The first was to provide the largest possible big end bearing on the connecting rod while maintaining stock crankshaft stroke 4. Currently existing connecting rod is manufactured by using carbon steel. Design evaluation and optimization of connecting rod parameters. Evaluating the impact of nonlinear contact modeling in. A parametric model of connecting rod is modeled using catia v5 r19 software and to that model, analysis is carried out by using ansys. Structural design and analysis of a servo crank press. A connecting rod has always been the subject of research and investigation from different aspects viz, design, production considerations, production. It should form effective oil sealing in the cylinder. Connecting rod, structural analysis, titanium, steel, gas load, fatigue, fea 1. According to forming press application, sf is selected by. These are classed as special connections and are treated separately.
Final project design a fourcylinder internal combustion engine project and engineering department. Pdf design of connecting rod of internal combustion engine. Anyone know of examples of engines that had trouble with connecting rod torsional stiffness. The alternate version is the hbeam, which has developed a significant following. Design considerations for a piston in designing a piston for an engine, the following points should be taken into consideration. Today,what takes a leading role in the market is the low cost,high strength anf tight tolerance.
Design of piston step by step procedure machine design how. Selection of material, shape, and manufacturing process. Fem analysis of connecting rod of different materials. It should have enormous strength to withstand the high pressure. That can be achieved by changing such design parameters in. 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. Selecting and saving a car will make browsing faster and more fun. The objective of the present work is to design and analyses of connecting rod made of aluminium alloy. Material design for advanced connecting rod for mass.
Together with the crank, the connecting rod converts the reciprocating motion of the piston into the rotation of the crankshaft. Strength calculations and determination of the critical part dimensions are specified for connecting rod design, crankshaft design, ram design, gear design with keyways, and main body. The connecting rod attaches to a small loose fit hole in a flatfiled area of the threaded rod. The project also analyses factors such as stress, strain, factor of safety, deformation, fatigue analysis and working cycle while taking. The piston end of the connecting rod is bend to a square u shape. In drop forging production process,the strict requirements for forgings are just as important as to the requirements of the finished product. Design analysis and optimization of various parameters of. A new strongrod systems design guide and revamped web pages provide information on new design options, components and configurations. The weight of the connecting rod is also reduced by 0. The objective of this paper is to modify the connecting rod design and changing the material of. The choice for all production rods has always been a simple ibeam design. This classic configuration can withstand tremendous vertical loads and can be extremely light.
Powder forging process powder forging consists of the rapid densification of a heated powderbased preform using a single forging strike. The computeraided design cad files and all associated content posted to this website are created, uploaded, managed and owned by third party users. Pdf design considerations for connecting rod researchgate. Finite element modelling a three dimensional connecting rod. Steel materials are used to design the connecting rod. The fundamentals of fatigue considerations, basic elements of fatigue design. Manufacturing variations in joint surface flatness and bearing crush were predicted. Review on design and analysis of connecting rod using different. A connecting rod, also called a con rod, is the part of a piston engine which connects the piston to the crankshaft. Design of connecting rod a connecting rod is a machine member which is subjected to alternating direct compressive and tensile forces. Modern manufacturing process of forged connecting rod.
Crankshaft design, materials, loads and manufacturing, by. Each cad and any associated text, image or data is in no way sponsored by or affiliated with any company, organization or realworld item, product, or good it may purport to portray. A connecting rod is subjected to a cyclic load during its service. 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. Connecting rod definition of connecting rod by merriam. Internal combustion engine handbook sae international. Hi guys this is our first video on design of piston step step procedure in machine design subject. Connecting rod, finite element analysis, modeling, static i. Nevertheless, connecting rod design is complicated because the engine is to work in variably complicated conditions and the load on the rod mechanism is produced not only by. Proe software is used for modeling and analyses are carried out in ansys software. A tubular connecting rod construction can be used to provide acceptable stiffness in axial, bending, as well as torsional load cases. Cap alingment method, bearing inset crush and or machined grooves for bearing tabs and finally, piston pin hole diameter press fit pin or sized for a bushing and floating pin in which case the little end needs a hole for some. New considerations in connecting rod design 8323 connecting rod design factors such as joint surface flatness, bearing crush, geometric shape, and capscrew torque can significantly affect bore distortion, assembly stresses, and bearing and joint load distribution. The connecting rod design is complicated because the engine is to work in.
Selection of material, shape and manufacturing process for a connecting rod abstract this activity centers on the courses of strength of materials and production design offered at a sophomore level mechanical engineering curriculum. A connecting rod also undergoes bending stresses, which rise commensurately with rpm and power output. Fatigue strength is the most important driving factor for the design of connecting rod and it is found that the fatigue. It should have minimum weight to withstand the inertia forces. Introduction a connecting rod can be of two types hbeam or ibeam or a combination of both. The crosssection of the shank of the connecting rod may be rectangular, circular, tubular, isection or hsection as shown in following diagram. A connecting rod is one of the most mechanically stressed components in internal combustion engines. Design and optimization of four wheeler connecting rod. The connecting rod is required to transmit the compressive and tensile forces from the piston, and rotate at both ends.
The proper condition of a connecting rod is fairly straightforward. They are used respectively depending on their field of application or use. Forces due to the cylinder pressure as well as the mass of the connecting rod and the piston assembly are illustrated in. The rod must be straight, centertocenter rod length must meet design specs, the pin bore and bigend bore must be perfectly round, each bore must be sized appropriately for wrist pin and crank rod pin fit and oil clearance and the rod must be free of potential flaws. Pathade 2 et al, he dealt with the stress analysis of connecting rod by finite element method using proe wild fire 4. The structural integrity and durability of a power component like the connecting rod in a powertrain system during high load operating conditions are important design considerations ramachandra, 2006 chacon, 2006. The objectives of this paper are to develop structural modeling, finite element analyze and the optimization of the connecting rod for robust design. Over the past 50 years,automotive forging manufacturing technology is in the continuous improvement. Geometry for a connecting rod with straight split ic engine handbook, r van basshuysen10 connecting rod is the main component of the combustion engines. There were two objectives for this initial design study.
The results can be used for optimization for weight reduction and for design modification of the connecting rod. Design and analysis of connecting rod using forged steel. This thesis describes designing and analysis of connecting rod. Connecting rod design factors such as joint surface flatness, bearing crush, geometric shape, and capscrew torque can significantly affect bore distortion, assembly stresses, and bearing and joint load distribution. It is a deepnitriding alloy containing 300 points of chrome, developed in the midnineties specifically for aerospace bearing applications. This project aims at designing a connecting rod with standard dimensions of.
Pdf connecting rod is one of the engines key components which connect the piston to the crankshaft. Simple connections can also be needed for skewed joints, beams eccentric to columns and connection to column webs. Fatigue analysis of connecting rod using finite element. Abstract the main objective of this study is to explore weight and cost reduction opportunities in the design and production of a connecting rod. To offer a technically correct and dimensionally accurate representation of an automotive type connecting rod, i think three things need to be addressed.
This paper presents the design connecting rod of internal combustion engine using the topology optimization. In designing a piston for an engine, the following. Several structural design considerations should be taken into account for economical and efficient welding. In this project the material forged steel of connecting rod replaced with aluminium alloy. Finite element analysis of connecting rod is done by considering the materials, viz. Since the compressive forces are much higher than the tensile force, therefore the crosssection of the connecting rod is designed as a strut. 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. There are two basic connectingrod designs that permeate the world of steel connecting rods. As a connecting rod is rigid, it may transmit either a push or a pull and so the rod may rotate the crank through both halves of a revolution, i. I suspect the real reason is the manufacturing method used for automotive h versus i section rods, as pat stated above. The structure of connecting rod was modeled utilized solidworks software. From what ive seen, the transitions between the beam and the big end and where the beam transitions to the small end, those two radii there definitely see the most stress in most of the cases ive looked at, stothers said.
The solution you chose may prove unworkable for any number of reasons and may require. Based on the observations of the static fea and the load analysis results, recommend the best alternative design for the connecting rod. The intermediate component between crank and piston is known as connecting rod. Design of the piston is carried out using catia software, static and thermal analysis is performed using finite element analysis fea. This project aims at designing a connecting rod with standard dimensions of a stock one in creo 3. Connecting rod definition is a rod that transmits motion between a reciprocating part of a machine such as a piston and a rotating part such as a crankshaft. So, we get a total of eight models for two different design and four different materials 6. Strongrod systems seismic and wind restraint systems guide the guide and website focus more on the unique design considerations for rod systems, how you should specify the system and highlight the design. This can be achieved by performing a detailed load analysis. Continuous rod restraint systems for multistory wood. The design of simple connections is based on bs en 199318 and its accompanying national annex.
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