OBRABOTKAMETALLOV Vol. 23 No. 3 2021 MATERIAL SCIENCE EQUIPMENT. INSTRUMENTS 5 3 Fig. 7. Maximum principal stress in existing crankshaft Ta b l e 1 Structural analysis results of existing crankshaft Total Displacement, mm Von-Mises Stress Theory, MPa Max Principal Stress, MPa Max. Shear Stress, MPa 0.050 162.05 132.01 93.00 Finite element analysis of optimized crankshaft using Ansys22R1 It is obvious that almost every component of the kinematic chain in the assembly, for which topological optimization has not been carried out, is overweight. The additional weight of structural elements leads to the use of excess material, which is the reason for the formation of excessive loads on moving components, reducing energy efficiency and increasing transportation costs [19–25]. And thanks to Topological Optimization technology (ANSYS Mechanical), there is a tool one needs to design strong and lightweight structural elements, regardless of its application. Targets can be easily defined and controls applied to ensure that manufacturing requirements are met, minimum material thicknesses are set, and exclusion areas are defined [26–29]. Topology optimization in ANSYS Mechanical allows: 1) taking into account multiple static loads in combination with optimization of natural frequencies (modal analysis); 2) meeting minimum material thickness requirements; 3) observing the rules regarding the direction of basing (installation) of the element (for example, for machining operations); 4) obtaining the possibility of implementing both cyclic and planar symmetry. The highlighted region in fig. 8 shows the results of the total deformation after applying a load of 320 tons to the centre of the crankshaft. The maximum deformation occurs in the middle of the crankshaft, where a load of 320 tons is applied, and the deformation value is 0.046 mm, but the deflection in the bearing area is practically 0 mm. Fig. 9 shows the equivalent stress at the end surfaces of the crankshaft. When applying a load of 320 tons, the crankshaft experiences the highest stresses on the end surfaces with a maximum equivalent stress of 191.24 MPa; in this case, the minimum equivalent stress occurs in the bearing area and is equal to 11.64 MPa.
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