EXAMPLE:1 determine the dimension of l section connecting rod for a petrol engine

from the following data. Diameter of piston =110 mm mass of the reciprocating
parts=2kg: length of the connecting rod from the center to center=325 mm; stroke
length=150mm; R.P.M=1500 with possible overspeed of 2500;compression ratio=4:1;
max.explosion presser=2.5N/mm2.
Diameter of pitch (a) =110mm
Mp=2Kg
l=32mm
L=150mm
Nmax=2500r.p.m
Pmax=2.5N/mm2
NO=4
Crank radius (l/2) = (150/2)
=75mm
Section
Plane thickness=t
Wed thickness=t
Width flange =4l
Design of section (h) =54
Section g material:
The plain steel is selected the material for collection rod width s ut=330N/mm2 and
=8000 kg/m

Area as= (2*45*t)+(3t*t)=11t2mm2

Moment inertia:
1
BH
IH= 2

1
( Bt ) ( h2t ) ]
= 12 [

1
1
4 t(5 t) 3
= 12
- 4 (4t*10a)3
=34.216 t4 mm4
1
Similiaty fx = h [1.28t2+3l4]
=10.216t4 mm4
Radius of gyration:
Kx2=

Iyy
A
34.161
11 A

=3.17t4 mm
Kyy=1.78t mm
Kx2=

Zxx
A =0.9972

Kxx=0.9962t mm
Fmax=23758 kW

1
Breaking connecting radius the final radiation = 75

5ae
1
300
Pr=Fmax=
700
[1+
]
1.78167
33011 t 2
1
300
=
700
[1+
]2
1.78167
t4+372=0.038t2
t4=98.96-29.162
t4-26.17t2-96.90=0

------- -(1)

t2=26.17t-98.96=0
t2=26.17

(98.96)2(40)(98.46)1

26.17 100.60
t=
2
2

t2=63.57
t=7.97

Dimension of cross section

Harge thickness (t) = 7.9 mm
Well thickness (t) = 7.9 mm
Width flange (B) = 412 = 31.6 mm
Depth of section = 39.5 mm

This is taken module. The connecting rod

Checking for breaking plane perpendicular plane rotational.

Le=0.5l=0.5*3.25=162.4mm
Kxx=0.9962t
=0.99632*7.9=7.84mm
Ac=11t2
=68.69 mm2
Breaking load (Fcr)
SycAc
2
= [1+ ]
Kyx

( )

1 162.5
(
)
7500 7.2

330686.5

1+
=

=214359.62 N

Nfa=4.1>4
The connecting rod is safe going bucking plane perpendicular plane of friction check for
fenonace bucking stress.
Wmax

2 250
60

=8000 kg/m3

rad/sec2

Zyy=

7.299
h/2

Zyy=68.87*10-9 m

bw

Aw 2 maxr d 2
a 3 Zyy

8006.86510 11.7507510 0.35

=
bw
9 368.877010

bw

=15.20 N/mm2

Sy
by= Nf

330
4

=82.5 N/mm2
As

b<

all

dee to connecting rod is safe against transfer banding stress.

Example : 2 Aconnecting rod required to be designed for high speed, four stroke I.C
engine, the following data are avaible. Diameter of piston=88mm; mass of reciprocating
parts=1.6Kg; length of the connecting rod from the center to center=300mm;
stroke=125mm; R.P.M=220(when developing 50Kw); possible overspeed=3000r.p.m;
compression ratio=6.8:1(approximately); maximum explosion presser(assumed shortly
after dead center. Say about 3 )=3.5N/mm2 Draw the fully dimensioned drawing of
the connecting rod showing the provision for the lubrication.
Given data :Ans.

Crank radius (r)= l/2 = 125/2 = 62.5mm

 Section of cross section flange thickness = 5.2mm

wall thickness (t) = 5.2mm

width of flange (B) = 4t = 4*5.2 = 20.8mm

depth of section (h)= 5t = 5*5.2 = 26mm

selection of material :The plain carbon steel is selected for the material for connecting rod with ,
SYC = 330N/mm2
= 2000 kg/m3

Area of cross section Ac = (2*4t)*t + (3t*t) = 11t2mm2

m.o.i of cross section :Bt

Ixx= 1/12 bh3 1/12 ( 5 t2t ( ) ]

= 34.9167 t4 mm4
Iyy = 2 1/12 t B3 + 1/12 (H-2t)t3= 10.917t4 mm4

radius of gyration, kyy=

Kxx =

Iyy
A =

34.9167 t
11 t

Ixx
10.9164 t
=
A
11 t

= 1.7816t mm

= 0.9962t mm

equivalent length for both ends hinged le= l = 300mm

Max. gas pressure (Fmax)=

D Pmax= ( 88 )2 3.5=21287.43 N
4
4

Bucking of connecting rod in a plane of rotation ,

tan =1/7500

NF Fmax =

4 2127.43=

Syc Ac
1+
kyy

[ ( )]

330 11 t
300
1+ 1/7500(
)
1.7816 t

t4 23.45t2 88.74 =0

take T= t2 in equation (1),

.(1)
T2-23.45T-88.74 =0

23.45 ( 23.45 ) +(4 88.74)

2
2

T=

26.766.63 mm

T = 26.76mm
t2 = 26.76 mm

t=5.17 mm .

check for bucking in a plane perpendicular to plane of rotation ,

Le= 0.5l = 0.5*300 = 150mm

k = 0.99621t = 0.9962*5.2 = 5.18mm
xx
A = 11t2 = 11*5.22 = 297.44 mm2
c

bucking load (fcs) =

SycAc
1+
kxx

[ ( )]

330 297.44
150
1+ 1/7500

5.18

( )]

f = 88284.94 N
cs

Fcr
88284.94
=
=4.14> 4
Nt = Fmax 21281.43
hence, the connecting rod is safe against bucking in a plane perpendicular to the

plane of rotation .

check for transverse bending stress :-

1) Wmax =

200 3000
=314.159rad / s
60

Iyy 2 34.9167 t
=
=1964.29mm
Zyy = h/ 2
5t
Zgg= 1964.29 10-9 mm3

A max . r . p 2000 257 314.55 2.5 10

=
=43.14 N /mm
9 3. Zyy
9 3 1964 10
all=

Sy 350
=
=82.4 N /mm
Nf
4

sut=all

so that connecting rod is safe against transverse bending stress.

EXAMPLE:3
design of plain carbon steel center crank shaft for a single acting four
stroke , single cylinder engine for the following data
piston diameter=250 mm; stroke=400mm; maximum combustion presser=2.5
N/mm2;weight of flywheel=16KN; total belt pull=3N; length connecting

rod=950mm.When the crank has turned through

30 from the dead center ,the

presser on the piston is 1 N/mm2and the torque on the crank is maximum .any other
data is required for the design may be assumed.
Given data:
D=250 mm
L=400 mm
Pmax=2.5 N/mm2
Mf=16 KN
Fb=3 N
l=950 mm
p=1 N/mm2
=30

Allowable stress:Allowable tensile stress

Shear stress

=100 N/mm2

all

=50 N/mm2

all

Design of crank:
D P max
Max gas force (fgmax) = 4

250 22.5=122.7210
= 4
Crank pin dia. (dcp) &length (lbc):Presser lubricated pin bearing Pb=10 n/mm2
Length of crank pin is taken ,
lbc =1.25 dcp

fgmax= lbc* dcp* pb

dcp=ko mm
lbc=1.25 dcp
lbc=125 mm
Check for direct shear stress;

=50 n/mm2

all

(fgmax)=

2[

=100 N/mm2

all

dc ]
4

122.72*10=6.28*100*
=7.81

N
< 50 N /mm
mm2

Hence crank pin is safe against shear.

Check for bending stress:

bc

3 f gmax l bc
d cp

=16.64 N/mm<100 N/mm

Hence crank pin is safe against bending failure.
Design of crank web:For crank web (

) =100 N/mm

all

Crushing stress m web at T.D.C position:

f gmax
= d cp T w

122.7210
100= 100T w

Tw=12.7mm

.(1)

By empirical relation
Tw=25dcp =.25*100=25mm.(2)
Tw=25mm
Taking larger of two value given by equation (1) & (2)
Maximum force applied by connecting rod on crank webs at maximum twisting moment :Crank radius (r) =l/2=

400
2 =200 mm

r sin =l sin
200 sin 30=90sin 30
=6.04

Force along the axis of cyi.is,

Fr=Fg+Fi

cos 2
D P+m
cos +

2
= 4
w
(
r r
ho

250 21
Fr= 4
+0

F=

Fr
cos(6.04) =49361.4

Component of E:Tangential component,

Ftw=F (+)
sin

6.04
=49361.4 (+30)
sin
=29041.78 N
Frw=F

(+ )
cos

=49361.4

(30+ 6.04)
cos

=39913.94 N
Stress in crank web:Bending stress (

d
3 F tw (r )
2
bw) =
T wbw
d
329041(200 )
2
=
25b w
d
3485.01(200 )
2
=
bw

Compressive stress: - (

cw

F rw
) = 2T wbw

39913.94
= 50b w
Resultant compressive stress
=

bw

cw

3485.01 200
=

bw

d
2

) + 39913.94 ( 3)
50b w

Dimension od web section from equation (3)

3485.01 200

100=

100

bw

d
2

) + 39913.94
50b w

b w 2=3485.01 200

d
+748.28 b w
2

B w2748.28 b w3485.01 200

d
=0 .. ( 4 )
2

Eq. 4 can be solved to calculated value of ' B w '

finding the shaft dia. d

When gas force is max. At T.D.C , Lets assume Ls=2D=2*250=500 mm

f gmax
L s+ (50+ 100 )L s
2

M=

122.7210 500
+150500
=
2
M=30.755*10 N.mm
Bending stress induced in shaft is given

bs=

100=

32 M
d

3230.75510
d

d=150 mm ..(5)
When twisting moment acting on shaft is,

F
L s+ ( 50+100 ) L s
M= 2
49361.4
*500+150*500
2

M=12.415*10 N.mm
Max. Twisting moment acting on shaft,
F tw
r
T= 2

29041.78
*200
2

=2.904*10
Equivalent twisting moment acting on shaft,

M +T

Te=

( 12.4110 ) +( 2.90410 )
6 2

6 2

=12.75106
Allowable shear stress induced in shaft is

=50 N/mm

all

The torsional shear stress induced in shaft is

=

16 T e
d

1612.7510
100 =
d
d=110 mm.(6)

Taking larger of the two value given by equation(5)&(6)

d=150 mm

(4)
Solution:
Given Data:
P

g=0.4

N
mm2

s=0.03

N
mm2

d v=80 mm
hm =24.73 mm
mv=519.81kg
N s=350 rpm
p= l w=250 mm
l
S ut=750 MPa
P

b=8

N
m2

N
2
mm

= 72

Gas for a valve when it is open (

F

g=

4d

2P
g

2
4 (180 ) 0.4

Fg

= 2010.61 N
Fmax

Maximum spring force (

Take stiffness (k) = 10

Fmax =

Fg

N
mm

d 2 *Ps*khm
4 *

= 2150.7964+247.50
Fmax = 398.29 N
Inertia force (fa) :Total angle of friction of crankshaft when the exhaust value is in operation
r=33 +180 +214
For four stroke engine total angle of rotation of cam shaft when the exhaust valve is the
operation
r =

r
2

214
2

= 107

r
2

Cam rotation for valve opening =

Cam rotation for valve closing=

r
2

= 107 /2= 53.50

= 53.50

For four stroke engine speed of cam shaft n = Ns = 350/2 = 175rpm.

No. of rotation of cam shaft for second = n/60 = 175/60 = 2.9167rps
Time required by cam shaft to complete one rotation tcr = 60/n= 1/2.9167 = 0.3428 s
Time required by cam shaft to complete rotation of one degree
Valve lift during const. acceleration S=hm/2 = 24.75/2 = 12.375 mm.
Const. acceleration of value can be determine by,
S = ut+avt2/2
12.375*10-3 = 0*0.0272547 + avt2/2
av = 38.36m/s2
There for the inertia force due to exhaust valve Fa = Mv*aw
=

5
9.81

*38.36

= 219.85 N

Total force acting on rocker arm :Fe = fg + Fmax + Fa

= 2010.01 + 398.29 +19.55
= 2428.44 N
Determination of load and effort arm :Lw = 5 khm = 5*24.75 = 123.75
=lw=125 m

Determination of fulcrum reaction = Rf

P*lp = Fe*lw
P =Fe*lw/lp= 2428.44 = 125/125
P = 2488.44 N
2
2
Rf = ( p +fe 2 pfecos ) ^1/2

Rf = 4487.172 N
Dimension of fulcrum pin :Let d = dia. Of fulcrum pin, mm
Lb = length of fulcrum pin , 1.25d
2
Bearing pressure pb = 8 N/ mm

Considering the bearing pressure of fulcrum pin

Rf = lb*d*pb
= 1.25d*d*8
= 21.1 = 22 mm
D = 22 mm
Lb = 1.25d = 27.5 mm
Direct shear stress =
Rf = 2*

2
d
4

4Rf
2
2d

2 d 2
=44487.7/ )

5.90 N
mm2

72

n
m m2

Hence , fulcrum pin is safe against shear failure

Diameter of boss of lever (ds) :Let, Do= outside diameter of boss , mm
Di = inside diameter of boss , mm
Consider a boss bush of 3 mm thickness is pressed into the boss
Di = dt(3*2)
= 22 + 6 = 28 mm
The bending moment acting on the boss as is
M= ie*lw
= 30.35*10^4 N.m
The max bending stress induced in the boss is ,
b=

m
i y * Y
md /2

1
lb(d o3d i 3)
12

lb ( d o 3D i3 )

=
6 ndo

70 =

630.3510 d 0
3
3
27.5( d o d i )

d o3

= 945.97do + 2195^2

Do = 38.86 mm
Do = 39 mm
Dimension of load forked end :Let, di = dia of roller pin, m
L = length of roller pin , = 1.25d
P = l1*d1*pb
2428.44=1.25 d^2 * 8
Di = 16 mm
L1 = 1.25 di
L1 = 20 mm
Direct shear stress :P = 2**

=6.05

16^2 *
4
N
mm

72 n/mm^2

Hence roller pin is safe against shear failure diameter

Dimension of eye :Thickness of eye (te):-

2 = 20/2 = 10 mm

Outer diameter of eye(de):- 2d1*22*16 = 32 mm

Dimension of lever as :The max. bending stress induced in lever as is

70 =

25.62102

2.5 tt6 t

T = 6.24 mm = 7 mm
B = 2.5t = 2.5*6 = 12.5 mm
H = 6t = 6*6 = 36 mm
T = 6 mm
Diameter of roller = de + 5 mm
= 32+5
37 mm

b =

Mly
I Y

Ml
ZL

Ml
bth