1 FATIGUE PERFORMANCE COMPARISON AND LIFE PREDICTION OF FORGED STEEL AND DUCTILE CAST IRON CRANKSHAFTS JONATHAN WILLIAMS, FARZIN MONTAZERSADGH, AND ALI FATEMI GRADUATE ASSISTANTS AND PROFESSOR, RESPECTIVELY MECHANICAL, INDUSTRIAL & MANUFACTURING ENGINEERING DEPARTMENT THE UNIVERSITY OF TOLEDO, TOLEDO, OHIO ABSTRACT The objective of this study was to compare the durability of crankshafts from two competing manufacturing processes, as well as to perform dynamic load and stress analysis, and optimization. The crankshafts used in the study were forged steel and ductile cast iron from a one-cylinder gasoline engine. Strain-controlled monotonic and fatigue tests as well as impact tests were performed on specimens machined from the crankshafts. Load-controlled component bending fatigue tests were also carried out on the crankshafts. Material tests showed that the forged steel had 26% higher tensile strength and 37% higher fatigue strength than the ductile cast iron, while component tests showed that the forged steel crankshaft had 32% higher fatigue strength resulting in a factor of six longer fatigue life. The S-N approach used to predict the fatigue lives of both crankshafts showed reasonable correlation to the experimental data from the component tests. Dynamic load analysis was performed to determine the in service loading of the crankshafts and FEA was conducted to find stresses at critical locations. Finally, the geometry, material, and manufacturing processes were optimized for the forged steel crankshaft. The optimization process included geometry changes compatible with the current engine, fillet rolling, and the use of MA steel, resulting in 18% weight reduction, increased fatigue strength and reduced cost of the crankshaft. INTRODUCTION A crankshaft is a highly stressed component in an engine that is subjected to bending and torsional loads. The crankshaft must be designed to last the life of the engine due to the catastrophic damage to the engine which would result if failure did occur. Considering the life of an engine in an automobile, for example, this results in requirement for an infinite life fatigue situation. Because of the long life and high stresses, as well as the need for weight reduction, material and manufacturing process selection is important in crankshaft design. There is competition among materials and manufacturing processes, due to cost, performance, and weight. This is a direct result of industry demand for components that are lighter, to increase efficiency, and cheaper to produce, while at the same time maintaining fatigue strength and other functional requirements. There are several ways to manufacture a crankshaft, including machining from a billet, forging, and casting. Due to cost and time, machining a crankshaft from a billet is seldom used except in very low production applications. The two most common types of crankshafts are made of cast iron and forged steel. One must also consider other design issues such as surface treatment techniques including induction hardening,
FATIGUE PERFORMANCE COMPARISON AND LIFE PREDICTION OF FORGED STEEL AND DUCTILE CAST IRON CRANKSHAFTS
May 17, 2023
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