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Highlights: Analytically modeling the effect of eccentricity on flexible crankshaft and piston secondary motion; Analytically modeling the eccentricity of the crankshaft; Analytically modeling the absolute value of the dynamic displacement of the center of the crankshaft; Showing how sensitive the dynamic displacement in flexible crankshafts is to the changes in its independent variables; Double experimental validation of the analytical models based on the eccentricity of the crankshaft and based on fatigue analysis; A proposed approach of fatigue failure analysis for vehicular dynamic components; A proposed nanostructure of crankshafts for improved structural mechanics. In spite of the fact that the flexibility of the crankshaft of diesel engines exhibits notable nonlinearities, analytical modeling of such nonlinearities is not yet realized. The present study thus analytically models the effect of eccentricity on flexible crankshaft and piston secondary motion. The eccentricity of the crankshaft is modeled as the summation of the hydrodynamic eccentricity and the dynamic mass eccentricity of the crankshaft. The study also models the absolute value of the vibrational dynamic displacement of the center of the crankshaft. The paper proves that such dynamic displacement of the center of the crankshaft is sensitive to the changes in its independent variables. It was found that the most influential parameters on the dynamic displacement of the center of the crankshaft due to vibration are the natural frequency and the eccentricity of the crankshaft. The modeling of the dynamic displacement in a flexible crankshaft was validated using a case study based on the eccentricity of the crankshaft showing a relative error of 4%, which is less than the relative error in the CMEM and GT-Power. Furthermore, the analytical modeling of the dynamic displacement in the flexible crankshaft was validated using another case study based on fatigue analysis of the crankshaft showing a relative error of 9%, which is less than that the relative error in Newman's model of diesel engine fuel consumption and Lansky's model of diesel engine cylinders. The paper also presents a proposed approach of fatigue failure analysis for vehicular dynamic components and presents a proposed nanostructure of crankshafts for improving such fatigue performance. The developed models would help develop efficient diesel engines and help prolong their service life. [ABSTRACT FROM AUTHOR]

The flexibility of a crankshaft exhibits significant nonlinearities in the analysis of diesel engines performance, particularly at rotational speeds of around 2000 rpm. Given the explainable mathematical trends of the analytical model and the lack of available analytical modeling of the diesel engines intake manifold with a flexible crankshaft, the present study develops and validates such a model. In the present paper, the mass flow rate of air that goes from intake manifold into all the cylinders of the engine with a flexible crankshaft has been analytically modeled. The analytical models of the mass flow rate of air and gas speed dynamics have been validated using case studies and the ORNL and EPA Freeway standard drive cycles showing a relative error of 7.5% and 11%, respectively. Such values of relative error are on average less than those of widely recognized models in this field, such as the GT-Power and the CMEM, respectively. A simplified version for control applications of the developed models has been developed based on a sensitivity analysis. It has been found that the flexibility of a crankshaft decreases the mass flow rate of air that goes into cylinders, resulting in an unfavorable higher rate of exhaust emissions like CO. It has also been found that the pressure of the gas inside the cylinder during the intake stroke has four elements: a driving element (intake manifold pressure) and draining elements (vacuum pressure and flow losses and inertial effect of rotating mass). The element of the least effect amongst these four elements is the vacuum pressure that results from the piston's inertia and acceleration. The element of the largest effect is the pressure drop that takes place in the cylinder because of the air/gas flow losses. These developed models are explainable and widely valid so that they can help in better analyzing the performance of diesel engines. [ABSTRACT FROM AUTHOR]