Geometric modeling and modal stress formulation for flexible multi-body dynamic analysis of crankshaft

Defining a procedure for the characterization of the crankshaft and entire engine unit, based on CAD-FEM multi-body methodology, would provide an analysis tool which avoids the simplified hypotheses usually accepted when designing these components. The methodology is based on the Craig-Bampton method, i.e. on the theory of component mode synthesis. According to the Craig-Bampton theory, the deformation of a flexible crankshaft interfacing with the rest of the engine is obtained through static and normal modes, considering the discretized model with a large number of degrees of freedom and using modal truncation. It is based on the separation of interface and internal d.o.f. Using modal stress analysis has the advantage of reducing the d.o.f. of the FEA model. The multi-body model includes the elasticity of the camshaft and the reduced inertia of the gearbox and timing system. Comparing simulations performed at different engine speeds, the crankshaft evidenced the angular oscillations of generic sections of the axis and shaft, without separating the bending and torsional d.o.f. At higher engine speeds, the vibrational response showed how the harmonics with greater amplitude correspond to the crankshaft’s first natural modes and are excited by some harmonics present in the engine moment.