Failure analysis of ductile iron crankshaft in compact pickup truck diesel engine

Aliakbari, Karim; Nejad, Reza Masoudi; Mamaghani, Tohid Akbarpour; Pouryamout, Pooya; Asiabaraki, Hossein Rahimi

doi:10.1016/j.istruc.2021.12.034

Cited by 26 publications

(9 citation statements)

References 44 publications

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“…The non‐failed sample had a visible crack but was small and fairly difficult to notice by the unaided eye. Similar to Aliakbari et al 32 findings, the fracture surfaces shown in Figure 12 right‐hand side provided a better perspective of the cracks' sizes. Once opened, the elliptical crack surface could be clearly distinguished from the forced‐open surface.…”

Section: Resultssupporting

confidence: 83%

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Crack propagation mapping at component‐level fatigue testing by means of natural frequency tracking control

Cunha

Rego

Victor

et al. 2022

Fatigue Fract Eng Mat Struct

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Advancements seeking structural components' strength and weight reduction necessarily pass through fatigue testing. Understanding failure phenomena and crack evolution is a way of methodologically achieving such a goal. An own-designed resonant fatigue test rig was used to study the behavior of three distinctly manufactured crankshaft batches. A control system and a resonant frequency estimator were developed to follow the overall stiffness reduction with crack advancement. The control algorithm followed the frequency decay to compensate for the input load. The control strategies were validated by finding the system's natural frequency at the beginning of the test and maintaining a constant nominal load. Fractographies made with failed and non-failed specimens revealed the connection between the expected physical results and the natural frequency shift evolution. The implemented logic enables crack advancement tracking and failure determination. The developments here can be overflown to different resonance fatigue systems to characterize their endurance performance.

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Section: Resultssupporting

confidence: 83%

“…The crack size was measured using a portable digital microscope, model DinoLite AM4013MZT. A scanning electron microscope (SEM) can further examine the crack nucleation and propagation, as discussed by Aliakbari et al 32 Figure 6 shows the crack inspection sequence.…”

Section: Methodsmentioning

confidence: 99%

Crack propagation mapping at component‐level fatigue testing by means of natural frequency tracking control

Cunha

Rego

Victor

et al. 2022

Fatigue Fract Eng Mat Struct

View full text Add to dashboard Cite

show abstract

“…A sample each from the main journal, crankpin and counter weight of the crankshaft are prepared with the size of 10 mm × 10 mm × 3 mm using the Wire EDM machine as shown in figure 4(a). As mentioned in the literature, Rockwell hardness tester is used under the stated conditions for inspection as per ASTM E18-15 standard in the manufacturing industry [16].…”

Section: Hardness Testing and Xrd Analysismentioning

confidence: 99%

Fatigue failure prediction through factor of safety and stress concentration in a malfunctioned AISI 4140 automotive crankshaft

Mylsamy,

Subramanyan

2023

Mater. Res. Express

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The performance and safety of any vehicle relies on proper design of crankshaft. Crankshaft failure occurs mainly due to the combination of imbalance and minor deflections when the materials is subjected to combined bending and twisting. Failure analysis is crucial to identify the causes and modes of failure, in order to improve the service life of automotive crankshafts and prevent accidents. This research analyses the root cause of failure by testing a failed crankshaft of a twin cylinder diesel engine used in mini commercial vehicle runs around 80000 km. The important research gap identified as that there is no fool-proof techniques and validation procedures are followed in the service stations during its life cycle period. This investigation of a failed crankshaft provides detailed composition of material, its micro structure and mechanical properties. Further, rotary analysis, experimental modal analysis and mechanical testing of materials are helpful in characterizing proper materials to be selected and analyzing the root cause of failure. The experimental setup helps to test a crankshaft and its specimen as per ASTM testing procedures and the results are correlated with numerical analysis using ANSYS software. The objective of this investigation is to provide insights through failure analysis to the designers and manufacturers, thereby improve the reliability and safety of automotive crankshafts, ensure safe operation of the vehicle, and eventually minimize financial losses.

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“…Procedural aspects in the present work such as meshing, element type selection, boundary conditions, and loading method were carried out according to [29][30][31][32]. According to the structure shown in Figure 3, a 3D model was created by 3D-modeling software and imported into ABAQUS.…”

Section: Simulation Analysis Of Mechanical Properties and Band Gap Ch...mentioning

confidence: 99%

Investigations on the Band-Gap Characteristics of Variable Cross-Section Periodic Structure Support Made of Acrylonitrile-Butadiene-Styrene

et al. 2022

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Based on the band gap theory of periodic structure, this article proposes a new variable cross-section periodic structure support made of acrylonitrile-butadiene-styrene. The band gap characteristics of the periodic structure support were studied experimentally. According to the basic theory of band gap calculation, two kinds of supports with the same installation size were designed, and they were manufactured by 3D printer. Then, the displacement–load curve and the vibration characteristic curves of the periodic structure support were obtained through simulation analysis. The band gap range of the two supports was measured by hammer excitation, and the accuracy of the finite element model was verified by comparison with the experiment results. Finally, the response curve of the periodic structure support with variable cross-section every 100 Hz was obtained by excitation of the shaker, which verified the vibration isolation effect of the measured band gap. The results show a band gap in the support of the variable cross-section periodic structure, compared with the support of the non-periodic structure. If the vibration frequency is within the band gap frequency, the vibration will be significantly attenuated.

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Failure analysis of ductile iron crankshaft in compact pickup truck diesel engine

Cited by 26 publications

References 44 publications

Crack propagation mapping at component‐level fatigue testing by means of natural frequency tracking control

Crack propagation mapping at component‐level fatigue testing by means of natural frequency tracking control

Fatigue failure prediction through factor of safety and stress concentration in a malfunctioned AISI 4140 automotive crankshaft

Investigations on the Band-Gap Characteristics of Variable Cross-Section Periodic Structure Support Made of Acrylonitrile-Butadiene-Styrene

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