International Journal of Engineering and Management Research, Vol.-2, Issue-6, December 2012 ISSN No.

: 2250-0758 Pages: 21-25 www.ijemr.net

Design Evaluation and Optimization of Connecting Rod Parameters Using FEM

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Suraj Pal1, Sunil kumar2 P.G. student, Y.C.O. Engg. Talwandi sabo, Department of Mechanical Engg. Senior Assistant Professor Y.C.O. Engg. Talwandi sabo, Department of Mechanical Engg.
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ABSTRACT
The main objective in the Design evaluation and optimization of connecting rod parameters by using finite element method is to achieve suitable design for connecting rod. That can be achieved by changing such design parameters in the existing design. Finite element analysis of single cylinder four stroke petrol engines is taken for the study; Structural systems of Connecting rod can be easily analyzed using Finite Element techniques. So firstly a proper Finite Element Model is developed using Cad software Pro/E Wildfire 4.0.Then static analysis is done to determine the von Misses stress, shear stress, elastic strain, total deformation in the present design connecting rod for the given loading conditions using Finite Element Analysis Software ANSYS v 12.In the first part of the study, the static loads acting on the connecting rod, After that the work is carried out for safe design. Based on the observations of the static FEA and the load analysis results, the load for the optimization study was selected. The results were also used to determine of various stress and the fatigue model to be used for analyzing the fatigue strength. Outputs of the fatigue analysis of include fatigue life, damage, factor of safety, stress biaxiality indication. Then results of present model in ANSYS are compared with the results of existing design in the reference paper.

KeywordsANSYS, Connecting Rod, Finite Element Analysis, Modeling.

I. INTRODUCTION
The connecting rod connects the piston to the crankshaft and they form a simple mechanism that converts linear motion into rotary motion. The maximum stress occurs in the connecting rod near the piston end due to thrust of the piston. The tensile and compressive stresses are produced due to gas pressure, and bending stresses are produced due to centrifugal effect & eccentricity. So the connecting rods are designed generally of I-section to provide maximum rigidity with minimum weight [1]. The maximum stress produced near the piston end can be

decreased by increasing the material near the piston end. P G Charkha and Jaju have presented the Analysis & Optimization of Connecting Rod. Finite element analysis of single cylinder four stroke petrol engines is taken as a case study; Structural systems of Connecting rod can be easily analyzed using Finite Element techniques. So firstly a proper Finite Element Model is developed using Cad software Pro/E Wildfire 3.0.Then the Finite element analysis is done to determine the von Misses stresses in the existing connecting rod for the given loading conditions using Finite Element Analysis Software ANSYS WORKBENCH 9.0.In the first part of the study, the static loads acting on the connecting rod, After that the work is carried out for safe design. Based on the observations of the static FEA and the load analysis results, the load for the optimization study was selected. The results were also used to determine of various stress and the fatigue model to be used for analyzing the fatigue strength. Outputs include fatigue life, damage, factor of safety, stress biaxiality, fatigue. The component was optimized for weight subject to fatigue life [1]. M Rasekh et al. have obtained the Maximum Stresses in Different Parts of Tractor (Mf-285) Connecting Rods Using Finite Element Method. In this study, detailed load analysis was performed for a MF-285 Connecting rod, followed by finite element method. In this regard, in order to calculate Stress in connecting rod, the total forces exerted connecting rod were Calculated and then it was modeled, meshed and loaded in ANSYSv9, software. The maximum stresses in Different parts of M F-285 connecting rod were determined. The maximum pressure Stress was between pin end and rod linkages and between bearing cup and connecting rod Linkage. The maximum tensile stress was obtained in lower half of pin end and between Pin end and rod linkages [2]. Vasile George & Imre Kiss presented a method used to verify the connecting rods stress and deformation using the finite element method with Ansys v.11. The study only analyses a component of the connecting rod,

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and that is the connecting rod foot, and only for one challenge (request)-the extension-due to the maximum inertia [3] The Connecting Rod considered here for study belongs to research paper of P.G. Charkha and Jaju ICETET-09.

II. OBJETIVES
The main aim of the project is to determine the Von Misses stresses, Shear stresses, and Equivalent Alternating stress, Total Deformation, Fatigue Analysis and Optimization in the existing Connecting rod. If the existing design shows the failure, then suggest the minimum design changes in the existing Connecting rod. A lot has been done and still a lot has to be done in this field. In this Project, only the static FEA of the connecting rod has been performed by the use of the software. This work can be extended to study the effect of loads on the connecting rod under dynamic conditions. Experimental stress analysis (ESA) can also be used to calculate the stresses which will provide more reasons to compare the different values obtained. Now a day a lot is being said about vibration study of mechanical component important role in its failure. So the study can be extended to the vibration analysis of the connecting rod. The study identified fatigue strength as the most significant design factor in the optimization process. Then the combination of finite element technique with the aspects of weight reduction is to be made to obtain the required design of connecting rod.

III. STEPS CONNECTING ROD

IN

MODELING

OF

Fig.2: CAD Model of connecting rod in PRO Engineer. The following is the list of steps that are use to create the required model : a. Choose the reference plane. b. Set the dimension in mm. c. Go to sketcher and sketch circular entities. d. Then extrude these entities for making the both ends of connecting rod. e. Again reference plane is selected for shank of connecting rod. f. Entities is made that should be tangential to both ends. g. Extrude the entities symmetrically. h. Plane is selected for making entities of groove. i. Groove is made on the shank and mirrored for creating groove on both side. j. Datum plane is selected for creating small holes on piston end k. Then holes are made on the periphery of piston end.

Optimized Connecting Rod has been modeled with the help of PRO/E Wildfire 4.0 software. The Orthographic and Solid Model of optimized connecting rod is shown in figures below.

IV. RESULTS OF FINITE ELEMENT ANALYSIS AND COMPARISION WITH EXISTING RESULTS
In this study four cases of finite element models are analyzed. FEA for both tensile and compressive loads are conducted. Two cases are analyzed for each case, one with load applied at the crank end and restrained at the piston pin end, and the other with load applied at the piston pin end and restrained at the crank end. In the analysis carried out, the axial load was 4319 N (Gas Force) in both tension and compression. In addition to this the analysis carried out taking Buckling Load of 21598N. Finally the comparisons are done for optimization purpose. The pressure constants for 4319 N are as follows used for applying Boundary Condition: Compressive Loading: Crank End: Po = 4319/ (17.5 x 10.708 x 3) = 13.31 MPa Piston pin End: Po = 4319/ (7.8 x 14 x 3) = 22.84 MPa Tensile Loading: Crank End: Po = 4319/ [17.5 x 10.708 x (/2)] = 14.68 MPa

Fig.1: Drawing of Connecting rod (Optimized).

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Piston pin End: Po = 4319/ [7.8 x 14 x (/2)] = 25.18 MPa Following are Figures shows the optimized results along with the results of figures in reference paper and comparison for static analysis of connecting rod at load 4319N.

Above figures shows the comparison equivalent von misses stress at 4319N.

Above figures shows the comparison equivalent von misses stress at 4319N.

Above figures shows the comparison of shear stress at 4319N.

Above figures shows the comparison of shear stress at 4319N

Above figures shows the comparison of equivalent elastic strain at 4319N Table: 1. shows the result comparison for static analysis

Above figures shows equivalent elastic strain at 4319N

the

comparison

of

Following are Figures shows the optimized results along with the results of figures in reference paper and comparison for static analysis of connecting rod at load 21598N.

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Above figure shows the comparison of safety factor at 21598N.

Following are Figures shows the optimized results along with the results of figures in reference paper and comparison for fatigue analysis of connecting rod at load 4319N.

Above figure shows the comparison of safety factor at 21598N. Following are Figures shows the optimized results a for fatigue analysis of connecting rod at load 4319N along with at load 21598N

Above figure shows the comparison of safety factor at 4319N. Above figures shows the life at 4319N and 21598N

Above figure shows the comparison of biaxiality indication at 4319N. Following are Figures shows the optimized results along with the results of figures in reference paper and comparison for fatigue analysis of connecting rod at load 21598N.

Above figures shows the damage at 4319N and 21598N.

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Table: 2. shows the result comparison for fatigue analysis

[2] M. Rasekh, M. R. Asadi, A. Jafari, K. Kheiralipour (2009) Obtaining Maximum Stresses in Different Parts of Tractor (Mf-285) Connecting Rods Using Finite Element Method Australian Journal of Basic and Applied Sciences, Vol.3, pp 1438-1449. [3] V. George, I. Kiss, (2010) Computer aided design of the connecting rod. [4] ANSYS WORKBENCH 12.0 Reference Manual. [5] Pro/E Wildfire 4.0 Reference Manual [6] Sharma. & Aggarwal Book of machine design.

Table 3: -Shows the comparison of Weight

Above table shows the weight optimization of connecting rod, in existing model weight of connecting rod was 131.5g. After optimization weight of connecting rod is126.73, the percentage weight reduction is 3.62.

V. CONCLUSION
Finite Element analysis of the connecting rod of a Hero Honda Splendor has been done using FEA tool ANSYS Workbench. From the results obtained from FE analysis, many discussions have been made. The results obtained are well in agreement with the similar available existing results. The model presented here, is well safe and under permissible limit of stresses. 1. Conclusion is based on the current work that the design parameter of connecting rod with modification gives sufficient improvement in the existing results. 2. The weight of the connecting rod is also reduced by 0.477g. Thereby, reduces the inertia force. 3. Fatigue strength is the most important driving factor for the design of connecting rod and it is found that the fatigue results are in good agreement with the existing result. 4. The stress is found maximum at the piston end so the material is increased in the stressed portion to reduce stress.

REFERENCES
[1] P. G. Charkha, S. B. Jaju (2009) Analysis & Optimization of Connecting Rod Second International Conference on Emerging Trends in Engineering and Technology, ICETET-09.

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