Study on Failure Analysis of Crankshaft Using Finite Element Analysis

Crankshaft is one of the crucial parts for the internal combustion engine which required effective and precise working. In this study, the aim of the study is to identify the stress state in the crankshaft and to explain the failure in automotive crankshaft and fatigue life of crankshaft by using finite element analysis. The 3D solid modelling of the crankshaft model was designed and developed using SolidWorks. A static structural and dynamic analysis on an L-twin cylinder crankshaft were used to determine the maximum equivalent stress and total deformation at critical locations of the crankshaft. The model was tested under dynamic loading conditions to determine fatigue life, safety factor, equivalent alternating stress and damage using the fatigue tool. The results obtained from this study indicated that the crankshaft has obvious fatigue crack which was belongs to fatigue fracture. The fatigue fracture developed was only attributed to the propagating and initiate cracks on the edges of the lubrication hole under cyclic bending and torsion. Overall, the crankshaft is safe for both static and fatigue loadings. In dynamic analysis, the critical frequency obtained in the frequency response curve should be avoided which it may cause failure of the crankshaft.