DESIGN OF A FULLY ASSEMBLED CRANKSHAFT FOR A 1.2 LITER HORIZONTALLY OPPOSED 4 CYLINDER S.I. ENGINECHUKWUDI

Abstract

This work aims to develop an analytical method of designing a fully assembled crankshaft for automotive
application. The design will incorporate innovative octahedral fixture of the main journal shafts to the webs. This distinct
feature of the design will basically improve the fatigue life of the design since most fatigue failures of assembled crankshafts
occur at this region due to alternating slip-fret.Theories and formulas deduced in the analysis will be illustrated in the design
of a crankshaft for a 1.2 litre horizontally opposed 4 cylinder spark ignition engine as charging power plant of a hybrid
vehicle. The analytical method will evaluated the nominal sizes and dimensions based on stress analysis of the crankshaft
configuration. Also analytically, the fatigue analysis will be performed to ensure that the part survives cyclic fluctuating
stresses during service for infinite life of operation. Since the part will be subjected to high cycle of operation, the stress-life
method of fatigue analysis will be adopted.For validation of the deduced analytical method, a finite element analysis of the
solid modelled part will be computer-simulated with ANSYS workbench software. Then the results of the analytical method
will be compared with that of FEA for conformity and agreement.The design and development of this innovation segmented
crankshaft for the charging power unit of a hybrid vehicle will play a vital role in the green transition.