DESIGN AND ANALYSIS OF PISTION WITH CONNECTING … · Cuicui Tian,Dan Fang ... vitality to the crankshaft through the associating pole. ... Load on the piston pin due to bearing pressure

DESIGN AND ANALYSIS OF PISTION WITH CONNECTING

ROD

MOHD MUSHARRAF1, Dr. I. SATYANARAYANA2,C.SIVAKANDHAN3,M.SOMESH4

1PG SCHOLAR, 2PROFESSOR, 3&4ASST PROFESSOR

DEPARTMENT OF MECHANICAL ENGINEERING, SRI INDU INSTITUTE OF

ENGINEERING AND TECHNOLOGY(Formerly ASEC)

AICTE approved, Affiliated to JNTUHSheriguda, Ibrahimpatnam(M), RangaReddy

District, Hyderabad, Telangana-501510

ABSTRACT

The advanced pattern is to create IC Engine of expanded power limit. One of the outline criteria

is the undertaking to decrease the structures weight and in this way to diminish fuel utilization.

This has been made conceivable by enhanced motor outline. Car segments are in extraordinary

request nowadays due to expanded utilization of autos. The expanded request is because of

enhanced execution and diminished cost of these parts. A definitive point of the undertaking

work is to explore the actuated distortions and worries in various designs of cylinder and

interfacing bar of a four wheeler. In this undertaking work, a current cylinder and interfacing

pole of a four wheeler (Tata Indica) has been mulled over. With the assistance of logical outline

methodology, the weight following up on the cylinder is ascertained. Plan and Finite Element

Analysis is led on five distinctive standard designs of the cylinder by applying the different

weights. For interfacing bar the little end is mulled over. The measurement of the bronze

shrubbery of the little end of the associating bar has been planned as cylinder stick differs.

1. INTRODUCTION

A connecting rod can be of two types H-beam or I-beam or a combination of both. They are used

respectively depending on their field of application or use. An I-beam is both light weight and

strong but the type of material used limits its capacity to handle load. Whereas an H-beam can

handle much more stress without bending. So they are used in high power engines. The

connecting rod is subjected to a complex state of loading [6]. It undergoes high cyclic loads of

the order of 108 to 109 cycles, which range from high compressive loads due to combustion, to

high tensile loads due to inertia. Therefore durability of this component is of critical importance

JASC: Journal of Applied Science and Computations

Volume 5, Issue 11, November/2018

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[7]. Due to these factors, the connecting rod has been the topic of research for different aspects

such as production technology, materials, performance simulation, fatigue, etc. For the current

study, it is necessary to investigate finite element modelling techniques, optimization techniques,

developments in production technology, new materials, fatigue modelling, and manufacturing

cost analysis.

LITERTURE REVIEW:

Isam Jasim Jaber and Ajeet Kumar Rai [6] have detailed that with the progression in

material science, light weight materials with great warm and mechanical properties can

be utilized for safeguard plan of the I.C.engine. This will lessen the fuel utilization and

ensure the earth.

N. P. Jadhav [8] has done FEA examination utilizing ANSYS for optimim geometry. The

work depicts the work advancement with utilizing limited component investigation

strategy to anticipate the higher pressure and basic district on the part.

S. Bhattacharya [3] have inferred that Piston mass could be decreased up as far as

possible, past which a further decrease would result in bending of the cylinder.

Mr. Ajinkya.A. Bhilare [1] have proposed that Change in the outline and material

outcomes in noteworthy impact on weight. As it accomplishes the target of decreasing the

heaviness of the motor segment, in this way lessening latency loads, diminishing motor

weight and enhancing motor execution and efficiency.

B.Anusha [4] has reasoned that the pressure instigated in the basic steel is not as much as

the cast press for the present examination. Here auxiliary steel can be utilized for creation

of interfacing bar for long sturdiness as cast press is weak material.

Sunden and R. Schaub [5] displayed a choice of a portion of the more for all intents and

purposes orientated standards of the fruitful produce of dark cast press cylinder rings

more noteworthy than 175 mm in breadth, and demonstrated that when considered with

the sciences of quality of materials and diesel building, the subject of cylinder rings turns

into an epitome of the more extensive subject of tribology.

P. C. Nautiyal [7] explored a substantial piece of the best cylinder ring wear of an IC

motor which happens in limit grease around top flawlessly focused (TDC) position. A

quantitative appraisal of the frictional conduct utilizing genuine cylinder ring and barrel



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liner under conditions near TDC was made. The components in charge of wear under

these conditions have been distinguished as surface temperature, top ignition weight, add

up to vitality on the wearing surfaces and other physical properties of the material under

sliding.

Pravardhan S. Shenoy [11] the University of Toledo did the dynamic load examination

and improvement of associating pole. The primary target of this examination was to

investigate weight and cost decrease open doors for a generation manufactured steel

interfacing bar. This has involved playing out a nitty gritty load investigation.

James R. Dale (2005) [9] introduced a work which gave Connecting Rod Evaluation in

which he outlined up with Most producing grade amalgam powders utilize nickel and

molybdenum and little measures of manganese to upgrade press hardenability without

creating stable oxide development.

Cuicui Tian,Dan Fang [10] completed the Sensitivity Analysis and Optimization for

Connecting pole of LJ276M Electronic Gasoline Engine. Affectability examination and

improvement in view of the mix of Pro/MECHANICAL and ANSYS are connected to

outlining of the interfacing bar of LJ276M electronic fuel motor. The most extreme worry

of associating pole on the biggest pressure condition is lessened by 4.9% after the

streamlining is connected, static intension wellbeing coefficient is expanded by 5.4% and

mass of interfacing bar is additionally diminished.

In the paper done by AbhinavGautam, K PriyaAjit [3] static pressure investigation of

associating bar made up of SS 304 utilized in Cummins NTA 885 BC motor is directed,

It is seen that the territory near base of the littler end is exceptionally inclined to

disappointment, might be because of higher squashing load because of gudgeon stick

gathering. As the pressure esteem is most extreme here and stresses are monotonous in

nature so odds of weariness disappointment are constantly higher near this locale.

Smash Bansal [12] was noticed that the interfacing bar distortion was for the most part

twisting because of clasping under the basic stacking and the greatest misshapening was

situated because of squash and shear disappointment of the enormous and little end

direction. So these zones inclined to show up the exhaustion split. Base on the outcomes,

we can estimate the likelihood of shared impedance between the associating bar and

different parts. The outcomes give a hypothetical premise to upgrade the outline and



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weariness life figuring.

In the paper by Kuldeep B, Arun L.R, Mohammed Faheem [13] it is reasoned that

Weight can be diminished by changing the material of the current al360 interfacing pole

to mixture ALFASiC composites. The new improved interfacing bar is similarly

significantly stiffer than the previous.

In the proposition by Pravardhan S. Shenoy and Ali Fatemi [14] Optimization was

performed to lessen weight and assembling expense of a produced steel interfacing pole

subjected to cyclic load including the pinnacle compressive gas stack and the pinnacle

dynamic pliable load at 5700 rev/min, comparing to 360o wrench point.

For the enhancement think about, Serag (1989) [15] created inexact numerical formulae

to characterize associating pole weight and cost as target capacities and furthermore the

requirements. The improvement was accomplished utilizing a Geometric Programming

method. Limitations were forced on the pressure, the bearing weight at the wrench and

the cylinder stick closes. Weakness was not tended to. The cost work was communicated

in some exponential frame with the geometric parameters

Mr. Pranav G Charkha [16] performed stack investigation on interfacing pole. Their

examination were manages two subjects, first, static load pressure investigation of the

interfacing pole, and second, advancement for weight. . Advancement was performed to

diminish weight. They found that weight can facilitate more decreased by changing the

material of the manufactured steel associating pole to split capable fashioned steel (C-

70). The upgraded geometry was 20% lighter than the current interfacing bar.

3.DESIGN OF PISTON: The cylinder is a circle which responds inside a chamber. It is either moved by the liquid

or it moves the liquid which enters the barrel. The principle capacity of the cylinder of an

inner ignition motor is to get the motivation from the growing gas and to transmit the

vitality to the crankshaft through the associating pole.

Fig 3.1: CAD Model of Piston



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3.1 Piston Head or Crown:

The thickness of the piston head (tH) is given by,

3.1.1 Piston Rings:

The radial thickness (t1) of the ring is obtained by, The axial

thickness (t2 ) of the rings may be taken as,

The minimum axial thickness (t2 ) may also be obtained by,

where nR = Number of rings. Width of

top land, Width of other ring lands,

3.1.2 Piston Barrel:

The maximum thickness (t3) of the piston barrel is calculated as

The piston wall thickness (t4) towards the open end is, 3.1.3 Piston Skirt: Maximum gas load on the piston, The side thrust (R) is given by R =Bearing pressure × Projected bearing area of the piston skirt The total length of the piston (L) is given by L = Length of skirt + Length of ring section + Top land 3.1.4 Piston Pin:

Load on the piston due to gas pressure or gas load,

Load on the piston pin due to bearing pressure or bearing load = bearing

pressure × bearing area



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Section modulus, Maximum bending moment, 3.2.Design of Connecting Rod:

In a responding cylinder motor, the associating pole interfaces the cylinder to the wrench or

crankshaft. In present day car inner burning motors, the associating bars are most typically made

of steel for generation motors, however can be made of aluminum (for delicacy and the capacity

to ingest high effect to the detriment of toughness) or titanium (for a blend of quality and

gentility to the detriment of reasonableness) for elite motors, or of cast press for applications, for

example, engine bikes

Fig 3.2 : CAD Model of Connecting Rod 3.2.1 Cross-section of the connecting rod Let thickness of the flange and web of the section = t Width of the section, Depth or height of the section, Area of the section, Moment of inertia of the section about X-axis Moment of inertia of the section about Y-axis



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The buckling load (WB) may be calculated by

3.2.2 Crank Pin and Piston Pin Maximum gas force, Load on the crank pin = Projected area × bearing pressure = Load on the piston pin, 3.2.3 Bolts for securing the big end cap

Force on the bolts,

Nominal or major diameter (db) of the bolt is given by, 3.2.4 Thickness of the big end cap Maximum bending moment acting on the cap, Section modulus for the cap, Bending Stress,

3.3 Specifications: The following dimensions have been taken from the existing design and modified design of the piston and connecting rod. Table 1: Geometrical dimensions of Piston



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RESULTS AND DISCUSSIONS PISTON:

0.012

0.011

(mm

) 0.010

Def

orm

ati

on

0.009

0.008

Tot

al Piston Dia=72 mm

0.007 Piston Dia=74 mm

Piston Dia=75 mm

0.006 Piston Dia=77 mm

Piston Dia=78 mm

0.005

2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0

Pressure acting on the Piston (MPa)

Fig 6.1 Pressure vs Total Deformation

When the measurement of cylinder diminishes from 75 mm to 72 mm then it causes

1.08% decline in all out distortion (i.e.. from 0.009998 mm to 0.00989 mm)

As the distance across of cylinder diminishes from 75 mm to 74 mm then it causes 5.88%

decline in complete misshapening (i.e. from 0.009998 mm to 0.00941 mm)

When the distance across of the cylinder increments from 75 mm to 77 mm then it causes

7.92% expansion in all out misshapening (i.e. from 0.009998 mm to 0.01079 mm)

As the breadth of the cylinder increments from 75 mm to 78 mm then it causes 12.04%

expansion in all out misshapening (i.e. from 0.009998 mm to 0.0112 mm)



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CONNECTING ROD:

26

(mm

) 24

the

Bus

h 22

20

Of

Dia

met

er

18

16

72 73 74 75 76 77 78

Diameter of the Piston (mm)

Fig 6.9 Diameter of the Piston vs Diameter of the Bush

When the distance across of cylinder diminishes from 75 mm to 72 mm then it causes

27.27% decline in breadth of shrubbery of the little end of associating pole (i.e. from 22 mm to

16 mm).

When the distance across of cylinder diminishes from 75 mm to 74 mm then it causes

18% lessening in breadth of shrub of the little end of associating bar (i.e. from 22 mm to 18 mm)

When the measurement of the cylinder increments from 75 mm to 77 mm then it causes

4.5% expansion in distance across of hedge of the little end of interfacing pole (i.e. from 22 mm



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to 23 mm)

When the distance across of the cylinder increments from 75 mm to 78 mm then it causes

13.63% expansion in breadth of hedge of the little end of interfacing pole (i.e. from 22 mm to 25

mm).

CONCLUSION

PISTON:

It has been reasoned that as the weight following up on the cylinder builds, add up to

misshapening increments. The aggregate misshapening increments if the measurement is

expanded for a given weight.

It has been seen that as the weight following up on the cylinder expands, Equivalent

(von-Mises) push, Maximum important Stress, Shear Stress increments. The pressure increments

when the distance across is expanded for a given weight.

It has been seen that as the weight following up on the cylinder builds, Maximum

Principal Elastic Strain, Equivalent Elastic Strain, increments and if the distance across is

expanded for a given weight Maximum Principal Elastic Strain increments.

It has been comprehended that as the weight following up on the cylinder builds, stack on

the cylinder increments. The heap on the cylinder increments if the distance across is expanded

for a given weight.

CONNECTING ROD:

It has been surmised that as the width of cylinder expands, distance across of shrubbery

of the little end of associating pole increments.

It is inferred that as the width of shrub of the little end of interfacing bar builds, add up to

distortion, Equivalent Elastic Strain and Maximum Principal Flexible Strain increments.

It is seen that as the width of cylinder expands, Equivalent Stress, Maximum Principal

Elastic Stress and Shear Stress increments.



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DESIGN AND ANALYSIS OF PISTION WITH CONNECTING … · Cuicui Tian,Dan Fang ... vitality to the crankshaft through the associating pole. ... Load on the piston pin due to bearing pressure