Research Paper on Static Structural Analysis and Simulation to Obtain Stress Magnitude at Critical Location of Crankshaft in Internal Combustion Engine

This research focuses on conducting a static structural analysis and simulation to assess stress levels at critical points on a crankshaft within an internal combustion engine. As a vital engine component, the crankshaft endures significant mechanical stresses generated by piston forces during operation. Finite element analysis (FEA) was employed to simulate the crankshaft’s response to static loads. The crankshaft model was initially developed in Pro/ENGINEER and then imported into ANSYS software for detailed simulation. The primary goal was to map the stress distribution across the crankshaft and identify areas susceptible to potential failure. The analysis indicated that stress concentrations are particularly high at certain critical locations, making them vulnerable to fatigue failure under prolonged cyclic loading. A comparison between forged steel and cast iron crankshafts revealed that the forged steel variant exhibited lower strain, suggesting superior performance and greater durability under static loading conditions. This study concludes that the forged steel crankshaft not only withstands the imposed stresses effectively but is also well-suited for mass production, which could result in cost savings. The insights gained from this research contribute to the refinement of crankshaft design, ultimately improving the efficiency and reliability of internal combustion engines.