Thermo-Mechanical Analysis of a Typical Vehicle Engine Using PTC-Creo


  • Jafar Mahmoudi Department of Sustainable Production Development, School of Industrial Engineering and Management, KTH Royal Institute of Technology, Stockholm, Sweden

Received: 20 April 2022; Revised: 20 September 2022; Accepted: 5 November 2022; Published Online: 29 November 2022


In this work, a typical vehicle engine is modeled within PTC-Creo software, and its thermal, mechanical, and thermo-mechanical performance are evaluated. This is followed by the vibrational, fatigue, and buckling analysis of the assembly of components, which are the predominant failure causes. The results show that the least temperature gradient occurs in the center of the pin, which connects the piston to the connecting rod, the maximum displacement is seen just below the piston head, and the thermo-mechanical failure is caused mostly (about 85%) by the mechanical load rather than the thermal one. Also, in fatigue analysis, the minimum and maximum values for the safety factor are 0.63 and 5, respectively. The results can prevent the reoccurrence of similar failures and help the enhancement of the components’ design and manufacturing process.


Stress analysis; Engine failure; PTC-Creo; Thermomechanical analysis


[1] Hermawan, M.V., Anggono, A.D., Siswanto, W.A., et al., 2019. The Influence of Material Properties to the Stress Distribution on Piston, Connecting Rod and Crankshaft of Diesel Engine. International Journal of Mechanical & Mechatronics. 19(6), 13-26.

[2] Deulgaonkar, V.R., Ingolikar, N., Borkar, A., et al., 2021. Failure analysis of diesel engine piston in transport utility vehicles. Engineering Failure Analysis. 120, 105008.

[3] Xu, X.L., Yu, Zh.W., 2018. Failure analysis of a truck diesel engine crankshaft. Engineering Failure Analysis. 92, 84-94.

[4] Zhang, M.Q., Zhao, Ch., Yan, Zh.Q., et al., 2019. The Structure, Stress and Modal Analysis of 1.6-Liter Gasoline Engine Connecting Rod Based on Finite Element Analysis. IOP Conference Series: Materials Science and Engineering. 677(3), 032094.

[5] Viet Nguyen, D., Duy, V.N., 2018. Numerical analysis of the forces on the components of a direct diesel engine. Applied Sciences. 8(5), 761.

[6] Liu, X., Wang, Y., Liu, W., 2017. Finite element analysis of thermo-mechanical conditions inside the piston of a diesel engine. Applied Thermal Engineering. 119, 312-318.

[7] Qin, Zh.J., Li, Y.S., Yang, Zh.Zh., et al., 2019. Diesel engine piston thermo-mechanical coupling simulation and multidisciplinary design optimization. Case Studies in Thermal Engineering. 15, 100527.

[8] Gopi, E., Saleem, M., Chandan, S., et al., 2019. Thermal and static analysis of engine piston rings. International Journal of Ambient Energy. 1-5.

[9] Rajakumar, S., Karthiyaraj, M., 2020. A comparative study of structural and thermal analyses on piston materials. International Journal of Scientific Development and Research (IJSDR). 5(12).

[10] Strozzi, A., Baldini, A., Giacopini, M., et al., 2016. A repertoire of failures in connecting rods for internal combustion engines, and indications on traditional and advanced design methods. Engineering Failure Analysis. 60, 20-39.

[11] Anderson, A., Yukioka, M., 2012. Connecting rod buckling analysis using eigenvalue and explicit methods. No. 2012-32-0102. SAE Technical Paper.

[12] Muhammad, A., Shanono, I.H., 2019. Static analysis and optimization of a connecting rod. Journal of Engineering and Technological Sciences. 6(1), 24-40.

[13] Pani, A.R., Patel, R.K., Ghosh, G.K., 2020. Buckling analysis and material selection of connecting rod to avoid hydro-lock failure. Materials Today: Proceedings. 27, 2121-2126.

[14] Rezvani, M.A., Javanmardi, D., Mostaghim, P., 2018. Diagnosis of EMD645 diesel engine connection rod failure through modal testing and finite element modeling. Engineering Failure Analysis. 92, 50-60.

[15] Witek, L., Zelek, P., 2019. Stress and failure analysis of the connecting rod of diesel engine. Engineering Failure Analysis. 97, 374-382.

[16] Andoko, A., Nauri, I.M., Paryono, P., et al., 2020. Failure analysis on the connecting rod by finite element method. AIP Conference Proceedings. 2262(1), 040011.

[17] Rodrigues, A., Silva, R.L., Cruz, R., et al., 2011. Experimental and numerical modal analysis of 6 cylinders diesel crankshaft. No. 2011-36-0358. SAE Technical Paper.

[18] Ang, Y.Z., Pei, X.K., 2021. Study on Failure Analysis of Crankshaft Using Finite Element Analysis. MATEC Web of Conferences. 335, 03001. EDP Sciences.

[19] Kumar, M., Senthil, S.R., Suresh, M., 2014. Analysis of crankpin failure in a single cylinder engine. International Journal of Mechanical Engineering and Robotics Research. 3(4), 260.

[20] Sola, J.F., Alinejad, F., Rahimidehgolan, F., et al., 2019. Fatigue life assessment of crankshaft with increased horsepower. International Journal of Structural Integrity.

[21] Infante, V., Freitas, M., Fonte, M., 2019. Failure analysis of a crankshaft of a helicopter engine. Engineering Failure Analysis. 100, 49-59.

[22] Gomes, J., Gaivota, N., Rui, F.M., et al., 2018. Failure analysis of crankshafts used in maritime V12 diesel engines. Engineering Failure Analysis. 92, 466- 479.

[23] Jiao, A.Y., Liu, B.H., Chen, X.M., et al., 2020. Fracture failure analysis of KL crankshaft. Engineering Failure Analysis. 112, 104498.

[24] Kurbet, S.N., Kuppast, V.V., Talikoti, B., 2020. Material testing and evaluation of crankshafts for structural analysis. Materials Today: Proceedings.

[25] Kumar, K.S., 2016. Design and Analysis of IC Engine Piston and Piston-Ring on Composite Material Using Creo and Ansys Software. Journal of Engineering and Science. 1(1), 39-51.

[26] Prasad, D.R., Naga, Ch.S., 2017. Design and Analysis of 150CC IC Engine Connecting Rod. International Journal of Scientific Engineering and Technology Research 6(17), 3397-3402.

[27] Bedse, U.A., 2016. Developing a GUI based Design Software in VB Environment to Integrate with CREO for Design and Modeling of CI Engine. International Journal of Latest Trends in Engineering and Technology (IJLTET). 6(4).

[28] Yang, J., Wang, Y., Xiao, M.W., 2011. Heat load analysis of piston based on the ANSYS. Advanced Materials Research. 199, 1192-1195.

[29] Citti, P., Giorgetti, A., Millefanti, U., 2018. Current challenges in material choice for high-performance engine crankshaft. Procedia Structural Integrity. 8, 486-500.

[30] Ellis, D.E., 1960. Mechanical properties of aluminum alloys at various temperature S. No. NAA-SR-Memo-5716. Atomics International. Division of North American Aviation, Inc., Canoga Park, California.

[31] Sirata, G.G., 2020. Fatigue Failure Analysis of Crankshafts-A Review. IJISET-International Journal of Innovative Science, Engineering & Technology. 7(5).

[32] Baumel Jr, A., Seeger, T., 1990. Materials data for cyclic loading. Supplement 1. Elsevier Science Publishers, P. O. Box 211, 1000 AE Amsterdam, The Netherlands.

[33] Korkmaz, S., 2010. Uniform material law: extension to high-strength steels: a methodology to predict fatigue life of high-strength steels. VDM.

[34] Zienkiewicz, O.C., Taylor, R.L., 1977. The Finite Element Method, Third editions.

[35] Jangam, S.P., Kumar, S., Maheshwari, S., 2018. Literature review on analysis of various components of IC engine. Materials Today: Proceedings. 5(9), 19027-19033.

[36] Rakic, S., Bugaric, U., Radisavljevic, I., et al., 2017. Failure analysis of a special vehicle engine connecting rod. Engineering Failure Analysis. 79, 98-109.


How to Cite

Mahmoudi, J. (2022). Thermo-Mechanical Analysis of a Typical Vehicle Engine Using PTC-Creo. Journal of Mechanical Materials and Mechanics Research, 5(2), 1–15.


Article Type