A Seminar on
Study Failure of The Crankshaft of Diesel
Engine
SCoE, T. E. (Mechanical), Seminar – 2015 Course, [2017 – 18] 1
CONTENTS
Introduction.
Crankshaft Terminology.
Causes Of Failure.
Prevention of failure
References.
SCoE, T. E. (Mechanical), Seminar – 2015 Course, [2017 – 18] 2
INTRODUCTION
Crankshaft main part of piston engine assembly
Converts reciprocating motion into rotary motion.
Generally designed for infinite life.
Large scope on research in investigating the failures of
crankshaft
Study of failures is important for safety of lives and
property
Knowing the causes of failure we can prevent the
failure from recurring
SCoE, T. E. (Mechanical), Seminar – 2015 Course, [2017 – 18] 3
CRANKSHAFT TERMINOLOGY
Main Journal And Bearings
Crank
Counterweights
Oil Hole
SCoE, T. E. (Mechanical), Seminar – 2015 Course, [2017 – 18] 4
CASE STUDY
• The crankshaft of 2.0 DTI diesel engine
• Failed after 260,000 km. No. of revolutions as
6.24 × 108.
• Chemical composition was normal but
hardness was low.
• Tensile stress alters from low to maximum
during one shaft rotation i.e. alternating stress,
bending due to gas forces, high stress
concentration due to small fillet radius
• Conclusion: large alternating bending stress,
low hardness and small pin fillet radius were
main reasons for failure.
SCoE, T. E. (Mechanical), Seminar – 2015 Course, [2017 – 18] 5
CAUSES OF FAILURE
Fatigue cracks due to cyclic nature of loading
Resonant vibrations-misalignment, fuel used and power
of engine
Low surface hardness at most critical region with bad
heat treatment process
Improper chemical composition of material used in
crankshaft
Lubrication failure
Poor surface finish
SCoE, T. E. (Mechanical), Seminar – 2015 Course, [2017 – 18] 6
CAUSES OF FAILURE
Repairing from unauthorized workshop
Overloading of vehicle
Presence of defects such as micro-cracks in the material
itself
Attitude of driver while driving
Poor road conditions
Weather changes
SCoE, T. E. (Mechanical), Seminar – 2015 Course, [2017 – 18] 7
PREVENTION OF FAILURE
Increase the fillet radius
Use of vibrational dampener
Repairing from authorised workshop
Use of suitable hardening process to get required
hardness
Selection of standard material
Proper lubrication system
Good surface finish
Avoid overloading
Proper maintenance
SCoE, T. E. (Mechanical), Seminar – 2015 Course, [2017 – 18] 8
REFERENCES
1. M. Fonte, V. Infante, M. Freitas, L.Reis, Failure Mode Analysis Of
Two Diesel Engine Crankshafts, XV Portuguese Conference On
Fracture, PCF 2016, 10-12 February 2016, Paço De Arcos,
Portugal.
2. Lucjan Witek, Feliks Stachowicz, Arkadiusz Zaleski, Failure
Investigation Of The Crankshaft Of Diesel Engine, 2nd
International Conference On Structural Integrity, ICSI 2017, 4-7
September 2017, Funchal, Madeira Portugal.
3. Lucjan Witek, Michał Sikora, Feliks Stachowicz, Tomasz
Trzepiecinski Rzeszow University Of Technology, Faculty Of
Mechanical Engineering And Aeronautics, 8 Powstancow.
Warszawy Ave., 35-959 Rzeszow, Poland And MTU Aero Engines
Polska, Tajecina 108, 36-002 Jasionka, Poland, 1 June 2017.
4. M. Fonte , Bin Li , L. Reis B M. Freitas, Crankshaft Failure Analysis
Of A Motor Vehicle, ICEMS-IST And Higher Nautical School,
Portugal And ICEMS-IST-Technical University Of Lisbon,
Portugal,30 January 2016.
SCoE, T. E. (Mechanical), Seminar – 2015 Course, [2017 – 18] 9
Thank you!
SCoE, T. E. (Mechanical), Seminar – 2015 Course, [2017 – 18] 10
