Connecting rod, aluminium alloy, forged steel, ansys workbench, etc. Fatigue and structural analysis of connecting rods. Stress analysis and optimization of connecting rod using. Currently, existing connecting rod is manufactured by using forged steel. Connecting rod used to connect between piston and crankshaft. When a compressive force of 14kn is applied on the big end when the small. Design and analysis of connecting rod using different materials. Quasi dynamic finite element analysis was performed at several crank angles. A connecting rod is rigid component, it may transmit either a push or a pull and so the rods may rotate the crank both halves of a revolution, i. The small end of connecting rod is piston pin end ppe and big end is crank shaft end cse. This shows that the connecting rod is four times strong in buckling about yaxis than aboutaxis. It connects reciprocating piston to rotating crankshaft, transmitting the thrust. Its primary function is to transmit the push and pull from the.
The mechanic didnt measure the bore for wear and rebuilt the engine with standard parts. Offside wear is usually an indication of misaligned crankshaft or bore. Connecting rods is toward lighter weight components. Pdf ic engine is heart of any vehicle, while in running conditions different components of. The main objective of this work is to explore weight reduction opportunities in the connecting rod of an i. And concluded that the stress induced in the small end of theconnecting rod are greater than the stresses induced at the bigger end, therefore the chances of. In this study the detailed load analysis under inservice loading conditions was performed for a typical connecting rod. Being one of the most integral parts in an engines design, the connecting rod must be able to withstand tremendous loads and transmit a great deal of power. The analysis clearly indicated the failure location at the thread root of the connecting rod, caused by improper screw thread profile. The design will always be satisfactory for buckling about yaxis. The intermediate component between crank and piston is known as. Catia v5 software and imported to ansys workbench 14. A parametric model of connecting rod is modeled using nx 10 software and to that model, analysis is carried out by using ansys workbench. A connecting rod is a machine member which is subjected to alternating direct compressive and tensile forces.
The main idea of this study is to do analysis of connecting. Another compressor of the same design with similar rod load has history of reliable operation applying practical root cause analysis and well known. A maximumcylinderpressure c f c maxcylp a 9u 4418 39762 2 2 4418 4 75 4. Structural strength for the connecting rod will be verified over an universal testing machine utm for tensile loading. Rods were tested in ideal conditions by applying variable loads. Buckling analysis of connecting rod for different materials. Abstract the connecting rod is the intermediate member between the piston and the crankshaft. The function of the connecting rod is to convert linear motion of the piston into rotary motion of the crankshaft. Automobile internal combustion engine connecting rod is a high volume production critical component. The study investigated weight and cost reduction opportunities of steel forged connecting rods. They replace steel aisi 4340 with aluminium 7078 and apply various load condition on the connecting rod such as compressive load, tensile load and buckling load and then analysis the connecting rod. Finite element analysis of connecting rod is done by considering the materials, viz. As tolerance chain analysis is an essential activity in process planning for geometry assurance, a tolerance chains study based on monte carlo simulations for the connecting rod line has been performed to develop improved manufacturing solutions to lower costs and increase quality.
It connects reciprocating piston to rotating crank shaft. Introduction a connecting rod can be of two types hbeam or ibeam or a combination of both. The most suitable section for the connecting rod is isection with the proportions shown mfg. Analysis focused on comparing and then optimizing a rod design using crackable forged steel c70. It has a hole at the upper end small end and is connected to the piston by the wrist pin. Fea analysis was carried out by considering two materials of connecting rod for 180cc engine. Practical root cause analysis of connecting rod bushing. The automobile engine connecting rod is a high volume production, critical component. Design optimization and analysis of a connecting rod using ansys g. International journal of innovative research in science. Replace all other bearings main connecting rod and cam shaft as their remaining service life may be short. Fatigue analysis of connecting rod using finite element analysis. The material of connecting rod will be analyzed for abstract connecting rods design was drawn using autodesk inventor software and save in step format. Using finite element analysis fea techniques, the author was able to.
The most critical sections of connecting rod are determined based on mechanical strength. Fatigue analysis of connecting rod using finite element. Analysis of connecting rod using composite material. Bearings improperly located during installation can sometimes be hard to spot. In the work presented here, a connecting rod is modeled numerically for a 4cylinder, 4stroke diesel engine. Generally connecting rods are manufactured using carbon steel and in recent days aluminium alloys are finding its application in connecting rod.
The longitudinal displacement at the centerline of the crankshaft is fixed to resist the inertia force applied at the piston pin. Design and analysis of connecting rod using forged steel ijser. Another compressor of the same design with similar rod load has history of reliable operation. In series of automobile engine components a connecting rod is highly critical and researchable one. Design and structural analysis of connecting rod irjet. Introduction internal combustion engine has many parts like cylinder, piston, connecting rod, crank and crank shaft. The study has dealt with two parts which are dynamic load and quasidynamic stress analysis of the connecting rod, and second to optimize the weight and cost. The piston pin end is the small end, the central shank is of icross section andthe crank end is the big end. Connecting rods are manufactured by means of forging.
Figure 1 shows two sets of parts from the same engine. Authors found that weight of connecting rods was reduced and all performed to the level of expectation. Feb 17, 2008 l connecting rod length centre to centre 122mm. It should withstand with greater power loads though it is lower in weight. The connecting rod is a vital component of any engine, which undergoes several stresses while in motion. Connecting rod is an important component in an engine.
The sn approach by modified goodman criterion to fatigue life prediction of the connecting rods is presented. It should withstand with greater power loads though it. Parameter value of connecting rod 150 outer diameter of big end 56 inner diameter of big end 48 outer diameter of small end 32 inner diameter of small end 24 table 1. Based on the observations of the static fea and the load analysis results, recommend the best alternative design for the connecting rod. Connecting rod, structural analysis, titanium, steel, gas load, fatigue, fea 1. Design and comparative analysis of connecting rod using. Ansys software was used for the analysis of connecting rod. The connecting rod is the connection between the piston and the crankshaft. Assemble the connecting rod and piston assembly to the crankshaft, using clevite bolt boots to protect crankshaft journals and cylinder walls.
Finite element analysis of connecting rod of ic engine. International journal of science and research ijsr. Rahman, it is concluded that the modeling of connecting rod and fe analysis has been presented. The connecting rod is considered like both ends the various forces acting on the connecting rod are as hinged for buckling about xaxis and both ends fixed for follows. Connecting rod rotates the crank shaft that helps the engine to maneuver on or any of the vehicles to rotate its wheels.
It is designed to resist stresses from combustion and piston movement. With crankshaft forced all the way forward in block, check end clearance between the. Analysis of connecting rod was carried out using anysy 14. Finite element method is used to analyse the connecting rods stress and deformation using ansys software. However the stiffness problem such as bearing failure usually. Localized wear on main bearings showing a pattern along the shaft, for example, worst wear on the middle bearings, is.
International journal of science and research ijsr, india. They are used respectively depending on their field of application or use. The firing load compressing the connecting rod should be included in the durability analysis. The stress and thermal for connecting rod can analyzed with this software. The connecting rod can be designed and analysis under a load ranging from tensile load, corresponding to various degree crank angle at the maximum engine speed as one extreme load, and compressive load corresponding to the peak gas pressure as the other extreme load. Burande2 1research scholar, sinhgad college of engineering, pune, maharashtra, india 2guide and professor, sinhgad college of engineering, pune, maharashtra, india abstract the objective of study is performed on a cast iron connecting rod of a compressor for the static and dynamic. Make sure caps match correct rods, and torque bolts to proper oe specifications. For this case, a fatigue and structural analysis will be. In this analysing software, can makes analysis to connecting rod of different material such as. And it also describes the modelling and analysis of connecting rod. Connecting rod is an integral component of internal combustion engine. Pdf a connecting rod of ic engine is subjected to complex dynamic loading conditions. The connecting rod experiences cyclic fatigue loading this is due to contributions from both gas forces and inertial forces.
Design and analysis of connecting rod using different. Connecting rod is one of the most important part in engine assembly acting as a link between crankshaft and piston. Dynamic analysis of loads and stresses in connecting rods citeseerx. In this work, the mechanical behavior of a connecting rod of a twostroke single cylinder engine is studied by means of finite element analysis to reduce its weight. The possibility failure of the connecting rod approach by failure index is the ratio of maximum principal stress to yield strength of material. Key words proe, ansys, stress analysis, connecting rod, fea. Pdf design and analysis of connecting rod using forged steel. The piston pin end, the central shank and the crank end. Pdf design, buckling and fatigue failure analysis of. His paper describes design, modeling and analysis of connecting rod. The main objective of this paper is to perform a modal analysis for the connecting rod for different. The objectives of the project are as follows i to develop structural modeling of connecting rod ii to perform finite element analysis of connecting rod iii suitable material study iv study of load factors. Force in the connecting rod results input r, l, and strok set values of 36. Gopal et al design and analysis of assembly of piston, connecting rod and crank shaft 237 international journal of current engineering and technology, vol.
Shenoy and fatemi 2005 were explained about optimization study was performed on a steel forged connecting rod with a consideration. Topology optimization were analyzed to the connecting rod and according to the results, it can be concluded that the weight of optimized design is 11. And it also describes the modeling and analysis of connecting rod. Design and analysis of assembly of piston, connecting rod and. The lower end, also called as big end, is attached to the crankshaft. First of all, to find the stress on the connecting rod, we use the formula. Dale vice president, member and industry relations metal powder industries federation 105 college road east princeton, nj 085406692 introduction since 1986, more than 500 million powder forged pf connecting rods have been manufactured and installed in automobiles worldwide. I section for connecting rod thickness of flange and web of the section t mm. Tension and compression analysis in reciprocating engine. Solution of manufacturing defects in connecting rod. The purpose of the project was to analysis connecting rod fracture using finite element analysis. Study the analysis of stresses in connecting rod 157 table 2.
Dynamic load analysis and optimization of connecting rod. The big end of the connecting rod connects to the crankpin to provide a pivot point on the crankshaft connecting rods produces as one piece or twopiece components. This thesis describes designing and analysis of connecting rod. Force on the piston due to gas pressure and buckling about yaxis. The original piston failed from excessive clearance and slapping. Static structural analysis was done by fixing the piston end and applying load at the crank end of the connecting rod. After measuring the dimension of connecting rod, model is developed in. Force is applied on one end keeping another end of connecting rod fixed.
Fatigue analysis of connecting rod using finite element analysis 789 the stress at any point on the connecting rod at this axial load can be interpolated from the axial stress analysis results. Engine bearing failure analysis guide edge wear due to distorted connecting rod imperfect journal geometry cavitation erosion spinning of the bearing in the housing. Select a bearing material with higher load capacity check. Connecting rods were manufactured by conventional method.
The collapse of connecting rod is a common cause of. Analysis of weight reduction in connecting rod by using different materials in ansys prakash s1, prabhahar m2, jeshuran samuel j 3 and manish kumar s 1research scholar, aarupadai veedu institute of technology, vinayaka mission university, india. The connecting rod must be light in weight to minimize the inertial forces. A solid model of the connecting rod was generated using proe wildfire 3. Connecting rod is the intermediate link between the piston and the crank. Fea analysis was carried out by considering three materials. Recommend that the operator avoid hot rod ding and lugging as these tend to shorten bearing life. Naga malleshwara rao professor of mechanical engineering, shri shirdi sai institute of science and engineering, anantapuramu, a. The connecting rod is very important part of an engine. Case study overview during startup of a new reciprocating compressor, multiple connecting rod bushing failures led to a detailed root cause analysis, data gathering, and testing this compressor met api 618 requirements for rod load and rod reversal. Connecting rod, finite element analysis, modeling, static i. Optimization of the connecting rod of a twostroke engine using finite.
Analysis and optimization of connecting rod used in. The design of this component is very crucial to improve the durability of the engine and the mechanical efficiency of it. Connecting rod converts reciprocating motion of piston to rotary motion of crank. Then, the drawing of connecting rod step format imported into ansys software. Design and analysis of assembly of piston, connecting rod. The connecting rod failed at the location indicated by the fea. The small end is press fit and can swivel in the piston. In this work connecting rod is replaced by aluminium based composite material reinforced with silicon carbide and fly ash. Pdf stress analysis of connecting rod using fea researchgate.
Design and analysis of connecting rod using forged steel. Stress analysis of connecting rod for weight reduction a. Currently existing connecting rod is manufactured by using carbon steel. The modeling of the connecting rod is done on proe wildfire 4.
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