A crankshaft is a component which is used to convert a reciprocating movement into rotating or vice versa. Through the past years classical manufacturing techniques did not leave space for a new approach regarding manufacturing this component. Powder Metallurgy provides a manufacturing technique which can revolutionize this procedure and make it more economical and more efficient. In order for this to be achieved, the crankshaft must be produced in different pieces. Webs, counter-webs and journal shafts must be produced individually and assembled together. The main challenge in this thesis is to understand if the crankshaft’s counter webs could be manufactured all in the same pieces or in as less pieces as possible. This thesis deals mostly with the technical requirements and proposing a new modular design. A kinematic-kinetic analysis is performed by using the values from the existing crankshaft which has been scanned and converted into a CAD model. The numerical values from the kinetic-kinematic analysis in Matlab are compared with a MBS model from Adams. Then the balancing of the crankshaft is analyzed and it is investigated how the counterweights should be arranged in space and what should be the mass and the geometrical properties of them. From the component’s design specifications, several models are generated and evaluated with the Pugh matrix. The original and the new proposed models are compared as far as concern the mass, center of mass, mass moment of inertia and natural frequencies. / En vevaxel är en motorkomponent som används för att omvandla den fram- och återgående rörelsen hos kolv och vevstake till en roterande rörelse. De klassiska metoderna att tillverka vevaxlar har varit dominerande och inte gett någon plats för alternativa tillverkningsmetoder. Powder manufacturing är en metod som kan revolutionera produktionens effektivitet och ekonomi. För att denna tillverkningsmetod ska vara möjlig måste vevaxeln tillverkas i delar. Webs, counter-weights och journal shafts måste produceras individuellt för att sedan sammanfogas. Den största utmaningen för denna avhandling är att förstå om vevaxelns counter webs kan tillverkas med samma form eller med så få olika former som möjligt. Denna avhandling handlar främst om att fastställa dessa tekniska krav och föreslå en ny, modulär design för PM. En kinematisk-kinetisk analys utförs med hjälp av en befintlig vevaxel som skannats och omvandlats till en CAD-modell. De numeriska värdena jämförs med en MBS-modell från Adams. Vevaxeln analyseras med avseende på balansering då motvikternas placering, massa och geometriska egenskaper undersöks. Nya modeller som följer de tekniska krav som krävs skapas och utvärderas med Pugh-matris. De nya föreslagna modellerna jämförs med den ursprungliga utformningen med tanke på massa, masscentrum, MMOI och egenfrekvenser.

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O presente trabalho objetivou ilustrar procedimentos de analise auxiliada por computador e metodologia de desenvolvimento para arvores de manivela tendo-se como meta sugestões de boas praticas de projeto visando a otimização de componentes segundo necessidades ditadas pelos clientes, competidores e legislações vigentes. Ilustrou-se uma lista das etapas principais do projeto e desenvolvimento de virabrequins com foco na analise dinâmica e estrutural do componente. Para estas etapas especificas, resumiu-se a teoria básica envolvida nos cálculos e analises necessários e, para casos de abordagens consagradas distintas na resolução de um mesmo problema, realizou-se uma comparação de precisão e custo envolvidos. Posteriormente, aplicou-se o conjunto de ferramentas analisadas em um estudo de caso com uma arvore de manivelas de quatro cilindros em linha, obtendo-se o desempenho estrutural e dinâmico do componente seguido de uma otimização paramétrica. Observou-se um potencial de ganho de precisão desde o calculo do carregamento aplicado no componente a otimização do mesmo, com o uso de métodos clássicos aplicados a nova tecnologia de software e hardware disponível. Concluiu-se que a organização adequada e utilização específica das ferramentas disponíveis trazem benefícios expressivos na qualidade dos resultados, melhor utilização dos recursos disponíveis e visão global do vinculo de diferentes parâmetros de desempenho. / In the current dissertation it was aimed to illustrate procedures regarding computer aided analysis and methodology for development of crankshafts seeking best practices suggestions to design and focusing on component optimization. These methods must adequate component design to customer, competitors and laws demands. Main development and design tasks for crankshafts were shown centering attention on dynamic and structural analysis. The basic needed theory for these specific tasks with calculus and analyses was summarized and, when more than one common approach was applicable, a cost and precision comparison was performed. Afterward, these tools were applied in a case study where main performance parameters for an inline four cylinder engine crankshaft were obtained. The component was analyzed structurally and dynamically for a subsequent parametric optimization. A potential benefit in precision was observed from applied loads calculation to the mentioned optimization by using available classic methods and modern software and hardware technology mutually. It was concluded that, with an adequate project organization and specific usage of available methods, expressive results can be obtained in results quality, best resources employment and general understanding of performance parameters links.

A controlled continuous laser output using a circular geometry with a gaussian intensity distribution was used to harden the surface of a particular metal specimen (44MnSiVS6). Said beam operated within a relatively small power interval, just barely past the melting point. The resulting martensite track was shown to expand laterally at a positive exponential rate, with respect to the energy input. This was furthermore accompanied with an increase of the average slope at each lateral edge. The thickness was seen to expand at a significantly slower rate (by about one order of magnitude), with declining efficiency in regard to the energy input used. Thermal measurements along the surface indicated somewhat uniform temperature patterns within a relatively large area surrounding the middle of the beam spot. Though a slight elevation in temperature was often noted in the vicinity of its centre. In addition to using a gaussian beam, three other intensity distributions were utilized. The results obtained from said distributions may suggest effectual alterations to occur in terms of the shape and extent of the resulting martensite zone, if the spread of the gaussian intensity profile is allowed to be modified. Ideally, this would be carried out while still remaining close to the melting point, as well as keeping the spot size unchanged. A series of vicker's hardness measurements was carried out for each track induced by a different beam distribution. A clear transition in hardness was noted across the perceived boundary between the martensite zone and the base material, confirming the legitimacy regarding the phase identification. / Stiffcrank - Advanced laser surface hardening of microalloyed steels for fatigue enhancement of automotive engine components, funded by EU-RFCS, no. 754155

O presente trabalho objetivou ilustrar procedimentos de analise auxiliada por computador e metodologia de desenvolvimento para arvores de manivela tendo-se como meta sugestões de boas praticas de projeto visando a otimização de componentes segundo necessidades ditadas pelos clientes, competidores e legislações vigentes. Ilustrou-se uma lista das etapas principais do projeto e desenvolvimento de virabrequins com foco na analise dinâmica e estrutural do componente. Para estas etapas especificas, resumiu-se a teoria básica envolvida nos cálculos e analises necessários e, para casos de abordagens consagradas distintas na resolução de um mesmo problema, realizou-se uma comparação de precisão e custo envolvidos. Posteriormente, aplicou-se o conjunto de ferramentas analisadas em um estudo de caso com uma arvore de manivelas de quatro cilindros em linha, obtendo-se o desempenho estrutural e dinâmico do componente seguido de uma otimização paramétrica. Observou-se um potencial de ganho de precisão desde o calculo do carregamento aplicado no componente a otimização do mesmo, com o uso de métodos clássicos aplicados a nova tecnologia de software e hardware disponível. Concluiu-se que a organização adequada e utilização específica das ferramentas disponíveis trazem benefícios expressivos na qualidade dos resultados, melhor utilização dos recursos disponíveis e visão global do vinculo de diferentes parâmetros de desempenho. / In the current dissertation it was aimed to illustrate procedures regarding computer aided analysis and methodology for development of crankshafts seeking best practices suggestions to design and focusing on component optimization. These methods must adequate component design to customer, competitors and laws demands. Main development and design tasks for crankshafts were shown centering attention on dynamic and structural analysis. The basic needed theory for these specific tasks with calculus and analyses was summarized and, when more than one common approach was applicable, a cost and precision comparison was performed. Afterward, these tools were applied in a case study where main performance parameters for an inline four cylinder engine crankshaft were obtained. The component was analyzed structurally and dynamically for a subsequent parametric optimization. A potential benefit in precision was observed from applied loads calculation to the mentioned optimization by using available classic methods and modern software and hardware technology mutually. It was concluded that, with an adequate project organization and specific usage of available methods, expressive results can be obtained in results quality, best resources employment and general understanding of performance parameters links.

The diploma thesis deals with a design of a crankshaft for a three-cylinder diesel engine for commercial vehicles. The engine is a member of a unified line of engines with the number of cylinders from two to six. The main points of the work are a draft of the crankshaft configuration, the balance of inertial forces and the moments in the crank mechanism, creation of drawings of the crankshaft and finally carrying out a strength analysis of the part, taking into account torsional vibration. The aim is formation of a part – crankshaft for potential usage in the automotive industry.

This thesis deals with the possibilities for realization of the crankshaft-cylinder four-stroke gasoline engine is flat, usable in the urban vehicle. In the work described stresses exerted on the crank mechanism can balance the crankshaft, torsional stress and strength calculation method of control. In the final part of this work is outlined proposal for implementation of the crankshaft.

Configuration of the powertrain of a flat-eight engine with ordered basic parameters is the theme of this thesis which name is Powertrain design of an eight-cylinder aircraft engine. This thesis occupies with configuration design of the crank mechanism and firing order, balancing of centrifugal and reciprocating forces and their moments, conceptual design of crankshaft and its stress calculation. This thesis also puts mind to calculation of torsional vibrations.

Configuration of the powertrain of a flat-engine with ordered basic parameters is the theme of this final thesis which name is Powertrain design of ten-cylinder aircraft engine. This thesis is occupied with configuration design of the crank mechanism and firing order, balancing of centrifugal and reciprocating forces thein moments, conceptual design crankshaft and its stress calculation of torsional vibrations.