Savitribai Phule Pune University

ACKNOWLEDGEMENT

I would like to express my gratitude, sincere thanks and deep sense of

appreciation to my seminar guide Mr. V. B. Rajmane, Assistant Professor, Department
of Mechanical Engineering, SVPM’s College of Engineering, Malegaon (Bk.) for
continuously assessing my work, providing great and valuable guidance throughout the
academic year by timely suggestions and discussions at every stage of this work making
my seminar work in reality.

I would like to express my heartedly sincere thanks and deep sense of gratitude to
Prof. (Dr.) S. S. Patil, Head, Department of Mechanical Engineering, SVPM’s College
of Engineering, Malegaon (Bk.) for his valuable support and kind cooperation. I also glad
to express my gratitude and thanks to Prof. (Dr.) S. M. Mukane, Principal, SVPM’s
College of Engineering, Malegaon (Bk.) for their valuable suggestions and comments.

Finally, I would like to wish special thanks to Management of SVPM’s College of

Engineering, Malegaon (Bk.), my family members and friends, without whose patience,
encouragement, and support this seminar work might never have been completed.

Mr. Bele Naresh Manikrao

PG17/ME03
ME (Mechanical – Design Engg.)
SVPMCOE, Malegaon (BK)

SVPM’s College of Engineering, Malegaon (Bk.), ME (Mechanical – Design Engineering)

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LIST OF FIGURES

Sr. No. Description Page No.

1.1 Gudgeon-Pin 1

1.2 Piston and connecting- rod joints 3

4..1 Design of Gudgeon Pin 30

4.2 Final Assembly of Gudgeon Pin CAD Model in CATIA 36

4.3 CAD model imported in ANSYS 37

4.4 Mesh model 38

4.5 Force Boundary Conditions 39

4.6 Fixed support conditions 39

4.7 Von mises stress for AL Alloy 40

4.8 Total Deformation for AL Alloy 41

4.9 A,B,C,D, show that imported CAD model in ANSYS, Mesh model , Fixed 42
support conditions, force applying for gudgeon pin model of composite
material.

4.10 Von-Mises stress for carbon material 42

4.11 Total Deformations for Carbon Fiber Material 43

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4.12 A,B,C,D, show that imported CAD model in ANSYS, Mesh model , Fixed 44
support conditions, force applying for gudgeon pin model of MS material.

4.13 Von-Mises stress for MS material 44

4.14 Total Deformations for MS Material 45

4.15 A, B, C, D, show that imported CAD model in ANSYS, Mesh 46

model , Fixed support conditions, force applying for gudgeon pin model of
SS material.

4.16 Von-Mises stress for SS material 46

4.17 Total Deformations for SS Material 47

5.1 UTM Machine 48

5.2 Geometrical View of Tensile Test Specimen 50

5.3 Experimental Setup For Tensile Test 50

5.4 Tensile Test-Load Vs Deformation Graph for Al Alloy 51

5.5 Tensile Test-Load Vs Deformation Graph for MS material 52

5.6 Tensile Test-Load Vs Deformation Graph for SS material 52

5.7 Tensile Test-Load Vs Deformation Graph for Composite material 53

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5.8 Experimental Setup for Compression Test 55

5.9 Compression Test-Load Vs Deformation Graph for AL Alloy material 56

5.10 Compression Test-Load Vs Deformation Graph for MS material 56

5.11 Compression Test-Load Vs Deformation Graph for SS material 57

5.12 Compression Test-Load Vs Deformation Graph for Composite material 58

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LIST OF TABLES

Table No. Description Of Table Page No.

3.1 Chemical composition (mass friction) (wt.%) of the EN35 23

3.2 Properties of MS steel 23

4.1 FEA Results 47

5.1 Properties of Tensile Test Specimen 50

5.2 Experimental Results by using Tensile Test 54

5.3 Properties of Test Specimen for Compression Test 55

5.4 Experimental Result by using Compression Test 58

6.1 FEA Result Using ANSYS Explicit Dynamics 60

6.2 Experimental Result by using Tensile Test 61

6.3 Experimental Result by using Compression Test 61

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CONTENT

CONTENTS PAGE NO.

SR. NO.

i
Acknowledgment

List of figures ii

List of tables v
Content vi
Abstract viii

1 Introduction 1
1.1 Introduction 1
1.2 Gudgeon pin 1
1.3 Piston and Connecting-rod Gudgeon-pin Joints 2
1.4 Problem Statement 4
1.5 Aim of the Project 4
1.6 Objectives 4
1.7 Methodology 4
1.8 Organization of Dissertation 5

2 Literature Review 6
2.1 Literature Survey 6
2.2 Summary of literature survey 17
3 Theory 18
3.1 Materials for the Piston Pin 18
3.2 Material properties for AL Alloy, MS, SS and carbon fibre 19
3.3 Manufacturing Process 25
4 Analytical And Numerical Analysis Of Gudegion Pin 30
4.1 Analytical Analysis
4.1.1 Design Consideration 30
SVPM’s College of Engineering, Malegaon (Bk.), ME (Mechanical – Design Engineering)
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4.1.2 Design Parameter 30

4.1.3 Calculation 31
4.2 Finite Element Analysis And Catia Design 34
4.2.1 Analysis of Gudgeon Pin for AL Alloy material 35

4.2.1.1 Pre-Processing 35
4.2.1.2 Solving 36
4.2.1.3 Post-Processing 36
4.2.1.4 Meshing 37
4.2.1.5 Loading and Boundary Conditions 39
4.2.16 Solution 40
4.2.1.7 Post-Processing 40
4.2.2 Analysis of Gudgeon Pin for Carbon Fiber material 41

4.2.3 Analysis of Gudgeon Pin for MS material 43

4.2.4 Analysis of Gudgeon Pin for SS material 45
4.3 Summary (From Finite Element Analysis) 47
5 Experimental Validation 48
5.1 Tensile Testing AL Alloy, MS, SS, Carbon fibre material 49
5.2 Tensile Test Result 53
5.3 Compression Testing AL Alloy, MS, SS, Carbon fibre material 54
5.4 Compression Test Result 58
6 Results And Discussion 60

6.1 FEA Result 60

6.2 Experimental Result 60
6.2.1 Tensile Test Result 60
6.2.2 Compression Test Result 61
7 Conclusion And Future Scope 63
7.1 Conclusion 63
7.2 Future Scope 64

References 65
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ABSTRACT

Premature wear of the Gudgeon pin is the major concern for the company. Gudgeon pin connects
the piston and the small end of the connecting rod of IC engines. This Report deals with Static
Structural analysis Gudgeon pin used in diesel engine. In stress analysis von-Mises stresses
coming on Pin are determined using finite element analysis tool ANSYS 16.effect of different
factors on Von-Mises stresses such as change in internal diameter of pin. Effect of change in
surface roughness of connecting rod small end bush and change in internal diameter of pin on
Stress is analyzed. Von-Mises stresses, Weight Optimization and Total deformation of materials
like AL Alloy, MS, SS and Carbon fibre of gudgeon pin is analyzed.

Key words:- Gudgeon Pin, Von-Mises Stresses, ANSYS.

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