Comparative Analysis and Design of Connecting Rod

International Journal of Innovative Research in Advanced Engineering (IJIRAE) ISSN: 2349-2163
Issue 07, Volume 5 (July 2018) www.ijirae.com
COMPARATIVE ANALYSIS AND DESIGN OF

CONNECTING ROD
Pramod Kumar Maurya
Research Scholar, Dept. Of Mechanical Engineering In CAD/CAM,
Rama University, Kanpur U.P., India
Pramodmaurya093@gmail.com;
Khalid Hussain Ansari
Assistant Professor, Dept. Of Mechanical Engineering,
Rama University, Kanpur U.P., India
Manuscript History
Number: IJIRAE/RS/Vol.05/Issue07/JYAE10080
Received: 02, July 2018
Final Correction: 10, July 2018
Final Accepted: 17, July 2018
Published: July 2018
Citation: Pramod & Khalid (2018). Comparative Analysis and Design of Connecting Rod IJIRAE:: International
Journal of Innovative Research in Advanced Engineering, Volume V,242-255
doi://10.26562/IJIRAE.2018.JYAE10080
Editor: Dr.A.Arul L.S, Chief Editor, IJIRAE, AM Publications, India
Copyright: ©2018 This is an open access article distributed under the terms of the Creative Commons Attribution
License, Which Permits unrestricted use, distribution, and reproduction in any medium, provided the original
author and source are credited
Abstract: The connecting rod is the intermediate member between the piston and the Crankshaft. Its primary
function is to transmit the push and pull from the piston pin to the crank pin, thus converting the reciprocating
motion of the piston into rotary motion of the crank. This thesis describes designing and Analysis of connecting
rod. Currently existing connecting rod is manufactured by using material. In this drawing is drafted from the
calculations. A parametric model of Connecting rod is modeled using NX 10.0 software and to that model,
analysis is carried out by using ANSYS 16.0 Software. Finite element analysis of connecting rod is done by
considering the materials Aluminum 360, Forged Steel, Titanium Alloy, Mild Steel, and Magnesium Alloy. The
best combination of parameters like Von misses Stress and strain, Deformation, Factor of safety and weight
reduction for four wheelers Connecting Rod were done in ANSYS software.
Keywords: Connecting Rod; NX 10.0; Ansys; FEA;
I - INTRODUCTION:
Internal Combustion engine has many parts like cylinder, piston, connecting rod, crank and crank shaft. The
connecting rod is very important part of an engine. Working of the connecting rod is to transmit power of piston
to crank pin. Connecting rod has two ends one is pin end and other is crank end. Pin end is attached with piston.
Fig1: connecting rod

The big end (crank end) is attached to the crank pin by a crank shaft. The function of crank shaft is to transmit
the reciprocating motion of piston into rotary motion.
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II- LITERATURE REVIEW:

1. Sarihan and Song (1990), for the optimization of the wrist pin end, used a fatigue load cycle consisting of
compressive gas load correspond ing to maximum torque and tensile load corresponding to maximum inertia
load. Evidently, they used the maximum loads in the whole operating range of the engine. To design for fatigue,
modified Goodman equation with alternating octahedral shear stress and mean octahedral shear stress was used.
For optimization, they generated an approximate design surface, and performed optimization of this design
surface. The objective and constraint functions were updated to obtain precise values.
3. Yoo et al. (1984) used variational equations of elasticity, material derivative idea of continuum mechanics
and an adjoint variable technique to calculate shape design sensitivities of stress. The results were used in an
iterative optimization algorithm, steepest descent algorithm, to numerically solve an optimal design problem.
The focus was on shape design sensitivity analysis with application to the example of a connecting rod. The
stress constraints were imposed on principal stresses of inertia and firing loads. But fatigue strength was not
addressed. The other constraint was the one on thickness to bound it away from zero.
4. Hippoliti (1993) reported design methodology in use at Piaggio for connecting rod design, which
incorporates an optimization session. However, neither the details of optimization nor the load under which
optimization was performed were discussed. Two parametric FE procedures using 2D plane stress and 3D
approach developed by the author were compared with experimental results and shown to have good
agreements. The optimization procedure they developed was based on the 2D approach.
III - RESEARCH DESIGN OF CONNECTING ROD
3.1. Introduction
NX 10.0 Software mechanical design automation software is a feature-based, parametric solid modeling design
tool which advantage of the easy to learn windows TM graphical user interface. We can create fully associate 3-D
solid models with or without while utilizing automatic or user defined relations to capture design intent.
Parameters refer to constraints whose values determine the shape or geometry of the model or assembly.
Parameters can be either numeric parameters, such as line lengths or circle diameters, or geometric parameters,
such as tangent, parallel, concentric, horizontal or vertical, etc. Numeric parameters can be associated with each
other through the use of relations, which allow them to capture design intent
3.2 Design procedure of Connecting Rod
For designing the Connecting Rod the following procedure has to be follow
Fig 2: 2d sketch of a connecting rod
Fig 3: Sketch & extrude

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Fig 4: Make Holes
Fig5: I-Section of connecting rod
Fig6: Drafting part of top view, front view, bottom view

3.3 Calculation of Connecting Rod
P- Pressure calculation for connecting rod
Engine type 4-strok air cooled
Bore × stroke = 68.5 × 72.0
Displacement = 796cc
maximum power(bhp@rpm) = 48 bhp @ 6000 rpm
________________________________________________________________________________________________
maximum torque (Nm@rpm) = 69 Nm @ 3500 rpm

Compression Ratio = 10.3 ± 0.4
Density of Petrol (∁ H ) = 737.22 kg⁄M = 737.22 E − 9 Kg⁄MM
Auto ignition temp. = 280℃ (536℉) = 553°k
Mass = Desity of petrol × Volume
Mass = 737.22 × 796 = 586,827.12 kg⁄m
Molecular Weight of Petrol = 114.228 g⁄mole = 0.11423 kg⁄mole
VI - COMPARISON OF MATERIAL
1) Density of comparison: The connecting rod has tremendous field of research. In addition to this, automobile
construction led the invention and implementation of quite new materials which are light and meet design
requirements.
10
8
Density
6
4
2
0
Density
Material
Fig7: Density comparison chart

2. Weight Comparison: Compared five materials used for manufacturing of connecting rod these are AL360,
Magnesium Alloy, Forged Steel, Titanium , Mild Steel. The modeling and analysis of connecting rod was done.
6
5
Weight
4
3
2
1
0
Material
Fig8: Weight comparison chart

V - EXPERIMENT METHODOLOGY
Fig9: Static Structural Analysis System

________________________________________________________________________________________________
Introduction to Ansys
Ansys is analysis software. It is used to check design feasibility of the design almost in all aspect. Ansys as a
software is made to be user-friendly and simplified as much as possible with lots of interface options to keep the
user as much as possible from the hectic side of programming and debugging process.
Fig10: First view of static structure

3) Importing External Geometry: As design of connecting rod is done on SOLID WORKS is imported as
shown below:-
Fig11: Importing external geometry
Fig12: Generate meshing

________________________________________________________________________________________________
4) Meshing After importing the external geometry further function is meshing. Meshing is done for better
accuracy in result. It is many types-
a) Triangular meshing
b) Rectangular meshing
c) Tetrahedron meshing ..........etc.
5. Working on Mode
a) After meshing we go to SET UP we click on CONNECTING and see like this-
b) In Details of CONNECTING click on assignment we see there are importing materials.
c) Then we select one of them for further implementation.
d) Static Structural Setting: In static structure Analysis we have to fixed one part then right click on static
structure then go to insert and further click on fixed support and apply on one part of the connecting
rod.
Fig13: Giving new material to connecting rod
Fig14: Giving fixed support

8) Definition of Stress: To define stress various theories have been already assigned in the ansys like Von-
Mises, Maximum principal etc. In this project Von- Mises used as stress theory.
Fig15: Applied stress in model

________________________________________________________________________________________________
9) Strain: There are many type of strain in ansys as von-mises, maximum principle strain, maximum shear
strain. In this project we discuss only von-mises strain.
Fig16: Strain in model

VI -Comparison of Different Materials
1) Strain comparison
Strain ,m/m
6.00E-04
Strain ,m/m
5.00E-04
4.00E-04
3.00E-04
2.00E-04
1.00E-04 Strain ,m/m
0.00E+00
Aluminium 360 Mild steel Titanium Forged steel Manisium alloy
Material
Fig17: Strain comparison chart

2. Stress comparison
Stress , m/m
1.14E+07
1.13E+07
Stress , m/m
1.12E+07
1.11E+07
1.10E+07
1.09E+07
Stress , m/m
1.08E+07
1.07E+07
Aluminium 360 Mild steel Titanium Forged steel Magnisium alloy
Material
Fig18: Stress comparison chart

3. Deformation comparison
1.40E-05
Deformation ,m
1.20E-05
1.00E-05
8.00E-06
6.00E-06
4.00E-06 Deformation ,m
2.00E-06
0.00E+00
Aluminium Mild steel Titanium forged steel magnisium
360 alloy
Material
Fig19: Deformation comparison chart

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VII - RESULT AND DISCUSSION
A. Analysis of Connecting Rod of Forged Steel
Fig20: Equivalent Strain Analysis
Fig21: Equivalent Deformation Analysis
Fig22: Equivalent Stress Analysis

Table-4.2 Result and Analysis Forged Steel
Minimum Maximum
Stress 1.224.4 Pa 1.1015e-007Pa
Strain 1.8385e-008 m/m 1.1477e-004 m/m
Deformation 0.m 0.m
B. Analysis of Connecting Rod of Magnesium Alloy
________________________________________________________________________________________________

Table-4.2 Result and Analysis Magnesium Alloy
Minimum Maximum
Stress 1264.8 Pa 1.106e+007 Pa
Strain 3.9509e-008 m/m 2.4586e-004 m/m
Deformation 0.m 1.2762e-005 m
C. Analysis of Connecting Rod of Titanium

________________________________________________________________________________________________
Fig25: Equivalent Deformation Analysi

Table-4.2 Result and Analysis Titanium
Minimum Maximum
Stress 12224.4 Pa 1.1015e+007Pa
Strain 1.8385e-008 m/m 1.1477e-4m/m
Deformation 0.m 5.9771e-005m
D. Analysis of Connecting Rod of Mild Steel
________________________________________________________________________________________________
Table-4.2 Result and Analysis Mild Steel

Minimum Maximum
Stress 1455.3 pa 1.1281e+007 Pa
Strain 1.8385e-008 m/m 1.1477e-004 m/m
E. Analysis of Connecting Rod of Aluminum 360

Table-4.2 Result and Analysis Aluminum 360
Minimum Maximum
Stress 1224.4 Pa 1.1015e+007 Pa
Strain 1.8385e-008 m/m 1.1477e-004 m/m
VIII – CONCLUSION
1. Solid modeling of connecting rod was made in NX 10.0 according to production drawing specification and
analysis under the effect of tensile and compressive loads in terms of pressure is done in ANSYS Workbench.
2. It is the conclusion of this study that the connecting rod can be designed and optimized under a load range
comprising compressive load as one extreme load and tensile load.
________________________________________________________________________________________________
3. The section modulus of the connecting rod should be high enough to prevent high bending stresses due to
inertia forces.
4. Weight of connecting rod is reduced, Thereby reduces the inertia force by comparing the results of three
different materials used for connecting rod analysis it is found that equivalent von mises stress for all the
materials is approximately same.
5. Maximum von mises stress, Maximum von mises strain and Maximum displacement are minimum in
connecting rod.
6. Comparing the different data it is observed that stress, strain and displacement is minimum in connecting
rod.
IX - FUTURE SCOPE
1. When we use this design of connecting rod our component life increase and minimizing maintenance.
2. Vibrational analysis can be done at ansys for minimizing the premature failure.
3. Thermal analysis can be done of connecting rod to minimize the thermal stress effect on connecting rod.
4. Design modification can be done to minimize the weight of connecting rod.
5. Work on the internal coating of hard material inside the both ends can be done to minimize the wear failure
in connecting rod.
X-REFERENCES
1. Repgen, B., 1998. “Optimized Connecting Rods to Enable Higher Engine Performance and Cost Reduction,”
SAE Technical Paper Series, Paper No. 980882.
2. Kuldeep B, Arun L.R, Mohammed Faheem “Analysis And Optimization Of Connecting Rod Using Alfasic
Composites”, ISSN: 2319-875, International Journal of Innovative Research in Science, Engineering and
Technology, Vol. 2, Issue 6, June 2013
3. Prof. N.P.Doshi, 1 Prof .N.K.Ingole “Analysis Of Connecting Rod Using Analytical And Finite Element Method”
International Journal Of Modern Engineering Research” (Ijmer) www.ijmer.com Vol.3, Issue.1, Jan-Feb. 2013,
ISSN: 2249-6645.
4. Om Prakash, Vikas Gupta and Vinod Mittal. 2013. “Optimizing the Design of Connecting Rod under Static and
Fatigue loading” International journal of Research in Management Science and Technology, Vol.1, June, pp. 39
– 43.
5. Khanali, M., 2006. "Stress analysis of frontal axle of JD 955 combines". M.Sc. Thesis. Thran University, 124.
6. J. Babu Rao et al, (2010), Development of light weight ALFA composites, International Journal of Engineering,
Science and Technology Vol. 2, No.11,pp. 50-59.
7. Christy V Vazhappilly and P. Sathiamurthi, (2013), Stress Analysis of Connecting Rod for Weight Reduction-A
Review International Journal of Scientific and Research Publications, Volume 3, Issue
8. Books
1. Design data by PSG.
2. A text book of Machine Design by S.Md. Jalaludeen.
3. Machine design by R.S. KHURMI, J.K GUPTA
________________________________________________________________________________________________

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International Journal of Innovative Research in Advanced Engineering (IJIRAE) ISSN: 2349-2163

Issue 07, Volume 5 (July 2018) www.ijirae.com

COMPARATIVE ANALYSIS AND DESIGN OF

Fig1: connecting rod

II- LITERATURE REVIEW:

Fig 2: 2d sketch of a connecting rod

Fig 3: Sketch & extrude

Fig 4: Make Holes

Fig5: I-Section of connecting rod

Fig6: Drafting part of top view, front view, bottom view

maximum torque (Nm@rpm) = 69 Nm @ 3500 rpm

Fig7: Density comparison chart

Fig8: Weight comparison chart

Fig9: Static Structural Analysis System

Fig10: First view of static structure

Fig11: Importing external geometry

Fig12: Generate meshing

Fig13: Giving new material to connecting rod

Fig14: Giving fixed support

Fig15: Applied stress in model

Fig16: Strain in model

Fig17: Strain comparison chart

Fig18: Stress comparison chart

Fig19: Deformation comparison chart

Fig20: Equivalent Strain Analysis

Fig21: Equivalent Deformation Analysis

Fig22: Equivalent Stress Analysis

Fig23: Equivalent Stress Analysis

Fig24: Equivalent Strain Analysis

Fig25: Equivalent Deformation Analysis

Fig26: Equivalent Strain Analysis

Fig27: Equivalent Stress Analysis

Fig25: Equivalent Deformation Analysi

Fig26: Equivalent Stress Analysis

Fig27: Equivalent Strain Analysis

Fig28: Equivalent Deformation Analysis

Table-4.2 Result and Analysis Mild Steel

Fig29: Equivalent Strain Analysis

Fig30: Equivalent Stress Analysis

Fig31: Equivalent Deformation Analysis

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