Finite Element Analysis of Two Wheeler Honda Bike Crank Shaft

Lakhan Gadge, K.K. Gadgey, Sunil Jamra

The most important objective of this study is to study weight and cost reduction opportunities for a crankshaft. The necessity of load history in the FEM analysis necessitates performing a detailed load analysis. Therefore, this study consists of two major sections: (1) FEM and stress analysis of existing crankshaft, (2) optimization for weight and cost reduction. Crankshaft is one of the vital components for the effective and precise working of the internal combustion engine. In this study, a static simulation is conducted on a crankshaft from a single cylinder 4-stroke petrol engine. A three dimension model of crankshaft is created using CATIA software. Finite element analysis (FEA) is performed to get the variation of stress magnitude at critical locations of crankshaft. The preliminary static analysis will be done on existing design of crankshaft with FEA Software ANSYS. The boundary conditions are applied according to the engine mounting conditions. The deflection, stress and strain will be obtained from FEA study. The second step consists of Topology optimization of crankshaft for similar boundary conditions.   The main purpose of optimization study is to reduce the weight of a crankshaft. The optimization will be carried out in Altair Optistruct software. The existing design will be divided in design and non-design space. Geometry, material, and manufacturing processes will be optimized considering special constraints, developing feasibility, and cost. The optimization process include geometry changes well matched with the current engine, reduce weight compared to existing design, cost of the crankshaft, without changing other components.