Abstract

The crankshaft is one of the important components for the effective and precise operation of the internal combustion engine, as the automotive industry requires an appropriate selection of materials for power transmission. The main goal of selecting the appropriate materials is to increase the effectiveness of the resistance to bending and torsion, in addition to performing a surface treatment to obtain the highest performance of the column, which is crucial. Accordingly, this research aims to study the mechanical behavior of the types of materials most commonly used in crankshaft manufacturing, by designing a four-piston crankshaft, analyzing the stresses and displacements resulting from the impact of the applied load, and determining the vibration frequencies, which provide valuable insights into the dynamic behavior. For this purpose, a three-dimensional model of the crankshaft was designed using CATIA V5R18 software, and the finite elements were subsequently analyzed using the ANSYS 2019 R1 program. The model was prepared for analysis, where 249,630 elements and 427,888 nodes were created under static and dynamic conditions with four different materials in different directions, including structural steel. Aluminum alloy 7475, cast iron, stainless steel 308. To verify the effectiveness of the proposed design, the current design was compared with the design within the reference study in terms of stresses and displacements, and the safety factor was confirmed, as it led to a decrease in stress by 17.7% and displacement by 0.6%. By comparing the results, a choice was made. Aluminum 7475 has the lowest value of equivalent stress, Von-misses, and displacement compared to other materials. The results show that the cast iron material has low values for vibration frequency compared to the other materials, while the structural steel material has very low values ​​for total deformation under the influence of the applied load, as the results indicate. The result is that by choosing the appropriate material for the right working conditions, the crankshaft will help to improve engine performance, ensure high productivity, and provide the best durability.