Commenced in January 2007
Frequency: Monthly
Edition: International
Paper Count: 30127
Finite Element Analysis of Connecting Rod

Authors: Mohammed Mohsin Ali H., Mohamed Haneef

Abstract:

The connecting rod transmits the piston load to the crank causing the latter to turn, thus converting the reciprocating motion of the piston into a rotary motion of the crankshaft. Connecting rods are subjected to forces generated by mass and fuel combustion. This study investigates and compares the fatigue behavior of forged steel, powder forged and ASTM a 514 steel cold quenched connecting rods. The objective is to suggest for a new material with reduced weight and cost with the increased fatigue life. This has entailed performing a detailed load analysis. Therefore, this study has dealt with two subjects: first, dynamic load and stress analysis of the connecting rod, and second, optimization for material, weight and cost. In the first part of the study, the loads acting on the connecting rod as a function of time were obtained. Based on the observations of the dynamic FEA, static FEA, and the load analysis results, the load for the optimization study was selected. It is the conclusion of this study that the connecting rod can be designed and optimized under a load range comprising tensile load and compressive load. Tensile load corresponds to 360o crank angle at the maximum engine speed. The compressive load is corresponding to the peak gas pressure. Furthermore, the existing connecting rod can be replaced with a new connecting rod made of ASTM a 514 steel cold quenched that is 12% lighter and 28% cheaper.

Keywords: Connecting rod, ASTM a514 cold quenched steel, static analysis, fatigue analysis, stress life approach.

Digital Object Identifier (DOI): doi.org/10.5281/zenodo.1125605

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 1310

References:


[1] Webster, W. D., Coffell R., and Alfaro D., “A Three Dimensional Finite Element Analysis of a High Speed Diesel Engine Connecting Rod,” SAE Technical Paper Series, Paper No. 831322,1983,
[2] Yoo, Y. M., Haug, E. J., and Choi, K. K., 1984, “Shape optimal design of an engine connecting rod,” Journal of Mechanisms, Transmissions, and Automation in Design, Transactions of ASME, Vol. 106, pp. 415-419,1984.
[3] Folgar, F., Wldrig, J. E., and Hunt, J. W. “Design, Fabrication and Performance of Fiber FP/Metal Matrix Composite Connecting Rods,”
[4] Serag, S., Sevien, L., Sheha, G., and El-Beshtawi, I., “Optimal design of the connecting-rod”, Modelling, Simulation and Control, B, AMSE Press, Vol. 24, No. 3, pp. 49-63,1989.
[5] Imahashi, K., Tsumuki, C., and Nagare, I., 1984, “Development of powder-forged connecting rods,” SAE Technical Paper 841221, pp. 1-7.
[6] El-Sayed, M. E. M., and Lund, E. H., “Structural optimization with fatigue life constraints,” Engineering Fracture Mechanics, Vol. 37, No. 6, pp. 1149-1156,1990.
[7] Sarihan, V. and Song, J., “Optimization of the Wrist Pin End of an Automobile Engine Connecting Rod With an Interference Fit,” Journal of Mechanical Design, Transactions of the ASME, Vol. 112, pp. 406-412,1990.
[8] Athavale, S. and Sajanpawar, P. R. “Studies on Some Modelling Aspects in the Finite Element Analysis of Small Gasoline Engine.SAE Technical Paper Series, Paper No. 911271,1991.
[9] Balasubramaniam, B., Svoboda, M., and Bauer, W. “Structural optimization of I.C. engines subjected to mechanical and thermal loads,” Computer Methods in Applied Mechanics and Engineering, Vol. 89, pp. 337-360,1991.
[10] Hippoliti, R., “FEM method for design and optimization of connecting rods for small two-stroke engines,” Small Engine Technology
[11] Sonsino, C. M., and Esper, F. J, “Fatigue Design for PM Components,” EuropeanPowder Metallurgy Association (EPMA),1994.