Design and fatigue characteristics of connecting rod by using finite. Connecting rods are manufactured by means of forging. The paper comes up with the overall design of the crankshaft connecting rod mechanism through the analysis of force on the calculation and selection of the. Design and analysis of connecting rod using different. Oscillatory motion of the connecting rod into the rotary motion d. Together with the crank, it forms a simple mechanism that converts reciprocating motion into rotating motion. Feb 17, 2008 design analysis engine connecting rod warwick shipway, mechanical engineering, year 3 17. Sustainable assessment is done using solid works 2014.
The most suitable section for the connecting rod is isection with the proportions shown mfg. The piston pin end is the small end, the central shank is of icross section andthe crank end is the big end. Al360 of connecting rod was replaced with aluminium fly ash silicon composite. To geometrically model the connecting rod as per the dimensions generated from the process of design procedure followed. Pdf design considerations for connecting rod researchgate. This project aims at designing a connecting rod with standard dimensions of a stock one in creo 3. The first was to provide the largest possible big end bearing on the connecting rod while maintaining stock crankshaft stroke 4. In this project the material forged steel of connecting rod replaced with aluminium alloy. The geometric model, finite element mesh, physical dimensions, and design. Finite element analysis of single cylinder four stroke petrol engines is taken for the study.
The connecting rod is modeled as plane stress problem using 25 quadrilateral pelements. Connecting rod is integral part of internal combustion engine. Sustainable design and lifecycle assessment of connecting. Design of connecting rod for weight reduction using c70s6. Connecting rod manufacture is a high volume, price sensitive application with strict performance, design and durability requirements. They developed the designed model of connecting rod using modelling software. Aluminum and titanium can be used for high performance engines like f1 cars where strength and lightweight dominate over the cost factor. Analysis of connecting rod using reverse engineering. A 3d model of crank connecting rod of a single cylinder internal combustion engine ice is established, whose force analysis was carried out in adamsview using virtual prototyping method. In this study, the design of the connecting rod will be modeled and at the same time increase the strength. Design and analysis of connecting rod using different materials. Introduction from a set of schematic drawings of a 4cylinder supercharged volkswagen engine a design analysis is performed to determine the stresses and hence operational safety factor of the connecting rod, using cad packages. Pdf design, buckling and fatigue failure analysis of. In the mechanical design of connecting rods, analytical calculations and numerical methods are used to evaluate the stresses, displacements, and contact.
The structure of connecting rod was modeled utilized solidworks software. Material used to manufacture connecting rod in mass. Since the main role of the connecting rod in the engine is to deliver the firing load to crankshaft and to rotate the crankshaft smoothly, the much severe forces to the connecting rod require a more reliable design in the fields of not only the fatigue strength but also the stiffness of the bigend structure. To design the connecting rod for a petrol engine so as to determine the section thickness of connecting rod. There were two objectives for this initial design study. To get a suitable design for connecting rod they change the design parameters in the existing design. Since the compressive forces are much higher than the tensile force, therefore the cross section of the connecting rod is designed as a strut and the rankine formula is used.
Design and analysis of connecting rod for weight and. Design considerations for connecting rod international journal of. Fatigue strength is the most important driving factor for the design of connecting rod and it is found that the fatigue results are in good. Working of the connecting rod is to transmit power of piston to crank pin. 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. Design of connecting rod of internal combustion engine. The electronic pdf version of this document, available free of charge. Design optimization of a diesel connecting rod sciencedirect. The optimization of connecting rod had already started as early year 1983 by webster and his team.
Where there are cranks of different geometrical configuration e. The piston pin end, the central shank and the crank end. The geometric model, finite element mesh, physical dimensions, and design variables are shown in figure 3. And different materials are applied for gaining more stability. Let us also know about the bush and bearing of the. A crankshaft bay includes all elements of the crankshaft between two adjacent main journals. Analysis and optimization of connecting rod used in.
To design a connecting rod of minimum mass with in designing a connecting rod, the following dimensions two constraints. The design will always be satisfactory for buckling about yaxis. Jan 01, 2018 finally, the optimized and improved design of connecting rod is investigated to avoid failure of the connecting rod due to high stresses. A solid model of the connecting rod was generated using proe wildfire 3. An early documentation of the design occurred sometime between 11741206 ad in the artuqid state. Abstract the connecting rod is the intermediate member between the piston and the crankshaft.
Rctilinear motion of the connecting rod into the rotary motion c. Fatigue analysis of connecting rod using finite element. Introductionconnecting rods are highly dynamically loaded components used for power transmission in combustion engines. Even though the mass of the optimize connecting rod is not the lowest, but the decision was also based on the maximum stress which is 320 mpa. In an internal combustion engine, connecting rods are usually located in between a piston and a crankshaft. The design of crankshafts is based on an evaluation of safety against fatigue in the highly stressed areas. Design of connecting rod a connecting rod is a machine member which is subjected to alternating direct compressive and tensile forces. Selection of material, shape, and manufacturing process. The connecting rod is very important part of an engine.
It has a hole at the upper end small end and is connected to the piston by the wrist pin. The weight of the connecting rod is also reduced by 0. The objectives of this paper are to develop structural modeling, finite element analyze and the optimization of the connecting rod for robust design. Dnvglcg0037 calculation of crankshafts for reciprocating. Analysis of connecting rod using composite material. The shape of the connecting rod is to be determined to minimize its weight subject to a set of stress constraints. Design and analysis of assembly of piston, connecting rod and. Fatigue strength is the most important driving factor for the design of connecting rod and it is.
Design of machine members 2 dmm 2 pdf notes 2020 sw. The analysis of the scania line together with a benchmark among different leading companies on the connecting rod manufacturing has been undertaken. The design of the crankshaft and connecting rod mechanism based. These fatigue tests were performed to directly mimic the stresses a connecting rod undergoes in an engine. The objective of the present work is to design and analyses of connecting rod made of aluminium alloy. Analysis of connecting rod using reverse engineering method.
Pdf connecting rod is one of the engines key components which connect the piston to the crankshaft and converts the pistons reciprocating. Pdf design and analysis of connecting rod using forged steel. The design of crankshafts are based on an evaluation. To analyze the buckling load which is equivalent stress due to inertia forces acting on each material. A comparison of manufacturing technologies in the connecting. A connecting rod may also convert rotating motion into reciprocating motion, its original use. Connection rods are mechanical components used for generating motion from a crankshafts piston alternating motion. Steel materials are used to design the connecting rod. Optimization of the connecting rod of a twostroke engine using finite. The small end is press fit and can swivel in the piston. The most critical sections of connecting rod are determined based on mechanical strength. Design of connecting rod depends upon the speed of the engine. Connecting rods are usually made of alloy steel, titanium and sometimes with aluminum. Rules for classification and construction vi additional.
Hippoliti 1993 reported design methodology in use at piaggio for connecting rod design, which incorporates an optimization session. The lower end, also called as big end, is attached to the crankshaft. Fatigue strength is the most important driving factor for the design of connecting rod and it is found that the fatigue. Analysis of connecting rod was carried out using anysy 14. Pdf design of connecting rod of internal combustion. Introduction internal combustion engine has many parts like cylinder, piston, connecting rod, crank and crank shaft. Weightoptimized connecting rod for maximum stress mahle group. Pdf on apr 28, 2020, muslim ali published lecture 4 design of the connecting rod find, read and cite all the research you need on. The connecting rod design with the help of bezier curve having less stress concentration as compare with the connecting rod which is design with the nominal curve.
In this project existing connecting rod that is of forged steel is replaced by ductile iron and aluminium. Connecting rod, aluminium alloy, forged steel, ansys workbench, etc. The magnitude of the forces depends on many factors which consist of crank radius, connecting rod dimensions, weight of the connecting rod, piston, piston rings, and pin. A connecting rod subjected to an axial load w may buckle with xaxis as neutral axis in the plane of motion of the connecting rod,or yaxis is a neutral axis. 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.
Design and analysis of assembly of piston, connecting rod. Design optimization of connecting rod for a single. The design of the connecting rod is created by proe wildfire and analysis is done on fea software. Sapat college of engineering, management studies and research, nasik 5,india. This thesis describes designing and analysis of connecting rod. Introduction a connecting rod can be of two types hbeam or ibeam or a combination of both. It is a pin jointed strut in which more weight is concentrated towards the big end. Figure 10 shows the new design of the connecting rod and mass of the connecting rod is 0. Connecting rod rectangular and ibeam crosssections with the assumed shape of the cross section for the connecting rod as shown in figure 2b, the cross sectional area of the ibeam section is 11 t 2. Internal combustion engine has many parts like cylinder, piston, connecting rod, crank and crank shaft. Its primary function is to transmit the push and pull from the. Design of connecting rod free download as word doc. Connecting rod failed due to insufficient strength to increasing the strength, automatically it will longer the life cycles of the connecting rod.
A parameterized model of connecting rod is modelled using catia software. The effect of inertia load due to the connecting rod, mentioned above, was analysed separately. Dimensions of cross failing either by fatigue or by buckling elastically. They are used respectively depending on their field of application or use. A connecting rod, also called a con rod, is the part of a piston engine which connects the piston to the crankshaft. The function of the connecting rod is to transmit the piston thrust to the. Keywords connecting rod, analysis of connecting rod, four stroke engine connecting rod, aluminum alloy connecting rod, design and analysis of connecting rod, rpm. Analytical study and design analysis of connecting rod of. Force due to friction of the piston pin and crank pin bearings. The connecting rod is required to transmit the compressive and tensile forces from the piston, and rotate at both ends. The connecting rod is considered like both ends hinged for buckling about xaxis and both ends fixed for.
To start the crankshaft design first all the basic engine details are required. In the work presented here, a connecting rod is modeled numerically for a 4cylinder, 4stroke diesel engine. Connecting rods were manufactured by conventional method. This type of connecting rod in which consists big end is made up of 2 pieces. These new and robust connecting rods meet even the highest requirements of modern engines. The bolts for the cap of big end of connecting rod are subjected to a. The connecting rod is the link between the piston and the crank shaft.
The big end of a single rod is made in one part instead of two. It is concluded that the weight of the connecting rod is also reduced by 0. Bedse1 1department of mechanical engineering, savitribai phule pune university gokhale education societys r. Design evaluation and optimization of connecting rod. Selection of material, shape, and manufacturing process for a. Introduction connecting rod is used in reciprocating engine to connect the piston to the crank shaft. Fatigue strength is the most important driving factor for the design of connecting rod. Ilia et al 2005 provide the minimum ibeam area for the connecting rod for the 1. Solve dimension of the connecting rod, diameter of big end and small end parts and find numb.
Connecting rod is one of the important driving parts of the petrol and diesel engine. In this video solve numerical problem related to connecting rod. 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. The connecting rod cr is the main moving part and an important component of an internal com. They do the structural analysis of the connecting rod. Design and analysis of connecting rod using forged steel ijser. Together with the crank, the connecting rod converts the reciprocating motion of the piston into the rotation of the crankshaft. Hello friends here in this video we will learn about the design procedure of connecting rod,which is a part of internal combustion engine. Comparative analysis of two proposed models of connecting rods. In the point of view that location of the cg point of connecting rod lies more towards the big end. The average life of a malleable iron connecting rod was 764,962 cycles at a 50% survival rate or 347,734 cycles at a 90%. In accordance with these design steps, medium carbon steel is preferred as a material for connecting rod. In a reciprocating piston engines, connecting rod connects the piston to the crank or crankshaft. The investigators identified design loads in terms of maximum engine speed, and loads at the crank and piston pin ends.
Gopal et al design and analysis of assembly of piston, connecting rod and crank shaft 237 international journal of current engineering and technology, vol. The connecting rod is designed using catia v5 6r 2014 according to the specifications given below. A connecting rod, also called a con rod, is the part of a piston engine which connects the piston. It is no surprise that a failure in a connecting rod can be one of the most costly and damaging failures in an engine. Currently existing connecting rod is manufactured by using carbon steel. Nov 17, 2017 a connecting rod is a shaft which connects a piston to a crank or crankshaft in a reciprocating engine. Connecting rod the connecting rod links the piston and the crankshaft. Design and analysis of connecting rod using forged steel. The main objective of this paper is to design evaluation through finite element analysis for fatigue life of connecting rod used in hero honda motor cycle.
Connecting rod design a6200 reengineering the model. Pdf design of connecting rod of internal combustion engine. Attention has to be paid to eliminate the stress risers in the connecting rod during production. Connecting rod, structural analysis, titanium, steel, gas load, fatigue, fea 1. This paper presents the design connecting rod of internal combustion engine using the topology optimization. Connecting rod is an integral component of internal combustion engine. The ratio of length of connecting rod to the crank radius lr is usually, a. Connecting rods for crankrocker engines using finite. This thesis has been focused on the study of the connecting rod manufacturing process. Crankshaft design procedure the below is brief guideline for designing the crankshaft.
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