element method in the computer-aided design systems. The objective of this work is to perform a strength calculationon the TWS 600 plunger pump body made of 09G2S steel. Materials and Methods. A method for determining the reactions of the crank shaft supports of a high-pressure plunger pump and strength calculation of the drive part housing is developed. The direction and magnitude of the resulting forces and reactions of the supports are determined graphically according to the superposition principle of the force action on the supports. Strength calculations were performed using the finite element method in the computer-aided design system Solid Works Simulation. In this case, solid and finite-element models of the body with imposed boundary conditions were used, which were identified during the analysis of the design and the calculation of the forces arising under the pump operation. Results. The reactions in the crankshaft supports are described with account for the forces generated by the plunger depending on its operating mode and the crank position. The forces acting on each of the plungers and the resulting reactions in each of the supports are determined. The diagrams of stresses and the safety factor are presented, which provide assessing the strength of the body and developing recommendations for creating a more rational design. Discussion and Conclusions. As a result of the calculations, we have identified areas of the structure with minimum safety factors, and areas that are several times higher than the recommended values. This provides optimizing the designunder study through strengthening the first and reducing the thickness of the metal on the second. From the point of view of weight and size characteristics and maintainability, the results of the strength calculation performed can be used to optimize the design of the pump body under typical operating conditions.

Impact of web and counterweight shape factors on crank shaft design for better strength and optimised geometry

Automotive industry is continuously focusing on developing weight efficient engines for better fuel economy without altering engine performance. To achieve a trade-off between performance and fuel economy, the design always demands downsizing of engine components with optimum geometry. Crankshaft is such an important component in deciding engine performance and overall weight. Torsional and bending stiffness of crankshaft plays a vital role in its structural integrity, particularly the Critical Cross Section (CCS) which connects main journal and crankpin. In the present study, the objective is to upgrade the crankshaft for higher torsional and bending stiffness and reduce weight without changing its performance. Three geometric shape factors of the crankshaft are identified and optimized in FEA and analyzed in AVL Excite® (1-D) simulation for its structural performance. Study shows the identification of shape factors and effect of their variation on torsional and bending stiffness of crankshaft. In addition, sensitivity analysis for various shape factors and their optimization has been done. The identified shape factors help designers to identify any scope to optimize the geometry of crankshaft and understand its role in structural strength. Using this methodology, specific regions defined by shape factors can be optimized for better strength and weight.

RANCANG BANGUN DAN UJI KINERJA MESIN PENYARING SISTEM GETAR UNTUK MEMISAHKAN BIJI DAN KULIT HANJELI HASIL PROSES PENGUPASAN

Hanjeli (Coixlacryma-jobiL.) is a cereal plant which has potential in producing carbohydrate. The high nutrient content of this plant has not been utilized optimally. In Indonesia, most of the hanjeli seed peeling processes are still using the manual way (pounding), so after the peeling process we have to do seeds and peel separating process. The purpose of this research is to devise a seed and peel filter machine occupied the results of the peeling process with vibrating screen which have been adjusted for the characteristic of hanjeli seeds. The method used in this research is engineering process, which is an activity to devise a hanjeli filter machine. The result of this research was the machine which has been designed with hopper, framework, filter unit, activator, seeds outlet, husk outlet and crank shaft as the main components. The main dimensions of the machine were 1340 mm long, 610 mm wide, 1000 mm high, the machine’s actual capacity was 29.024kg/h and the activator is 0.5 HP. The results of the hanjeli filter engine test are: the actual engine capacity is 29.024 kg / hour, the engine efficiency is 38.7%, the pulley rotation speed is 305 rpm, the electric motor power is 0.138 kW, and the noise level is 62.78 dB. Keywords: designing, hanjeli seed, hanjeli peel, performance test, vibrating screen

Development of special purpose silk thread through reverse engineering and yarn geometry for use in engines of battle tanks

One of the Engine factories in India is manufacturing three types of engines that power various types of battle tanks. While operating the tanks, the crank shaft main journals and pins need lubrication for smooth running with minimum friction and to dissipate the heat produced. In order to prevent the leakage in the lubricating system, special purpose silk thread is wound around the threaded portion of the bolt before tightening the nut with gasket and washer that has to withstand the oil pressure of 14 kg/cm2 at a temperature of 140 °C. The expected life of the engine is 10 years approx. (500 h of actual running), so the special purpose silk thread should have self-life of more than the engine life. Earlier, the special purpose silk thread of 77.2 Tex (maximum) that would have a breaking load of 2 kgf (minimum) with 18% elongation at rupture (minimum) was sourced from Japan indirectly. Due to decline in the silk production in Japan, the supply chain broke and ceased to exist. The technical know-how on yarn manufacturing was unknown but details of eight thread characteristics were available. CSTRI, Bangalore, with the data, manufactured the special purpose silk thread through reverse engineering by designing the yarn geometry using indigenously produced multivoltine raw silk reeled on multiend reeling machine. Subsequently, the special purpose thread was produced in commercial scale and supplied to the Engine factory, Avadi that is being used as oil seal in the engines of battle tanks after getting the performance test report from the Defence quality control agency. This research paper deals with process of reverse engineering and design of yarn geometry in achieving the desired characteristics of the special purpose silk thread.

Electrification of a Heavy-Duty CI Truck—Comparison of Electric Turbocharger and Crank Shaft Motor

A combustion engine-driven vehicle can be made more fuel efficient over some drive cycles by, for example, introducing electric machines and solutions for electrical energy storage within the vehicle’s driveline architecture. The possible benefits of different hybridization concepts depend on the architecture, i.e., the type of energy storage, and the placement and sizing of the different driveline components. This paper examines a diesel electric plug-in hybrid truck, where the powertrain includes a diesel engine supported with two electric motors, one supporting the crank shaft and one the turbocharger. Numerical optimal control was used to find energy-optimal control strategies during two different accelerations; the trade-off between using electrical energy and diesel fuel was evaluated using a simulation platform. Fixed-gear acceleration was performed to evaluate the contribution from the two electric motors in co-operation, and individual operation. A second acceleration test case from 8 to 80 km/h was performed to evaluate the resulting optimal control behavior when taking gear changes into account. A cost factor was used to relate the cost of diesel fuel to electrical energy. The selection of the cost factor relates to the allowed usage of electrical energy: a high cost factor results in a high amplification from electrical energy input to total system energy savings, whereas a low cost factor results in an increased usage of electrical energy for propulsion. The difference between fixed-gear and full acceleration is mainly the utilization of the electric crank shaft motor. For the mid-range of the cost factors examined, the crank shaft electric motor is used at the end of the fixed-gear acceleration, but the control sequence is not repeated for each gear during the full acceleration. The electric motor supporting the turbocharger is used for higher cost factors than the crank shaft motor, and the amplification from electrical energy input to total energy savings is also the highest.

Method for calculating dynamic loads and energy consumption of a sucker rod installation with an automatic balancing system

The efficiency of sucker rod pump installations, which have become widespread in mechanized lift practice, is largely determined by the balance of the drive. During the operation of sucker rod installations, the balance of loads acting on the rod string and the drive can change significantly due to changes in the dynamic fluid level, which leads to a decrease in balance and an increase in loads on the pumping equipment units. The increase and decrease in the dynamic level in accordance with the pumping and accumulation cycle occurs in wells operating in the periodic pumping mode. 
 It is shown that during the operation of equipment in a periodic mode, fluctuations in the dynamic level and, accordingly, in the loads acting on the nodes occur. This leads to the need for dynamic adjustment of the balancing weights to ensure the balance of the pumping unit. A system for automatic balancing of the rod drive has been developed, including a balancing counterweight, an electric motor that moves the load along the balance beam, a propeller and a computing unit.
 To study the effectiveness of the proposed device, a complex mathematical model of the joint operation of the reservoir - well - sucker rod pump - rod string – pumping unit has been developed. It is shown that due to the dynamic adjustment of the balance counterweight position, the automatic balancing system makes it possible to significantly reduce the amplitude value of the torque on the crank shaft (in comparison with the traditional rod installation) and provide a more uniform load of the electric motor. Equalization of torque and motor load reduces the power consumption of the unit.

Research of transverse dynamic oscillation for the piston in labyrinth compressor

In labyrinth compressor, non-contact labyrinth sealing clearance was designed between piston and cylinder wall to process oil-free gas containing fine particles. To prevent the collision between piston and cylinder wall, this labyrinth clearance was usually set bigger than 2‰ of the piston diameter. Such a big clearance seriously increased the leakage rate and reduced the volume efficiency of the compressor. Thus, it was necessary to investigate the piston transverse oscillation, and find a way to minimize the oscillation amplitude to reduce the labyrinth clearance set. In this paper, a dynamic model was established to predict the piston transverse oscillation based on inertia mass vibration analysis and finite difference method. Experiments investigation of the piston transverse oscillation track showed high prediction accuracy of the proposed model. Then, structure parameters optimization of the compressor was carried out to reduce piston oscillation amplitude. It was found that ratio of the crank shaft radius to connecting rod length and the position of the guide bearing were two key parameters determining the oscillation amplitude. Finally, a case study showed that the oscillation amplitude could be reduced by 53% by adopting optimized parameters.

Theoretical modelling and analysis of a four-wheeler crank shaft by different aluminum alloys

Crankshaft used to transform the give back movement of piston into spinning movement. Crankshaft has a shaft component which resonate inside number one bearings, crankpins to huge ends of connecting rod are related, crank palms or web which attach the crankpins and shaft factors. The crankshafts are experience to surprise and also fatigue masses. This fabric of crankshaft needs to hard and also fatigue resistant. Common place substances used in the crankshaft are Carbon Steel or Nickel-Chrome-Moly amalgam steel or Nickel-Chrome or explicit cast-iron. Aim of the task to format and production of crankshaft to a four-cylinder IC engine with the aid of the manner of using theoretical calculations in format vicinity for Aluminum alloys6061 and business enterprise grade. A 2dimensional drawing is drafted for crankshaft through the calculations and 3-D version is created inside the three-D modeling software utility software program.

Calculation of the torque on the crank shaft of the low-speed balancing drive sucker rod pumps

AnnotationThe operation of well sucker rod pump installations is the most massive way of mechanized oil production. A significant part of the wells equipped with low-speed plants of this type have a low flow rate and high water cut. Such conditions create certain restrictions on updating and modernization of the production fund of equipment in operation. The life cycle of a rocking machine is usually significant and often exceeds 20 years. During ISPR operation, both ground and downhole equipment will inevitably wear out. A significant proportion of failures of the ground part of low-speed ISPR is associated with the reduction of the rocking machine, which is the most responsible and most expensive drive element. The resource of the gearbox directly depends on its load, which is characterized by the moment on its crank (output) shaft. Reducing the maximum torque and moment fluctuations in one full swing of the rocking machine will significantly increase the reliability of the gearbox and the entire installation. This paper describes the mathematical apparatus for calculating the moment on the crank shaft of the gearbox, based on the exact kinematics of the drive and the principle of possible movements. The proposed methodology will allow to solve the problems of designing a balancing drive of a low-speed ISPR, to determine the requirements for the engine and transmission.

Failure studies on the support of rotary kilns and their thermal effect

The main goal for this work is rotary kiln misalignment and crank shaft features study for cement plants. This kiln preventive maintenance study is constructed about the initial parameters method, which is programmed by C ++ visual studio language. This method simulates tolerated overload like ratio between generated forces and support static efforts. A due to misalignment overload equal to 10.0% maximum static load can be tolerated. Firstly, a loads and displacements set of experimental measurement was realized on supports without any materials product. Then, for the best stiffness matrix reality approach, we modeled the ferrule and the refractory wall like a beam shape which has simple supports. We compared the overload and misalignment initial parameters method results with those obtained by experimental tests. Concerning the rotary kiln thermal conductivity study, we validated the finite elements models simulating the kiln behavior at work. A thermal gradient experimental measurements set was done while kiln was in work, and then we validated the study with the finite elements code. This later was programmed with the FORTRAN language. In another contest, the kiln deformability mechanical tenure and eccentricity was realized in hot conditions. The ferrule and refractory wall numerical simulation validation by finite elements method was elaborated using PATRAN/NASTRAN software. To approach the real kiln behavior, the FEM results are compared with those obtained by the experimental tests.

Disc Brake Type of Braking System on Rear Shaft of Go-kart Daiho 7.5 HP

Go-kart is one of the four-wheeled racing vehicles with high speed at a speed of approximately 100 km/hour more depending on the type and specification of the machine. One of the types of kart machines uses 4-step and 2-step machines. It means that the 4-step machine works by rotating two rounds of the crank shaft and 4 times the downward piston. The result of the calculation of the The weight of the kart taken at the central point is 678.8 mm and the rear kart is 273.7 mm. Torque obtained from the disk brake system is 377.5 Nm. As well as from torque obtained retarding 0.102 m/s. Braking force Result is 895.965 N. As well as force press on the brake canvas is 3.318 N. As well as the flow rate of the brake system is 1.078 kg/cm. From this study, we can draw the conclusion that the braking disc brake is influenced by the flow rate, the radius inside and outside the wheels and center of gravity Central point karts at the time of installation of the disc brake system so that the braking system can be maximal. Vital braking has a function and purpose that can be used as the main equipment on the kart or other vehicles. In addition, the use of a disc brake system is mostly used both on two wheels and four wheels because of its ease to treat and use and replacement of the spare parts.

Design and Development of Pneumatic Air Engine using Linear Actuator

A study was performed to produce a pneumatic air engine using two linear actuators and then the linear motion was converted to a rotating motion using a crank shaft. This study aims to increase the use of linear actuators in pneumatic air engines as well as to apply pressurized air as an efficient and convenient transportation mechanism in line with the development of technologies developed through products available in the market. Two units of linear actuator such as pneumatic cylinders with two units of 5/2 way directional control valve with double solenoid actuation are used to control the cylinder movement. The cylinder will rotate the crank shaft when receiving a signal from the solenoid valve with 5 bar air pressure. In conclusion, the system can travel up to 153 meters for a 24-liter air-pressure with 5 bar pressure when the test is run for a charging cycle by the compressor motor. If the compressor motor able to charge the compressor continuously, the movement distance can be increased.

Lubricating condition evaluation of the rotary compressor under high ambient temperature

Abstract Propane has been suggested as one of the alternative working fluids for room air conditioners in hot climate areas because of its excellent environmental properties and lower discharge temperature though there still is concern about its flammability. The lubricating condition of rotor bearings system should also be emphasized because a heavier load and lower viscosity in the oil sump could impair the reliability of rotary compressor under high ambient temperature. In this study, in order to obtain the input of simulation, the dynamic pressures and viscosity of a R290 air conditioner are experimentally measured under several conditions. On these bases, lubricating characteristics are numerically simulated by coupling the dynamics equation of crank shaft and the modified Reynolds equation of oil film using finite element method. The results show that the load on crank under 50 °C is twice as large as that of 30 °C while the viscosity of bottom oil sump decreases from 1.89 to 1.59 mPa⋅s. Simulation results imply that the minimum oil film thickness decreased to 0.44 µm under 50 °C, in which asperity contact force peaks at 3 N when arithmetic mean roughness is 0.2 µm. Asperity contact force would significantly increase to 174 N if surface roughness is 0.6 µm and boundary lubrication regime is reached. Strategies to increase oil sump viscosity is recommended to avoid adhesive wear in this case.

Fatigue analysis of high performance race engines

This paper presents a multidiscipline dynamic simulation tool for fatigue testing. A non-linear finite element formulation embedding control system modeling is augmented to include fatigue analysis based on a mathematical representation of virtual brittle lacquer and strain rosettes. A new efficient method for rosette strain calculations based on super node displacements are applied and presented. These features are used to predict the hot spots and durability of a high performance race engine. Real physical testing is performed to capture all engine properties influencing the crank shaft stress distribution. The results predict the most critical failure modes during racing applications as well as the life in terms of drag laps before failure.

RESEARCH OF LOADS ON DRIVE OF ROD INSTALLATIONS IN LOW SPEED MODE AT HIGH-VISCOUS OIL PRODUCTION

Reliability and power consumption of the rod installations are largely determined by the drive balancing rate. Today, due to the increasing share of hard-to-recover reserves, issues of balance during the extraction of high viscous and paraffinic products, characterized by increased loads on the rod string due to increasing forces of hydrodynamic friction, paraffin deposition on the walls of sucker rods and pipes, are becoming urgent. The effect of the viscosity of the pumped liquid and the degree of paraffinization of the bore of the elevator pipes on the magnitude of the loads on the drive and power consumption of the rod systems, as well as on the optimal position of balancing crank loads, is studied. As a balance criterion, the minimization of the maximum torque on the crank shaft is taken. A mathematical model of the rod installation based on the analytical model of the balancing drive, taking into account the specified kinematics of the four-link mechanism of the rocking machine is developed. When calculating the hydrodynamic friction loads, the Navier-Stokes equations are used for the steady-state fluid flow in the annular space between the rods and tubing. A study of the loads on the drive at various viscosities and degrees of overlap of the cross section of the elevator pipes showed that an increase in the product viscosity (up to 200 mPa ∙ s) and intensive paraffin deposition on the walls of the rods and elevator pipes (overlapping up to 50 % of the cross section of the elevator lift) leads to an increase in the required torque up to 50 % on the crank shaft of the gearbox (the torque applied to the crank and created by the electric motor) and an increase in the consumed electricity and power up to 100 %, i.e. 2 times.

Weight Reduction of Crank Shaft by using Composite Material Kevlar 49

For an IC Engine, Crankshaft is one of the most important component. It basically converts the reciprocating motion of the piston into rotating motion with the aid of connecting rod which connect piston to crankshaft. Crankshaft is mounted on number of main bearings and a flywheel at one end, which is further connected to clutch and transmission. Current automotive IC engine crankshafts are made of carbon steel alloys, contains of iron and small percentage of carbon (0.25%-0.45%) along with combination of several alloying elements. In this project, a composite material called Kevlar epoxy is suggested for crankshaft. Crankshaft is designed using standard design procedure and modeling is done using SOLIDWORKS. Analysis is performed on the crankshaft made of carbon steel and composite material using analysis software called ANSYS WORKBENCH. Comparison of deformation, stresses and strains is done between crankshaft made of carbon steel and composite material, Kevlar epoxy. Considering the optimum results, crankshaft is fabricated.The aspect of this project is to optimize the weight of the crankshaft. The objective of improving engine performance, reducing initial loads and fuel economy can be achieved by reducing the weight of the crankshaft by using composite material, Kevlar epoxy. It is logical that during its large volume production, reduction of weight of crankshaft will result in large savings

Three-dimensional simulation of two-phase flow in a complex gallery and telescopic pipe coupled system

Highly efficient cooling of heavy duty marine diesel engine pistons is one of the key parts of modern advanced engine piston design. Due to the high efficiency of the shaker cooling system, oil cooling galleries are extensively used. These galleries on low-speed marine engines are particularly complex, including a telescopic pipe and an air hole on the cross head. Few work has been done on coolant flow in such complex system under coupling of reciprocating, pressure and inertial force until now. The flow behaviour is relatively poorly understood. This study focuses on the influence of telescopic pipe on the two-phase flow details for a marine low-speed diesel engine. A 3D CFD model is established including both the piston gallery and a telescopic pipe. With this model, the change in the two-phase flow pattern with the progression of the crank angle was investigated, and the pressure and mass flow rate through typical sections of the oil cooling system were analysed. By changing the oil inlet pressure and crank shaft speed, key parameters characterising the flow pattern inside the galleries were compared. The numerical results demonstrate a strong correlation between the telescopic pipe and two-phase flow characteristics. Both decreasing the crank shaft speed and increasing the inlet pressure will reduce the backflow of outside air from the air hole boundary and increase the oil filling ratio. The proposed numerical model is able to predict the complex two-phase flow phenomenon in the gallery, which is important and provides a basis for further studies on the heat transfer mechanism and optimal design of the cooling system.

Design Modification of Engine Crank Shaft Assembly

The crankshaft is a compact revolving element present in IC engines that transform the rectilinear motion of the piston into continuous rotary motion. The proper design and assembly of the crankshaft can ensure the smooth conversion of mechanical energy from reciprocating pistons to the drive system. The power dissipation, energy losses, noise, and vibration that are produced during operation directly affects the efficiency of the vehicle. The existing design of the crankshaft is a track-proven model for many decades. The manufacturing process of this involved large number of machining operation. Even though, during the long course of application, the crankshaft assembly produces some noise, vibration that leads to discomfort in ride and sharp fall in mileage of the vehicle that reduces efficiency. In order to overcome these problems, the design modification is done to improve the life and performance of the crankshaft assembly. A detailed study and analysis of the existing model are undertaken. Based on the experimental and analytical reviews; suitable design modification is made to suit the compact assembly in place of existing high weight and large crankshaft assembly. In the present work, design modification and numerical investigation of a crankshaft assembly is carried out. This crankshaft assembly is used mainly in a single cylinder, four strokes internal combustion engine. The stress comparison study is carried out between the existing design and the modified design by doing finite element analysis. The result shows that the modified design exhibits better performance and low stress than the existing model.