Optimization through CAE Practices for Forged Crankshaft of a Two - Wheeler to Effect Mass Reduction

The main objective of this study was to investigate mass and cost reduction for forged crankshaft of two wheeler. Every stroke of the engine subjected to its adjacent components to cyclic loading that pulls and pushes the components like piston, connecting rod and crankshaft. The crankshaft, in turn, is connected to the transmission system and is a critical component from the design perspective. The design of the crankshaft can be done in a justifiable manner if an attempt is made to identify the effects of the operating loads on the component in the form of the type of stress induced with its peak value and the location of these stresses over the component. This study consists of two major sections, Finite Element Analysis and Optimization for mass reduction. In this dissertation work, 3-D finite element analysis is planned to be carried out by virtue of static stress analysis of crankshaft. Alternatives for Design would be suggested while attempting to modify the geometry of the Crankshaft by changing the different parameter. The load was applied to FE model in Hypermesh, and boundary conditions were applied according to engine mounting conditions. The no. of cycles of failure can be predicted using MSC Fatigue software