Effect of Crankshaft Offset on Piston Friction in a Heavy-Duty Vehicle Air Compressor: FEA of Conventional and New Mechanisms
Abstract
In today's energy conversion systems, mechanical friction is one of the fundamental loss mechanisms that limit efficiency. This study examines an innovative crankshaft-connecting rod mechanism developed to reduce lateral forces generated at the piston skirt–cylinder interface in brake air compressors and compares its friction performance with that of a traditional mechanism at different crankshaft offsets. The proposed design utilizes a rigidly connected piston rod and a low-friction linear bearing system that enables linear motion. This eliminates the lateral forces on the piston caused by the angular motion of the connecting rod, ensuring that the piston moves only linearly. Since the load transfer occurs through the linear bearing, the piston skirt-cylinder contact is minimized, significantly reducing friction losses. Numerical modeling and finite element analysis conducted within the 0–12 mm crankshaft offset range evaluated the piston lateral force, moment, and friction losses depending on the crankshaft angle. The results show that a 3 mm offset in the thrust side direction is a critical comparison point and that under these conditions, the new mechanism reduces piston torque by 86% and friction losses by 84%. The linear bearing configuration has reduced friction-induced energy losses by an average of 80–85%. These findings demonstrate that crankshaft offset is an effective design parameter for increasing mechanical efficiency in auxiliary systems such as compressors and show that geometric optimization can significantly improve friction performance.
Keywords
Air compressor alternative crank-connecting rod mechanism FEA Piston Friction Crankshaft offset
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Details
| Primary Language | English |
|---|---|
| Subjects | Vehicle Technique and Dynamics, Automotive Engineering (Other) |
| Journal Section | Research Article |
| Authors | |
| Submission Date | January 23, 2026 |
| Acceptance Date | March 8, 2026 |
| Publication Date | March 10, 2026 |
| DOI | https://doi.org/10.30939/ijastech..1869160 |
| IZ | https://izlik.org/JA64SW65AL |
| Published in Issue | Year 2026 Volume: 10 Issue: 1 |
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[2] Can Ö, Öztürk E, Solmaz H, Aksoy F, Çinar C, Yücesu HS. Combined effects of soybean biodiesel fuel addition and EGR application on the combustion and exhaust emissions in a diesel engine. Appl Therm Eng. 2016;95:115–124.
[3] Sezer İ. A review study on the using of diethyl ether in diesel engines: Effects on CO emissions. Int J Automot Sci Technol. 2019;3(1):6–20.
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[5] Solouk A, Shakiba-Herfeh M, Kannan K, Solmaz H, Dice P, Bidarvatan M, et al. Fuel Economy Benefits of Integrating a Multi- Mode Low Temperature Combustion (LTC) Engine in a Series Extended Range Electric Powertrain. In: SAE Technical Papers. 2016.
[6] Gupta HN. Fundamentals of internal combustion engines. PHI Learning Pvt. Ltd.; 2012.
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M.M. Topaç is a senior researcher in automotive engineering at Dokuz Eylül University Department of Mechanical Engineering.
Main research topics:
• Vehicle engineering / Automotive systems,
• Vehicle design,
• Chassis systems engineering,
• Vehicle suspensions & steering,
• Ground vehicle dynamics,
• Failure analysis and prevention in vehicle design,
• Vehicle structures,
• Applied optimisation in vehicle engineering,
• Defence engineering,
• Electromobility.
Current research interests:
• Chassis systems design for special purpose vehicles: multi-axle land platforms, heavy-duty commercial vehicles, articulated vehicles / trailers, tracked vehicles,
• Alternative urban transportation: design of electric vehicles / urban electric microcars,
• Failure analysis and optimal design of vehicle components and structures,
• Dynamics of special purpose land vehicles,
• Modelling, design, optimisation and manufacturing of vehicle suspensions, axle systems and steering systems (including multi-axle steering systems for special purpose land vehicles and trailers),
• Design and optimisation of chassis and vehicle body structure,
• Powertrain modelling / Drivetrain dynamics.
Since 2006, he has been serving as a project consultant for automotive industry. He has been directing projects related to design and optimisation of suspensions, steering linkages, chassis, body and the other mechanical subsystems of wheeled vehicles. Moreover, he is investigating the effects of the design parameters of suspension and steering systems on handling behaviour and dynamics of wheeled and tracked land vehicles. He is also interested in topology optimisation-based lightweight design applications in vehicle engineering.
He is a member of SAE International.
Ir Prof Pak Kin Wong received the Ph.D. degree in Mechanical Engineering from The Hong Kong Polytechnic University, Hong Kong, in 1997. He is currently a Professor in the Department of Electromechanical Engineering and Dean of Graduate School, University of Macau. He is also the Fellow of the Hong Kong Institution of Engineers and Chartered Fellow of Chartered Association of Building Engineers, U.K. His research interests include automotive engineering, artificial intelligence for medical applications, fluid transmission and control and mechanical vibration. He has published over 354 scientific papers. 238 out of 354 are refereed journal papers.
Dr. Yanan Camaraza-Medina is a Postdoctoral Fellow in the Department of Mechanical Engineering, University of Guanajuato, Mexico. He received his M.Sc. in thermal engineering from the Universidad de Matanzas “Camilo Cienfuegos” in 2011 and the M.Sc. in electrical engineering from the Universidad Central de Las Villas “Marta Abreu” in 2015. He received his Ph.D. (Doctor in Technical Sciences) from the Universidad Central de Las Villas “Marta Abreu” in 2019. His research interests include problems of the heat transfer and fluid mechanics, with a special focus on thermal radiation, convective heat transfer and numerical modeling of thermal processes. He is a member of Editorial Advisory Board of three Scopus Indexed Journals, Mathematical Modelling of Engineering Problems (IIETA), Journal Européen des Systèmes Automatisés (IIETA), Recent Patents on Engineering (Bentham Science). Dr. Camaraza-Medina is the author and coauthor of more than 60 papers and several books.
Dr. Ramazan Şener is an expert in thermofluids, CFD and ICEs. He earned his PhD at Marmara University focusing on engine performance improvement and emissions reduction using advanced simulation tools and experimental methods. He also had the opportunity to conduct his research at the University of Catania, Italy. He is currently an Associate Professor at Bandirma Onyedi Eylul University, where he teaches and conducts research in thermofluids, optimization, ICEs, and renewable energy systems.
Dr. Gang Li is an Assistant Professor at Michael W. Hall School of Mechanical Engineering at Mississippi State University. His research interests include the fields of renewable energy technologies, applied artificial intelligence, dynamics and vibration, control theory, condition monitoring algorithms, structural health monitoring, and life cycle assessment, and involve AI for engineering, numerical simulation, experimental validation, and industrial application. Dr. Li is a recipient of the NSF EPSCoR Research Fellow Award and DOE EnergyTech UP Faculty Explorer Award. Dr. Li's research has been funded by NSF, DOE, the Maryland Energy Innovation Institute's Energy Innovation Seed Grant, the Maryland Technology Development Corporation’s Maryland Innovation Initiative (MII) Grant, the Maryland Offshore Wind Energy Research (MOWER) Challenge Grant Program, General Electric (GE), and Baltimore Gas and Electric (BGE). Dr. Li is a member of ASME, IEEE, and SAE International.
Editorial Board
International Journal of Automotive Science and Technology (IJASTECH) is published by Society of Automotive Engineers Turkey
