Calculation, design, prototype production of crank shaft, connecting rod, piston and flywheel for the four cylinder diesel engine that output is 90 kw at 1500 RPM

In this master thesis for a brand new design four cylinder diesel motor, which will produce 90 kW power in its synchronous speed, crank shaft, connecting rod, piston and fly wheel component calculations were handled in terms of dynamic and static aspects.Pre-design of above mentioned products and the whole motor were done by Şahin Metal İmalat A.Ş. administrative board chairman Mech. Eng. Mustafa ESER. On this pre-design process thermo dynamical calculations of Yıldız Technical University lecturer Prof. Orhan DENİZ were used.In the thesis work, pre-designed motors kinematic and dynamic calculations were done by using Matlab?s m-file functionality, under supervisory of Yıldız Technical University lecturer Prof. Necati TAHRALI. As a result of these calculations position and mass of balancing weights were determined.After determination of acting forces on crank shaft, the rotational inertia of fly wheel, which the responsible component from the uniformity of the engine, calculated. Calculation indicated that rotational inertia of the pre-design fly wheel was appropriate.After determination of the forces of other components acting on the crack shaft, strength calculations of the crank shaft were investigated. Crankshaft calculations were handled in three sub categories for comparability. These sub categories were torsional strength, bending strength and combined strength. In each sub category, shear force, bending moment and torsion moment acting on the section area was calculated by analytical methods. In the bending strength sub category bushing forces and moments were determined by using Maxwell -Clapeyron equations.On the second step, bending and torsion moments were calculated by using 1D modeling techniques in MSC.Nastran. These calculations were compared by analytical solutions.On the third step, 3D modeling techniques used for taking into affect of the stresses due to shape factors in MSC.Nastran. In this step bending, torsional and combined stresses were calculated.On the 1D stress analysis so far, maximum stress value on the crank shaft was determined by analytical calculations and verified by 1D MSC.Nastran analysis. Although deformed shape and maximum critical stress location were determined in 3D stress calculations, final results were obtained from MSC.Adams calculations. In MSC.Adams calculations rapidly varying dynamic affects on the crank shaft were calculated due to neutral frequency based dynamic calculation techniques.On the fourth step, MSC.Adams model used for dynamic calculations which was included, masses of piston connecting rod balancing weights and fly wheel, simulating with the correct combustion timing and taking into affect of stiffness of the main journals. On this detailed model bending torsional and combined stress states were calculated separately.Maximum stress values acting on the crank shaft versus crack shaft angle were obtained from MSC.Adams model and used in MSC.Fatigue calculations. These calculations were compared with hand drawn Woehler diagrams.As a result of crank shaft calculations, it was decided that the main journal diameter should expand up one segment. But it was concluded that smaller main journal diameter could be used after proper testing.The third part examined after the crank shaft was connecting rod. For the static analysis done for pre-design connecting rod,a second revision was developed and stress magnitude was reduced about 40 percent. This calculation was done in MSC.Nastran environment and results were matched with the MSC.Adams calculations.Finally, piston was examined in MSC.Nastran under gas pressure and pre-design piston was found safe.As a result, with revisions on crack shaft and connecting rod, piston and fly wheel pre-designs were accepted and manufacture orders of these four parts were approved.Key WordsCrank Shaft, Connecting Rod, Piston, Fly Wheel, Dynamic Stress Anaylsis, Finite Element Method.