Abstract - The crankshaft is the part of an engine which translates

reciprocating linear piston motion into rotation. In converting the linear

motion of the piston into rotational motion; crankshafts operate under high
loads and require high strength and stiffness to withstand the high loads in
modern engines, and to offer opportunities for downsizing and weight
reduction .We have came with an idea of suggesting a new crank shaft
material 20MnCr5 steel, which has high strength and stiffness and satisfies
the all the requirements of the crank shaft materials. We did the various
important testing like hardness test(Rockwell Hardness), impact test, torsion
test, fatigue test, on this 20MnCr5, our paper deals with our experimental
works on this 20MnCr5. The objective of this testing is to 2oMnCr5 metal is to
suggest that this is the one of the suitable material for making crankshafts
for the modern engines. Keywords: Crankshaft, Strength, Stiffness, weight
reduction, 20MnCr5 steel.
1. Introduction:
Crankshaft is among the largest components in internal combustion engines.
The crankshaft converts reciprocates motion to rotational motion. It contains
counter weights to smoothen the engine revolutions. Crankshaft is one of the
most critically loaded components and experience a typical automotive
crankshaft consisting of main journals (located on shaft centerline),
connecting rod journals (located off-centerline), a trust bearing journal,
cranks
that
connect
the
journals and hold
the
component
together, and a
number
of
auxiliary
parts.
Cyclic loads in the
form of bending
and
torsion
during its service
life.

2.

CRANKSHAFT MATERIALS

Crankshafts materials should be readily shaped, machined and heat-treated,

and have adequate strength, toughness, hardness, and high fatigue strength.
The crankshafts are manufactured from steel either by forging or casting.
The main bearing and connecting rod bearing liners are made of babbitt, a
tin and lead alloy. Forged crankshafts are stronger than the cast crankshafts,
but are more expensive. Forged crankshafts are made from SAE 1045 or
similar type steel. Forging makes a very dense, tough shaft with a grain
running parallel to the principal stress direction. Crankshafts are cast in steel,
modular iron or malleable iron. The major advantage of the casting process is
that crankshaft material and machining costs are reduced because the
crankshaft may be made close to the required shape and size including
counterweights. Generally automobile crankshafts were forged in past to
have all the desirable properties. However, with the evolution of the nodular
cast irons and improvements in foundry techniques, cast crankshafts are now
preferred for moderate loads. Only for heavy duty applications forged shafts
are favored. The selection of crankshaft materials and heat treatments for
various applications are as follows.

3.

DESING OF CRANK SHAFT:

Length of the Crankshaft: 2.42M

Crank throw: 0.31M
Crank Webs Diameter or Thickness: 0.25M
Length: 0.91 M

4.

CONCLUSION:

Tempered martensite is a microstructure which we observed after the surface

treatment the hardness which maintains 58 HRC in case and 42 HRC in core
the metastable martensite improve the endurance strength of the material.
The higher endurance strength will cause the metal to fail after a large
number N of applications of the stress. Results of the fatigue tests are shown
that there is no discontinuity in the relation between lifetime and stress
amplitude beyond 107 cycles, meaning that a Very High Cycle Fatigue effect
is observed from these materials SAE 5120-20MnCr5 so we conclude and

suggest that 20MnCr5 can be used as a crankshaft material for the

transportations.