Selection of material, shape, and manufacturing process. Aluminium alloys also can be used for these as an alternative. Fatigue analysis of connecting rod using finite element. The average life of a malleable iron connecting rod was 764,962 cycles at a 50% survival rate or 347,734 cycles at a 90% survival rate. Comparission of two different materials for connecting rod using ansys. Solid45 element type is use for connecting rod material. In this study, we investigated the fatigue characteristics of sma40 materials as a potential application in connecting rod material for an automobile.
The mass of these conrods is 2025% less than that of steel. Weight can be reduced and strength can be achieved by changing the material of. Connecting rods t651 billet aluminum connecting rod. This 8620 material is used in most pushrod tip applications and has a. The capacity of this machine is 10,000 pounds tension and compression. A connecting rod is one of the most mechanically stressed components in internal combustion engines. Steel materials are used to design the connecting rod. Pdf connecting rod is an essential component of an internal combustion. 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.
Compared with traditional methods, this technique has remarkable advantages. Index terms connecting rod, weight reduction, fatigue strength, better machinability i. Fracture splitting method is an innovative processing technique in the field of automobile engine connecting rod conrod manufacturing. Inspecting, maintaining and repairing connecting rods. The test is performed using a loading apparatus such as the tinius olsen machine. We were asked to pull tensile specimens to check mechanical properties and to provide a chemical analysis of the metal to determine the alloy. Comparission of two different materials for connecting rod. It is subjected to high tensile, compression and bending loads. Show full abstract connecting rod is replaced by aluminum based composite material reinforced with silicon carbide and fly ash. Check the connecting rod bore for outofroundness with an inside micrometer. The results obtain by fea for both aluminum 7068 alloy and.
Fem analysis of connecting rod of different materials. Aluminum precision products recently received a connecting rod sample machined from billet. Forces due to the cylinder pressure as well as the mass of the connecting rod and the piston assembly are illustrated in figure 2. 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. The analysis of the scania line together with a benchmark among different leading companies on the connecting rod manufacturing has been undertaken. The aim of this study is to redesign a connecting rod for its light weight. The material properties are one of the major inputs to perform the fea and optimization.
Introduction he connecting rod is the connection between the piston and the crankshaft. Coupling to the crankshaft is achieved through solid journal. 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. Connecting rod made using particulate reinforced aluminum. Do not repair defective connecting rod bolts, except for removing small burrs by using a fine rectangular file. The average life of a malleable iron connecting rod was 764,962 cycles at a 50% survival rate or 347,734 cycles at a 90%. If you doubt the condition of a bolt or a nut, replace it. Design and analysis of connecting rod using forged steel. The material of connecting rod will be optimized depending upon the analysis result output. Factor of safety of connecting rod i material used for connecting rod is structural steel. Caterpillar, fiat, ford, iveco, john deere, opel, perkins, psa, rover. In a few twostroke engines, the connecting rod is only required to push.
Pdf design and analysis of connecting rod with modified. In this project the material carbon steel of connecting rod replaced with forged steel. Together with the crank, the connecting rod converts the reciprocating motion of the piston into the rotation of the crankshaft. Connecting rod conrod is one of the main components in every internal combustion engines. Modern manufacturing process of forged connecting rod. This thesis has been focused on the study of the connecting rod manufacturing process. The ductile iron connecting rod experienced an average life of 1,605,902 cycles at a 50% survival rate or 635,811 cycles at a 90% survival rate. Powdered metal pressed together and then put into an oven where it is sintered that means granuals are melted together and forms the rod. To offer a technically correct and dimensionally accurate representation of an automotive type connecting rod, i think three things need to be addressed. They developed the designed model of connecting rod using modelling software. Its light and has the ability to absorb high impact, but it comes a. In this study three materials al360, beryllium alloy 25 and magnesium alloy have considered for analysis. A connecting rod is subjected to many millions of repetitive cyclic loadings. The connecting rod is required to transmit the compressive and tensile forces from the piston, and rotate at both ends.
Sarkate et al, 20 carried out an analysis to find out an optimum material for connecting rod. Strength analysis of connecting rods with pistons using finite. Metallographic of casting defect of the connecting rod discussion based on the results obtained from analyzing the finite element, it can be noticed that the connecting rod subjected into diverse loads led to some deformation during the. A connecting rod, also called a con rod, is the part of a piston engine which connects the piston to the crankshaft. Material choices 4 last month, we looked further into the use of titanium for con rods and this month we look briefly into the use of steel, which remains in many cases the material of choice for con rods. The function of the connecting rod is to transmit the thrust of the piston to the crankshaft and translate the transverse motion to rotational motion. Current automotive ic engines connecting rods are made of steel. A connecting rod is subjected to a cyclic load during its service. 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. The density decreases with increasing fly ash content. Analysis of connecting rod using composite material. In this project the material forged steel of connecting rod replaced with aluminium alloy.
Journal of asian scientific research failure analysis of a. 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 lubrication. A connecting rod basically connects the piston to the crankshaft whilst transmitting power of the combustion from the combustion chamber to rotate the crank. This material, when heat treated correctly, exhibits excellent wear properties and is very impact resistant. Connecting rods forged 4340 steel connecting rod material. Connecting rods convert rotating motion into linear motion. Manufacturing procedures, equipment and tools investment can be decreased and energy consumption reduced remarkably in this method. Introduction connecting rods are widely used in variety of automobile engines. Crackable connecting rod material selection by using. Comparison of mechanical properties of possible connecting rod. The connecting rod with piston and crank converts linear motion into rotary motion and also rotary motion into linear motion with a simple mechanism. Design of connecting rod for weight reduction using c70s6.
Stress analysis of connecting rod for weight reduction a. The mechanical properties of titanium alloy connecting rods are then compared with pf11c5060 and it is concluded that yield strength of powder metallurgy. Table 2 material properties of aisi 4340 density 7. Material properties play an important role in the result of the fe analysis. Cad model of connecting rod will be modelled in proe and then be.
This forging part is a single part weighting 540 grams,the distance from the centerline of the connecting rod to the centerline is 129. Mechanical properties analysis of an almg alloy connecting rod. In this in order to have a connecting rod equally strong in buckling about both the axis, the buckling loads must be equal. Keywords crackable connecting rod, material selection, topsis method, ranking 1. A blocking impression become a necessity only when the component is to be accurately made or the component has deep pockets or thin ribs, which are. Therefore, durability of this component is of critical importance. Connecting rod, modeling, stress analysis of connecting rod, fatigue analysis, optimization.
Analysis of connecting rod was carried out using anysy 14. Tension and compression analysis in reciprocating engine. Cad model of connecting rod will be modelled in proe. Pdf comparision of two different materials for connecting rod. Youngs modulus e 210 gpa, yield strength s y 210 mpa, poissons ratio. These fatigue tests were performed to directly mimic the stresses a connecting rod undergoes in an engine. Al360 of connecting rod was replaced with aluminium fly ash silicon composite. A study on fatigue characteristic of connecting rod. The finite element analysis helped to define the tapered shape of the small end of the connecting rod, and it helped in the selection of 4340 steel as the connecting rod material.
Comparision of materials for twowheeler connecting rod. Here stainless steel, aluminum alloy and high strength carbon fiber 280gsm bidirectional are used to analyze the connecting rod. And it also describes the modeling and analysis of connecting rod. Connecting rod virtual labdayalbagh educational institute. First of all, to find the stress on the connecting rod, we use the formula. The objective of the present work is to design and analyses of connecting rod made of aluminium alloy. There are far more manufacturers of con rods who offer steel rods than any other material. Enter ansys in the working directory specif ied by your instruct or using.
Parting edge where cap and the rod meet is fractured. Design and buckling analysis of two wheeler connecting rod. Material design for advanced connecting rod for mass. However, when tested under fretting condition, decrease in fatigue lifetime was 20% and fatigue limit was reduced to 350 mpa. Average fatigue life of 168,700 cycles and fatigue limit of 437 mpa was determined from sma40 specimens. The connecting rod provides the mechanical linkage between piston and crankshaft and must exhibit properties of high strength, low inertial mass, and uniformity of mass with the other connecting rods attached to the crankshaft. Furthermore, the improvement in the mechanical properties of the connecting rod forged from predeformed material is evaluated in comparison to. Engine connecting rod an overview sciencedirect topics.
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