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Large axial displacement at the edge of a flywheel causes a clutch to fail to disengage in high-speed rotation. To find out the root cause, a numerical procedure is proposed to investigate the vibration source and to understand dynamic behavior of the crank-train system. A simulation of the whole engine system including block, crankshaft, piston, and connecting rod was performed with AVL/Excite. The resulting CAE baseline model had good correlation with measurements. A comprehensive study was conducted for a set of flywheel and crankshaft models with different materials and unbalanced masses. The contribution to flywheel wobbling of each vibration order was carefully investigated, and an optimal design was presented.

The influence of the pin/main bearing journal diameters and the counter weight orientation to crankshaft axial vibration were examined using a fully flexible finite element engine model. The simulation, performed with AVL/Excite, incorporates modal contributions of all interfacing engine components and enables the study of interactions among the components. The simulation successfully predicted crankshaft axial vibration and was validated by measurements. The correlated CAE model was used to study modifications in crankshaft pin and main bearing journal diameters and in the orientation of the crankshaft counter weights. Design direction on how to minimize axial vibration was provided.