Saturday, June 7, 2014

Critical Speed of Vehicle: Calculation and other important considerations


CRITICAL SPEED OF A VEHICLE



"One of our user Mr Manoj Nain asked us about critical velocity and its calculation. In this article, we have included fundamentals of critical velocity and its calculation in the practical context. We hope that you all will enjoy the article and will let us know in case you want more information. We love receiving queries from our users and answer them to help you evolve .So here is the article......".


Critical speed of a vehicle is the speed at which the vehicle will lose lateral control on the roadway. There are different methods to calculate the critical speed. It depends on friction force, elevation and radius of turn. Calculation of critical speed of a vehicle plays a vital role in the field of accident reconstruction.

Calculation of Critical speed
According to Newton’s 1st Law of motion, a body moving in a straight line will continue in a straight line unless acted on by an external force. A body moving on a circular path with constant speed will have a changing velocity (directional speed) due to the body's changing direction. This velocity change with time, called centripetal acceleration, has a radial direction toward the center of the circular movement and is given by the following equation:
­ 
                                                                    a= V2 /R.............................................1

V: velocity (m/s)
            R = Radius of Turn (m)
                    a = Centripetal acceleration

Since Newton's second law tells us that a force has to act on the body to produce an acceleration. Therefore,
                                                                          F = m a................................................2

m = mass of vehicle
              a = centripetal acceleration
   F = Centripetal Force
Therefore,
                                                                         F = m v2/R...................................................3

Now, the lateral force on a vehicle moving in a circular motion on a pavement surface is produced by the frictional force between the tires and the roadway as follows :
                                                                         
                                                                         F = µN.................................................4

Where, N=Normal Reaction
Therefore,
                                                                        F = µmg.........................................................5

Condition for a vehicle to not to slip: Centripetal force should not exceed the Frictional force. Therefore, equating both the forces will give the critical velocity which should not be exceeded.

                               m v2/R = µmg..............................................6

 Solving the equation will give, critical velocity v,

                                   V critical = (µgR) 0.5    .............................7

Equal sign is important. g = 15 is used for practical design (accident reconstruction).The formula is not valid for low radial speeds. To calculate critical speed, equal sign is important. Converting the above Equation to allow for the velocity, v, in mph, and accounting for the roadway curve super-elevation, e, yields the familiar form of the centripetal acceleration equation.
It is important to understand here, that above equation can be applied on the basis of following assumptions and they are:

  • Vehicle should be at its friction limit so that the slipping starts
  • Vehicle follow a circular arc
  • Vehicle  should be within the tyre marks
  • Speed of the vehicle is constant
   
     Application of the above equation: 
  • Highway curve design
  • Elevations
  • Speed limit elevations
  • Emergency turns by vehicle
From the above equation derived, we can conclude many  characteristics.They are:
  
Characteristics of Critical speed 
  • It depends on the friction between the road surface and tyre. Higher is the coefficient of friction, more is the critical velocity. But it is proportional to square root of the coefficient friction and value of coefficient of friction is not very high relative to other values (g, R) hence effect will not be more than the other parameters.
  • It depends on the elevation or the banking of the road, as the normal reaction changes accordingly.
  • It depends on the Turning Radius. Radius can hold any value hence it can have large values too thus, it will have higher influence on critical velocity. Thus, it is critical to design turns carefully or design vehicle for higher radius of turn.
  • It is not affected by the position of CG. However, it affects Yaw, Pitch and Roll which is a different concept and seems to clash with this phenomenon. 
  •  Does not depend on the vehicle geometry.
  •  CSF is valid for the assumptions described earlier in the article
  •  CSF is not applicable for low values of coefficient of friction.
  •  CSF does not take care of quantities such as steer angle, temperature effects, suspension etc.
  • CSF should be calculated using the radius derived from earliest possible part of the tire marks as possible. Use curvature traced out by leading front tire for better results.
 ·      There is always uncertainty in using CSF formula and hence uncertainty or standard deviation    should be taken care of while designing using CSF.

In this article, we have tried to give brief idea of the concept called as critical velocity. We can work to give more detailed calculation and theories developed for measuring critical velocity in practical context. We hope that this information will be useful for our users. Please let us know whether this was useful or not. Thanks for believing in us...and yes don't forget to like..for our efforts...

Tuesday, June 3, 2014

Crankshaft Design


CRANKSHAFT DESIGN



One of our member wanted to know about Crankshaft design, So here we have compiled the basic method of a Crankshaft Design.



Crankshaft in an IC Engine is used to convert the reciprocating motion of Piston into rotary motion (or vice versa while cranking the Engine). The crankshaft main journals rotate in a set of supporting bearings (main bearings), causing the offset rod journals to rotate in a circular path around the main journal centres, the diameter of which is twice the offset of the rod journals. The diameter of that path is known as Piston stroke. The big ends of the connecting rods contain bearings which ride on the offset rod journals.


Components of Crankshaft

There are many components in a crankshaft, each for a particular function. Figure-1 shows the components but while designing the crankshaft for an engine, designing each of the component is not needed. Main components focused for designing are Main Journals, Crankpin Journals & Crank webs are designed and rest other components are calculated on the basis of Automotive Industry Norms & Design relations which has been produced by years of Research & Development.



Figure-1 : Components of Crankshaft

Design Procedure
      
      1.     Material Selection

First & the important step in any designing process. Material should be selected on the basis of loads & condition to which the component is subjects. The Material should have following properties:
·         Enough strength to withstand high tensile & bending forces.
·         Rigidity to avoid distortion.
·         Minimum weight (Specially in aero engines).

In industrial engines, 0.35 Carbon steel of ultimate tensile strength 500MPa to 525 MPa and 0.45 Carbon steel of ultimate tensile strength of about 627 to 780 MPa are commonly used.

In transport engines, alloy steel e.g. manganese steel having ultimate tensile strength of about 784 to 940 MPa is generally used.

In aero engines, nickel chromium steel having ultimate tensile of about 940 to 1100 MPa is generally used.

The heat treatment for this steel consists in normalizing at 871-927 degC, annealing to the desired structure or machinability; heating to 788-816 degC, quenching in oil, and tempering at 483 degC.
      
      2.     Design Concept

Based on the material properties, we will now decide the dimensions which will be calculated from the loads and conditions. The crank shaft is designed considering two positions of the crank:
a)     When Crank is at Dead centre (Maximum Bending Moment).
b)     When Crank is at angle where Twisting Moment is maximum.

a)   When Crank is at dead centre

Stepwise procedure:
ü  Draw a Free Body Diagram of the Crankshaft with various horizontal and vertical forces.
ü  Calculate the piston force. (We know Maximum Piston pressure, It can be assumed according to the industry norms as 200 bar for Diesel & 180 bar for SI Engines). Piston force is Max. Piston pressure * Area of piston.
ü  Industry assumptions while calculation of forces in FBD.
ü  Find all the horizontal & vertical reactions.

(i)               Design of Crank Pin

Crankpin is also subjected to shear stress due to twisting moment. Thus we can calculate bending moment at centre of crankpin and twisting moment on crank pin and the resultant moment.
Stepwise procedure:
ü  Calculate Bending Moment at the centre of Crank Pin(from FBD).
ü  Equate the BM to (MOI*Bearing stress) for crank Pin (Sigma-b)
ü  Solve and find Diameter of Crank Pin.
ü  Solve FBD for length.

(ii)            Design of Crank Web

The crank web is designed for eccentric loading. There will be two stresses acting on the crank web, one is direct compressive stress and the other is bending stress due to piston gas load (Fp).


Industry Assumptions:
ü  Thickness of crank web Tst = 0.65 *dc + 6.35 (dc = Dia. Of Crank pin)
ü  Width of crank web is, w = 1.125 * dc +12.7


Stepwise procedure:
ü  Calculate the Bending Moment from FBD.
ü  Check if BM is positive or negative. If Negative the increase the crank pin diameter and solve again. If positive then your design is safe.

(iii)          Shaft under the Flywheel

The total bending moment at the flywheel location will be the resultant of horizontal bending moment due to gas load and belt pull and the vertical bending moment due to the flywheel weight.

Then you can find the diameter by using the Moment equation. M=(MOI*Sigma-b).

b)   When the crank is at an angle of maximum twisting moment

The twisting moment on the crankshaft will be maximum when the tangential force on the crank (FT) is maximum. The maximum value of tangential force lies when the crank is at angle 30º to 40º for constant pressure combustion engines (i.e. diesel engines).

When the crank is at angle at which the twisting moment is maximum, the shaft is subjected to twisting moment from energy or force stored by flywheel. The above design parameters can be cross checked for the factor of safety while designing by considering the crankshaft at an angle of maximum twisting moment.

If the factor of safety is more than 1 then the design is safe. Considering this, we have to various forces acting on crankshaft at different twisting angles.


This is a basic design concept used in the industry for designing Crankshafts for various IC Engines, but there are various parameters & relations which are only known to the industry and is their copyright. Thus for studying you can refer to various design data handbooks available in the market for Machine design.

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