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Stream/Area:
-
Subject:
-
Paper ID:
IJSREM62822
Volume:
10 |
5 |
May 2026
Pages:
1-10
Publication Frequency:
Monthly (12 issues per year)
License:International Journal of Scientific Research in Engineering and Management follows the Creative Commons Attribution 4.0 (CC BY 4.0) License, allowing free use and distribution with proper attribution.
Department of Mechanical Engineering
Siddhant College of Engineering, Sudumbre, Pune
Department of Mechanical Engineering
Siddhant College of Engineering, Sudumbre, Pune
Department of Mechanical Engineering
Siddhant College of Engineering, Sudumbre, Pune
Department of Mechanical Engineering
Siddhant College of Engineering, Sudumbre, Pune
The crankshaft is an essential component of a two-wheeler internal combustion engine, as it converts the reciprocating motion of the piston into rotational motion. Due to high-speed operation and cyclic loading conditions, the crankshaft experiences a complex combination of bending, torsional, and shear stresses during operation, making its design highly susceptible to fatigue failure. Therefore, accurate stress analysis and design optimization are essential to ensure durability, reliability, and efficient performance. This study focuses on the stress analysis and geometric optimization of a two-wheeler crankshaft using Finite Element Analysis (FEA). A three-dimensional model of the crankshaft is developed using CAD software and analyzed under realistic loading and boundary conditions. Special attention is given to critical regions such as fillets, crankpin, and journal interfaces, where stress concentration is most prominent. A parametric approach is adopted to modify key geometric features, particularly the fillet radius, to improve stress distribution and structural integrity. In addition to static structural analysis, modal and harmonic analyses are carried out to evaluate the dynamic behavior of the crankshaft under operating conditions. The study also incorporates experimental testing to understand material behavior and support the simulation process. By integrating computational analysis with design modification, this work aims to develop an optimized crankshaft design that achieves improved mechanical performance and enhanced service life for two-wheeler engine applications.
KEYWORDS
· This study presented the stress analysis and geometric optimization of a two-wheeler crankshaft using Finite Element Analysis (FEA). The initial analysis identified critical stress concentration regions, particularly at the fillet areas between the crankpin, web, and journal. Based on these observations, the fillet radius was modified to improve stress distribution and reduce peak stresses. · The optimized crankshaft geometry demonstrated improved structural performance with reduced stress and deformation, indicating enhanced strength and durability. In addition to static analysis, modal and harmonic analyses confirmed better dynamic behavior, with increased stiffness and reduced vibration response under operating conditions. · Experimental validation through compression testing showed close agreement with the FEA results, supporting the precision and dependability of the simulation approach. · Overall, the study highlights that targeted geometric optimization, especially at fillet regions, can significantly improve crankshaft performance without major design changes. The methodology adopted provides a practical and effective approach for designing lightweight, reliable, and high-performance crankshafts for two-wheeler engines.
1. Dadhich, M. (2024). “Optimization of two-wheeler bike engine among three different designs using design of experiments”. 2. Zheng, B. (2022). “Crankshaft optimization based on experimental design and response surface method”. 3. Xu, Z. (2023). “Fatigue life analysis model of crankshaft under uncertain working conditions”. 4. Que, T. (2023). “Crankshaft high-cycle bending fatigue experiment for automotive applications”. 5. Wei, Z. (2025). “Crankshaft high cycle bending fatigue test method based on extended Kalman filtering algorithm”. 6. Rui, S. (2023). “Research of the crankshaft high cycle bending fatigue experiment method”. 7. Al Ghifari, K. (2024). “Optimization of car crankshaft strength with ductile iron material through Solidworks simulation”. 8. Ferreira, R. N., et al. (2024). “Experimental and numerical fatigue evaluation of crankshafts.” 9. Deepanshu Yadav & Vikash Dwivedi (2025). Finite Element-Based Geometry Optimization to Enhance Fatigue Life of a Single-Cylinder Engine Crankshaft. 10. Husnain, M. N. M., Lee, J. Q., Akramin, M. R. M., et al. (2025). Finite element analysis of bending tests for fatigue cracking assessment.
Publication Date
5/8/2026
Peer Review Type
Double-Blind Peer Review
Review Rounds: 2
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The authors declare no conflict of interest related to this research work.
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