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Corresponing author: Ajay Kumar Choubey E-mail address: ajay.choubey24@gmail.com

Doi: http://dx.doi.org/10.11127/ijammc2016.09.05 Copyright@GRIET Publications. All rights reserved.

Advanced Materials Manufacturing & Characterization Vol 6 Issue 2 (2016)

Advanced Materials Manufacturing & Characterization

journal home page: www.ijammc-griet.com

Analysis of Connecting Rod by the Finite Elements Method

Ajay Kumar Choubey1, RashmiDwivedi 2, GeetaAgnihotri3

1Research Fellow, TEQIP-II Project, MSME Department, Maulana Azad National Institute of Technology, Bhopal (M.P.) – 4620051 2Research Scholar, Mechanical Engg. Department, Maulana Azad National Institute of Technology, Bhopal (M.P.) – 4620051

3Professor, Mechanical Engg. Department, Maulana Azad National Institute of Technology, Bhopal (M.P.) – 4620051

Abstract In this paper, finite element analysis of single cylinder four stroke petrol

engines is taken as a case study. Connecting rod is high volume

production from automobile side; it is subjected to more Stress than

other engine components. The main aim of this paper is to determine the

von-Mises stresses, shear stresses, total deformation. In this paper, only

the static FEA of the connecting rod has been performed by the use of the

software. This work can be extended to study the effect of loads on the

connecting rod under dynamic conditions. A lot has been done and still a

lot has to be done in this field. Structural systems of connecting rod can

be easily analyzed using Finite Element techniques. So firstly a proper

Finite Element Model is developed using FEM software ANSYS 14.0. The

static loads acting on the connecting rods, after that the work is carried

out for safe design. In this study two different size connecting rod uses

for static analysis.

Keywords: Connecting rod, FEA, stress, static analysis etc

1. Introduction

Connecting rods are widely used in variety of car and bike

engines. It is an integral component of internal combustion

engine and classified under functional component. It acts as a

linkage between piston and crank shaft. The main function of

connecting rod is to transmit the translational motion of piston

to rotational motion of crank shaft. The function of the

connecting rod also involves transmitting the thrust of the piston

to the connecting rod. Connecting rod has three main zones.

The piston pin end, the center shank and the big end. The piston

pin end is the small end; the crank end is the big end. Connecting

rods are subjected to forces generated by mass and fuel

combustion(Tony George Thomas, 2011).

Kamaldeep Grover and BalvinderBudania (2012) carried out the

Finite Element Analysis and optimization of connecting rod

using ANSYS. The main objective of this study was to reduce the

weight for structural steel connecting rod.

Neeraj Kumar, P. M. Kasundra (2012)presented a method used

to verify the stress and deformation in the connecting rod using

the finite element method. The study only analyses the

connecting rod foot. The obtained results provided by this

method were compared to the results obtained by calculation.

Although, the Finite Element Method (FEM) is a very powerful

tool for simulation of the engineering problems, the FEM

simulation of non-linear problem is a time consuming

procedure. In the present paper, the connecting rod is simulated

with ANSYS 14.0 Software. Steel and Aluminum materials are

used for stress analysis.

2. Aim of the Study

The main objective of this work is to investigate the stresses on

different size of the connecting rod. In this paper, only the static

FEA of the connecting rod was performed. The aim of the paper

is to determine the von- Misses stresses, Shear stresses, Total

Deformation and Optimization of pressure in the existing

Connecting rod. If the existing design shows the failure, then

suggest the minimum pressure for the existing Connecting rods.

Also the comparison between two materialsof connecting rod

analyzed.

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Fig.1. Connecting Rods

3. Methodology

The methodology adopted in this study consists of a number of

steps and sub steps. Starting from the creation of a 3-D FE model

and then defining input parameters such as material properties,

parameters. The mechanical boundary conditions were then

imposed on the model and the solution was done by meshing of

the model by using SOLID185 element type. The FE model was

made using ANSYS software. The steps of the study are shown in

the following chart:

Fig.2. Methodology 4. Finite Element Analysis

The 3-D FE model for connecting rod was created by using

ANSYS 14.0 software. The connecting rod is analyzed in ANSYS

in three steps. First is preprocessing which involves modeling,

geometric clean up, element property definition and meshing.

Next comes, solution which involves imposing boundary

conditions and applying loads on the model and then solution

runs. Next in sequence comes post processing, which involves

analyzing the results plotting different parameters like stress,

strain, total deformation and many. The mesh has been

generated using tetra free element and mesh size is 2. The Solid

185 element type is adopted to mesh the model. The mesh of the

connecting rod consists of 64944 elements, 12958 nodes are

included in the finite element model.

Figure 3 showing FE model of connecting rod model prepared in

ANSYS 12.0.1.

Fig.3. FE model of connecting rod

Figure 4 showing meshing of connecting rod FE model.

Fig.4. Meshing of connecting rod model

5. MATERIAL PROPERTIES OF CONNECTING ROD

Steel is used in this study withYoung’s Modulus (E) of 210000

MPa and Poisson’s ratio (υ) as 0.30 (Also taken tangent modulus

& strain hardening component). The density (ρ) of the Mild Steel

is taken as 7850 Kg/m3. The value of yield stress (σYS) is 250 MPa

and ultimate tensile stress (σUTS) is 410 MPa.

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6. CALCULATION OF MAXIMUM FORCE Force acting on piston = area of piston Х gas pressure

This maximum gas force applied on the surface of piston from

where it will transfer to connecting rod through piston pin.

Table I: Specification of the engine to which connecting rod

belongs

Parameters Dimensions

Bore 57 mm

Engine Displacement 143.91 cc

Compression Ratio 9.5:1

Maximum Power 9.57 kW at 8500 rpm

Maximum Torque 11.68 m at 6500 rpm

7. Result& Discussion

Connecting rod simulation and modeling have done by ANSYS.

The simulation results as shown in below:

Fig.5. von-Mises stress at 0.5 MPa

Fig. 5 showing when the pressure on connecting rod small end is

0.5 MPa than the von-Mises stress value is 2.185 MPa.

Fig. 6 von-Mises stress at 2.5 MPa

Fig. 6 showing that when the pressure increasing from 0.5 to 2.5

MPa at small end than the value of von-Mises stress increasing

from 2.185 to 10.923 MPa

Fig.7. von-Mises stress at 3.5 MPa Fig. 7 showing when the pressure on connecting rod small end is

3.5 MPa than the von-Mises stress value is very high.

Max. Stress

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Fig.8. Stress vs Pressure

Figure 8 disusing that all stresses value on connecting rod. It

show that when the pressure will increase from 0.5 to 4 MPa

than the value of stress also increasing.

Fig.9. von-Mises Stress vs Pressure

Figure 9 show that pressure will increase then von-Mises stress

also increases but steel is better from aluminum.

Small Connecting Rod –

Pressure(Mpa) Steel(Max) Aluminium(Max)

0.5 2.0 2.114

2.5 10.4 10.5

3.5 14.6 14.7

BigConnecting Rod –

Pressure(Mpa) Steel(Max) Aluminium(Max)

0.5 2.185 2.2

2.5 10.923 11.008

3.5 15.411 15.411

Conclusions

By the help of simulations some results are finding –

When the pressure on small end of connecting rod increases

from 0.5 to 3.5 MPa than the von-Mises stress also increases

from 2.185 to 15.2.

When the pressure applied on connecting rod than steel is

better perform comparison to aluminum.

References [1]. Tony George Thomas, S. Srikari, M. L. J Suman, “Design of

connecting rod for heavy duty applications produced by different processes for enhanced fatigue life”, SASTECH Journal, Vol. no. 10, Issue no. 1, Page no. 1-7, 2011.

[2]. A. Mirehei, M. HedayatiZadeh, A. Jafari, M. Omid , “Fatigue

analysis of connecting rod of universal tractor through finite element method (ANSYS)”, Journal of Agricultural Technology, Vol. no. 4, Issue no. 2, Page no. 21-27, 2008.

[3]. Anil kumar, Kamaldeep Grover, BalvinderBudania,

“Optimization of Connecting Rod Parameters using CAE Tools”, International Journal of Latest Trends in Engineering and Technology, Vol. no. 1, Issue no. 3, Page no. 98-104, 2012.

[4]. Mohammad Ranjbarkohan, Mohammad Reza Asadi,

MasoudMohammadi, AhangariHeidar, “Fatigue Analysis of Connecting Rod of Samand Engine by Finite Element Method”, Australian Journal of Basic and Applied Sciences, Vol. no. 5, Issue no. 11, Page no. 841-845, 2011.

[5]. Mansour Rasekh, Mohammad Reza Asadi, Ali Jafari, Kamran

Kheiralipour, “Obtaining Maximum Stresses in Different Parts of Tractor (Mf-285) Connecting Rods Using Finite Element Method”, Australian Journal of Basic and Applied Sciences, Vol. no. 3, Issue no. 2, Page no. 1438-1449, 2009.

[6]. Ram Bansal , “Dynamic Simulation of a Connecting Rod made of

Aluminum Alloy using Finite Element Analysis Approach”, IOSR Journal of Mechanical and Civil Engineering , Vol. no. 5, Issue no. 2,. Page no. 01-05, 2013.