Selection of material, shape, and manufacturing process. In this work existing connecting rod material are replaced by beryllium alloy and magnesium alloy. Connecting rod materials must have good fatigue and shock resistances. The big end of the connecting rod connects to the crankpin to provide a pivot point on the crankshaft connecting rods produces as one piece or twopiece components.
The materials are changed so that the weight of the connecting rod is less when aluminum alloys and carbon fiber are used by. This type of connecting rod in which consists big end is made up of 2 pieces. The modern connecting rod is made of materials that include alloy elements of titan ium, aluminium, magnesium, and polymeric connecting rods. The connecting rod is designed using catia v5 6r 2014 according to the specifications given below. A connecting rod can rotate at both ends, so that the angle between the connecting rod and the piston can change as the rod moves up and down and rotates around the crankshaft. Overall product from automotive and pull from the proper lubrication property study of the engine which the best. 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.
Pdf selection of connecting rod for good performance of engine is very difficult. Together with the crank, the connecting rod converts the reciprocating motion of the piston into the rotation of the crankshaft. Connecting rods manufacturing improvements and process. In this project we are going to perform following activities, existing material of connecting rod. In this present investigation connecting rod material is a major area of concentration.
Analysis of connecting rod was carried out using anysy 14. Distorted connecting rod imperfect journal geometry cavitation erosion spinning of the bearing in the housing. The connecting rod is required to transmit the compressive and tensile forces from the piston, and rotate at both ends. 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. Factor of safety of connecting rod i material used for connecting rod is structural steel. Pdf comparision of two different materials for connecting. A bush made of bronze or gunmetal is fitted between the connecting rod s small end and piston.
As mentioned isometric exploded view all dimensions are in mm machine element design practice ii meigroup6 scale. Selection of material, shape and manufacturing process. The fatigue limit is indicated by the horizontal part of the curve. 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%. Thermal conductivity is the ability of a material to. Al360 of connecting rod was replaced with aluminium fly ash silicon composite. Design and analysis of connecting rod with modified materials. In an internal combustion engine, connecting rods are usually located. After analysis a comparison is made between existing steel connecting rod viz. Monotonic and cyclic deformation behaviors, as well as straincontrolled fatigue properties of the two materials are evaluated and.
A comparison of manufacturing technologies in the connecting. According to 1, a piston in petrol combustion engine serves to. In this project the material forged steel of connecting rod replaced with aluminium alloy. Let us also know about the bush and bearing of the. The sn chart below compares data from fatigue tests on the corus branded and industry standard steel grades. Selection of material, shape, and manufacturing process for a. Design and optimization of connecting rod for different material.
Two different materials, steel alloy and titanium alloy were assigned to. This paper contains a preparation of al356 master alloy, analysis and comparison of results with existing connecting rods manufactured by using ss material. Pdf connecting rod is an essential component of an internal combustion engine. They developed the designed model of connecting rod using modelling software. Ilia et al 2005 provide the minimum ibeam area for the connecting rod for the 1. 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. Carbon steels, high strength low alloy steel, corrosion resistant high strength low alloy steel, and quenched and tempered alloy steel. Yield stress 625 mpa ultimate tensile strength 827 mpa.
The percentage of fpm connecting rods is now surely much higher. Pdf design and analysis of connecting rod using forged steel. Connecting rod, aluminium alloy, forged steel, ansys workbench, etc. During its operation connecting rodundergoes various types of loads. For buckling consideration, the end conditions of connecting rod in plane of motion are, a. Sustainable design and lifecycle assessment of connecting. Connecting rod forging numbers page 370 crankshaft forging numbers. Sustainable assessment is done using solid works 2014. Yield stress 625 mpa ultimate tensile strength 827 mpa density 7820 kgm3. Working of the connecting rod is to transmit power of piston to crank pin. Comparision of manufacturing methods and analysis of. This activity centers on the courses of strength of materials and production. The material used in the connecting rod should be chosen. Topology optimization, connecting rod, finite element analysis, minimum weight, linear static method.
Youngs modulus e 210 gpa, yield strength sy 210 mpa, poissons ratio. Finite element analysis of connecting rod is done by considering the materials, viz. Thats right, connecting rods are made from metal powder. A connecting rod basically connects the piston to the crankshaft whilst transmitting power of the combustion from the combustion chamber to rotate the crank. Fatigue behavior and life predictions of forged steel and powder. Material optimization of connecting rod using finite element. Anilkumar, et al 2011 4 the reinforced aluminum alloy al 6061 composites samples, processed by stir casting route are reported in this paper. Let us also know about the bush and bearing of the connecting rod. Materials with higher fatigue limits such as fractim and vanard 925 can be used for connecting rods subjected to higher loads.
After perform analysis on steel material connecting rod and s. Rajkamal 1 associate professor, department of mechanical engineering velammal institute of technology, chennai, india. The fourth section consists of original equipment crankshaft forging numbers references to the correct block number for main bearing applications. Definition, parts, types, function, material notes. Introduction connecting rods are highly dynamically loaded components used for power transmission in combustion engines. Design and analysis of connecting rod using different materials. As of 20, 25% of the worlds automotive connecting rods were manufactured by the forged powdered metal fpm process. Connecting rod manufacture is a high volume, price sensitive application with strict performance, design and durability requirements.
Introduction a connecting rod is an engine component which transfers motion from the piston to the crankshaft. The big end of a single rod is made in one part instead of two. Construction of con rod normally connecting rods are forgemanufactured and the material used is typically mild and medium carbon steel. Fatigue analysis of connecting rod using finite element.
Then, the drawing of connecting rod step format imported into ansys software. In recent automotive internal combustion engines, the connecting rods are usually made of steel for production engines, but can be made of aluminium for lightness and the ability to absorb high impact at the expense of durability or titanium for a combination of strength and lightness. Connecting rods for automotive applications are typically manufactured by forging from either wrought steel or powdered metal. Dimensions of crosssection of the connecting rod, dimensions of the crankpin at the big end and the piston pin at the small end. While the majority of connecting rods used for automotive production are steel connecting rods, other materials and technologies exist for high performance applications.
Solution of manufacturing defects in connecting rod. Abstract this paper presents a study of redesigning of connecting rod for its weight reductionusing c70s6 material. Material properties the connecting rod has been simulated for buckling load for two materials such as forged steel and aluminium 7075. Design and analysis of connecting rod with modified. Depending on the application, connecting rods are made of carbon steels or steel alloys. Pistons are commonly made of a cast aluminum alloy for excellent and lightweight thermal conductivity.
The connecting rod or conrod is bridge between the piston to the crank or crankshaft in reciprocating engines. Comparision of two different materials for connecting rod. The connecting rods are usually employed in the inner combustion engines and are subjected to countless varied. Materials used connecting rods can be made from various grades of structural steel, aluminum, and titanium. Pdf design and analysis of connecting rod using forged. The current manufacturing processes for connecting rods by fracture split drop.
Its function is to transfer the force produced by the piston to the crankshaft, as a result, the reciprocating motion of the piston is converted into the rotating motion of the crankshaft. Comparision of two different materials for connecting rod using ansys. Material properties assign to the model is listed below. Pdf analysis and optimization of connecting rod with different. This activity centers on the courses of strength of materials and.
Youngs modulus e 210 gpa, yield strength s y 210 mpa, poissons ratio. In an automobile engine, the connecting rod joins the piston and crank through piston pin. The material of connecting rod will be analyzed for abstract connecting rods design was drawn using autodesk inventor software and save in step format. Internal combustion engine has many parts like cylinder, piston, connecting rod, crank and crank shaft. Piston and types of piston, definition, function, pdf. Design and analysis of connecting rod using forged steel. Design of connecting rod for weight reduction using c70s6 material deepak g. Connecting rods are generally manufactured by forging. Finite element analysis and sustainable assessment of connecting rod is done by considering three materials, viz. The most common types of materials used for connecting rods are steel and aluminium.
The most objective of the project is to analysis of connecting rod with typical and composite material. Their applications are best used for daily drivers and endurance racing due to their high strength and long fatigue life 7. Modal and kinematic analysis of a connecting rod for different materials 1kaliappan s 2revanth raam ap 3charan b 4asswin s 5mohammed ibrahim sm 6 dr. The tensile strength, compression strength and hardness increased with the increase in the. Parameter value of connecting rod 150 outer diameter of big end 56 inner diameter of big end 48 outer diameter of small end 32 inner diameter of small end 24 table 1. Connecting rods are widely used in variety of engines such as, inline engines, vengine, opposed cylinder engines, radial engines and opposepiston engines.
Powder forging makes a better connecting rod jstor. The connecting rods are usually employed in the inner combustion engines and are subjected to countless varied stress cycles resulting in fatigue failure however during this method we tend to sculptural the rod by exploitation some typical. In this analysing software, can makes analysis to connecting rod of different material such as. Engine connecting rod an overview sciencedirect topics. Bent or twisted connecting rod appearance bent rods will exhibit heavy wear on diagonally opposite sides of each shell, typically in an edgeloaded pattern. Connecting rods are fabricated mainly by two methods drop forging operation and molding operations.
The existing connecting rod material can be replaced with a now composite material. The research carried out on the powder forged in the 1970s and 1980s has led to the. In this thesis, the connecting rod is modeled in proengineer, forces are calculated, analysis is done on the connecting rod using materials aluminum 6061, aluminum. The connecting rod helps to change the reciprocating motion of a piston into a revolving motion at the crankshaft. Finally obtaining the new optimized connecting rod which is comparatively much stiffer than the former 2. Connecting rods manufacturing improvements and process planning tolerance chain analysis and training material silvia garde gonzalez master thesis 2015 kth royal institute of technology. Steel rods are the most widely produced and used as connecting rods. I021991 design and analysis of connecting rod using forged steel leela krishna vegi1, venu gopal vegi2 department of mechanical engineering jawaharlal nehru technological university, kakinada, ap, india email id. Changing the material for connecting rod static structural analysis of the connecting ro d at 15kn bearing lo ad with different materials was performed by.
If the connecting rod bearing is damaged, replace all main and connecting rod bearings. Introduction internal combustion engine has many parts like cylinder, piston, connecting rod, crank and crank shaft. Analysis and optimization of connecting rod used in. The project focuses on selection of suitable material, design. The connecting rod provides the mechanical linkage between piston and crankshaft and. Remove the connecting rod bearing cap with the connecting rod bearing. Analysis of connecting rod using composite material. This article consists of definition, construction or parts, types, function and material notes and pdf of connecting rod. Twisted rods will exhibit wear running diagonally across the bearing surface. The connecting rod with piston and crank converts linear motion into rotary motion and also rotary motion into linear motion with a simple mechanism. Weightoptimized connecting rod for maximum stress mahle group. In this study a solid 3d model of connecting rod was developed using solid works2016 software.
Static load analysis was performed to determine the in vonmises stresses of the connecting rod. Strength analysis of connecting rods with pistons using finite. The ends where the rod is connected to the xhead or crankpin have bearings which are made of white metal working surface and shims thin packings are used to make the necessary adjustments. Comparision of materials for twowheeler connecting rod using. Aluminum alloys are lesser in weight, corrosion resistance, nontoxic, flexible in design and stiffer than other material like steel. Material optimization of connecting rod using finite. Connecting rod rectangular and ibeam crosssections with the assumed shape of the cross section for the connecting rod as shown in figure 2b, the cross sectional area of the ibeam section is 11 t 2. The aim of this study is to redesign a connecting rod for its light weight. The optimization of connecting rod had already started as early year 1983 by webster and. It converts reciprocating motion into rotating motion.
A connecting rod is rigid component, it may transmit either a push or a pull and so the rods may rotate the crank both halves of a revolution, i. A parameterized model of connecting rod is modelled using catia software. Damaging action a bent or twisted connecting rod results in misalignment of the bore, causing the bearing to. Steel materials are used to design the connecting rod. Design, simulation and manufacturing of a connecting rod. To come to these conclusions, the results obtained with the connecting rods manufactured by isothermal forging from previously. The condition for connecting rod to be equally strong in plane of motion xx and a plane perpendicular to plane of motion yy is, a. Buckling analysis of connecting rod for different materials. Forged steel has more factor of safety, reduce the weight, increase the stiffness and reduce the stress and stiffer than other material like carbon steel. Analysis of connecting rod using al356 master alloy as an. Ashby, shercliff and cebon 2008 have identified high strength magnesium, aluminum and ultra high strength steels as attractive candidates for connecting rod materials based on the constraints of high cycle fatigue and fracture toughness.
Fea analysis was carried out by considering five material aluminum 360, forged steel, titanium alloytiv11cr3al, magnesium alloy, beryllium alloy 25. There are far more manufacturers of con rods who offer steel rods than any other material. The three connecting rod materials had the same maximum safety factor, i. Design and fatigue characteristics of connecting rod by using finite. Modelling and analysis of different connecting rod material. Comparative study of connecting rod materials using. Selection of material the connecting rods are most usually made of steel for lightness and the ability to absorb high impact at the expense of durability titanium for a combination of lightness with strength, at higher cost for high performance engines, or of cast iron for applications such as motor scooters. The spare parts of the motorcycle are not available as the production has stopped. Therefore, high strength malleable steels should be used as connecting rod material. Connecting rod made using particulate reinforced aluminum.
In this project the material carbon steel of connecting rod replaced with forged steel. Pdf selection of material, shape, and manufacturing process for. The fifth section consists of the actual set listings and pertinent. Aluminum alloys are used for manufactured the connecting rods. Pdf design of a connecting rod, national institute of. Select a bearing material with higher load capacity check. Scan across to the part number required, making sure to select the desired undersize from. These new and robust connecting rods meet even the highest requirements of modern engines. One big end attaches to the crankpin and the big end usually uses a plain.
1551 958 778 677 79 120 239 766 1453 677 475 1395 1064 62 75 854 31 963 1083 1091 888 274 780 314 1044 601 424 1090 59 852 555 706 217 883