Indian Journal of Science and Technology

Abstract

Objective: There are enormous ways to reduce crankshaft weight, which includes web design optimisation, reducing the bearing diameters etc. This paper exploits the crankshaft optimization through conceptualizing hollow shaft design. Methods: The optimization of engine components for mass reduction should be carefully done ensuring the functionality of the components is within the safety limits. The optimization of the crankshaft is made viable through the detail study of crankshaft dynamics and advanced calculations such that the design is not only within safer limits but also it must be durable throughout the engine life. The crank pin and journal are made hollow and validation results are within the safer limits. Findings: The Automobile industries are currently in surge of meeting high customer needs and emission regulations which heuristics to develop innovative methods assuring less exhaust emissions and high power. As the mechanical losses are more, the pragmatic way for achieving this customer needs, government regulations and enhance the performance of the engine is by the development of light weight components. Lightweight engine components design is a method of improving fuel economy and dynamic behaviour of engine. Apart from these the other advantages that we can achieve by reducing the inertial mass is the decrease in power required for accelerating the moving components. Variety of studies have shown that further optimization of the crankshaft which is the prime rotating component within an engine is also possible. This paper demonstrates the crankshaft optimization through the hollow crank pins and journals which yields a weight reduction of 22% and also doubles the safety factor of the existing solid crankshaft design. Applications: This concept can be successfully implemented for light commercial vehicles which require more power in addition to the torque requirements. The racing cars which require high durable light weight components can use this concept to achieve high power vehicles.
Keywords: Crankshaft Dynamics, Hollow Crankshaft