Paper Contents
Abstract
The reliability of a system that converts linear piston displacement into shaft rotation largely depends on the crankshaft, a critical component whose failure can disrupt the entire mechanism. As a high-volume production part with complex geometry in internal combustion engines (ICE), the crankshaft plays a key role in converting the reciprocating motion of the piston into rotational motion, thereby harnessing the power generated during combustion in the cylinder. Analysing the stress experienced by the connecting rod under different load conditions is essential for efficient power transmission. This is typically done by creating 3D models in CATIA V5 and performing stress analysis in ANSYS. Evaluating crank throw distortion and stress distribution helps optimize the design by reducing weight without compromising strength. This study focuses on developing a 3D model of the crankshaft system in CATIA V5 and conducting a detailed analysis in ANSYS to understand its motion and load behavior. Topology optimization is employed to minimize weight while maintaining functionality. Testing under three loading conditions (22624 N, 32624 N, and 42624 N) identifies Model 3 as the most efficient design, showing the lowest stress, minimum deformation, and reduced weight. The topology optimization process successfully decreases material usage while preserving performance and reliability.
Copyright
Copyright © 2025 Akash Wahane. This is an open access article distributed under the Creative Commons Attribution License.
