Design optimization for the weight reduction of 2-cylinder reciprocating compressor crankshaft

This study aims to optimize the 2-cylinder in-line reciprocating compressor crankshaft. As the crankshaft is considered the "bulkiest" component of the reciprocating compressor, its weight reduction is the focus of current research for improved performance and lower cost. Therefore, achiev...

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Bibliographic Details
Published in:Archive of Mechanical Engineering 2021-10, Vol.68 (4), p.449-471
Main Authors: Arshad, Ali, Cong, Pengbo, Elmenshawy, Adham Awad Elsayed, Blumbergs, Ilmārs
Format: Article
Language:English
Subjects:
Aerospace engines
Aerospace industry
crack modeling
crank web
crankshaft lightweight design
crankshaft optimization
Crankshafts
Cylinder liners
Design optimization
Mechanical properties
Modal analysis
reciprocating compressor
Reciprocating compressors
Stress analysis
Stress concentration
stress distribution
Three dimensional models
Topology optimization
Weight reduction
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Summary:This study aims to optimize the 2-cylinder in-line reciprocating compressor crankshaft. As the crankshaft is considered the "bulkiest" component of the reciprocating compressor, its weight reduction is the focus of current research for improved performance and lower cost. Therefore, achieving a lightweight crankshaft without compromising the mechanical properties is the core objective of this study. Computational analysis for the crankshaft design optimization was performed in the following steps: kinematic analysis, static analysis, fatigue analysis, topology analysis, and dynamic modal analysis. Material retention by employing topology optimization resulted in a significant amount of weight reduction. A weight reduction of approximately 13% of the original crankshaft was achieved. At the same time, design optimization results demonstrate improvement in the mechanical properties due to better stress concentration and distribution on the crankshaft. In addition, material retention would also contribute to the material cost reduction of the crankshaft. The exact 3D model of the optimized crankshaft with complete design features is the main outcome of this research. The optimization and stress analysis methodology developed in this study can be used in broader fields such as reciprocating compressors/engines, structures, piping, and aerospace industries.
ISSN:0004-0738
2300-1895
DOI:10.24425/ame.2021.139311