ISSN: 2455-8761
www.ijrerd.com || Volume 02 – Issue 07 || July 2017 || PP. 203-213
Abstract: The connecting rod (CR) is the main moving part and an important component of an internal com-
bustion (IC) engine. The connecting rod is the intermediate member between the piston and the Crankshaft. It’s
primary function is to transmit the push and pull from the piston pin to the crank pin, thus converting the reci-
procating motion of the piston into rotary motion of the crank. The main objective of this paper is to Design
evaluation through Finite Element Analysis for fatigue life of connecting rod used in Hero Honda Motor Cycle.
Structural systems of connecting rod can be analyzed using Finite Element techniques. So firstly a proper Finite
Element Model is developed using Cad software CATIA. Then the Finite element analysis is carried out to de-
termine the stresses and displacement in the present design of the connecting rod for the given loading condi-
tions using Finite Element Analysis software (HYPERMESH). Structural strength for the connecting rod will be
verified over an Universal Testing Machine (UTM) for tensile loading. Based on the observations of the static
FEA and the load analysis results, recommend the best alternative design for the connecting rod.
Keywords: Connecting Rod, Finite Element Analysis, Modeling, Static
I. Introduction
The intermediate component between crank and piston is known as connecting rod. Connecting rod is
also known as conrod and is used to connect the piston to crankshaft. As a connecting rod is rigid, it may trans-
mit either a push or a pull and so the rod rotates the crank through both halves of a revolution, i.e. piston push-
ing and piston pulling. Earlier mechanisms, such as chains, could only pull. In a few two stroke engines, the
IJRE RD
connecting rod is only required to push. Today, connecting rods are best known through their use in internal
combustion piston engines, such as automotive engines. These are of a distinctly different design from earlier
forms of connecting rods, used in steam engines and steam locomotives. One source of energy in automobile
industry is internal combustion engine. Internal combustion engine converts chemical energy into Mechanical
energy in the form of reciprocating motion of piston. Crankshaft and Connecting rod convert reciprocating mo-
tion into rotary motion. Connecting rod is one of the important driving parts of Light vehicle engine it forms a
simple mechanism that converts linear motion into rotary motion that means the connecting rod is used to trans-
fer linear, reciprocating motion of the piston into rotary motion of the crankshaft.[6]
203 | P a g e www.ijrerd.com
International Journal of Recent Engineering Research and Development (IJRERD)
ISSN: 2455-8761
www.ijrerd.com || Volume 02 – Issue 07 || July 2017 || PP. 203-213
FEA software and there is no any experimentation and validation results are found .In other side very less re-
search work done on the stress distribution and fatigue life of CR in light vehicle engine are analyzed using the
commercial 3D finite element software. The new analysis will examine the calculations for the stresses and fati-
gue failure of the component
V. Objectives
a) Find out the problem areas by studying the existing system of linkages in which identify the different para-
meters such as stresses, deflection and fatigue failure of the component for redesign of the connecting rod.
b) CAD model of connecting rod will be created in CATIA and it’ll be analyzed in HYPERMESH software.
c) To conduct test on Universal Testing Machine to find stress and deflection of existing connecting rod.
d) To analyze the alternative geometry for connecting rod using suitable tools such as HYPERMESH software.
e) To recommend the best alternative design for the connecting rod through experimentation and validation.
TABLE I
Dimensions of Connecting Rod
Sr. Parameters Value
no.
1. Length of connecting rod 123mm
TABLE III
Material Properties of Connecting Rod[11]
Material Selected Carbon Steel
204 | P a g e www.ijrerd.com
International Journal of Recent Engineering Research and Development (IJRERD)
ISSN: 2455-8761
www.ijrerd.com || Volume 02 – Issue 07 || July 2017 || PP. 203-213
Tensile Strength 400-500 Mpa
B. Design Calculation
Gas Force = Pressure x Cross section area of piston
Fl = P x π/4 x D2= 16xπ/4x502 = 31415.93 N
Inertia Force
Stroke length, l = 123mm IJRE RD
C. Inertia force
FI = m ω 2r(cosθ+cos2θ/n)
= 72.9x10 -3x837.76 2x24.75x10 -3x (1+1/4.97)
= 1521.1 N
E. Fatigue Calculation
σmax = 30.59 MPa
σmin = - 30.59 MPa
F. Amplitude Stress
σa = (σmax - σmin) / 2 = (30.59 – (-30.59))/2
= 30.59 MPa
205 | P a g e www.ijrerd.com
International Journal of Recent Engineering Research and Development (IJRERD)
ISSN: 2455-8761
www.ijrerd.com || Volume 02 – Issue 07 || July 2017 || PP. 203-213
G. Mean Stress
σm = (σmax + σmin) / 2 = (30.59 + (-30.59))/2
= 0 MPa
H. For Forged Steel
Yield strength, Sy = 625 MPa
Ultimate strength, Sut = 827 MPa
Fatigue endurance strength, Se’ = 0.5 σut
= 0.5X827
= 413.5 MPa
I. Endurance limit
Se = ka* kb* kc *kd* ke* kf* Se’
= 0.8*1.2*1*1*1*1*413.5= 396.96 MPa
From modified Goodman line
σa/Se + σm/Sut = 1/n=(30.59/396.96) + (0/827)
= 1/n = 0.077
n = 12.98
As σm = 0
J. Finite Life
N = (σa / a)1/b
a = (f Sut)2 / Se
where f = 0.82
a = (0.82x827)2/396.96= 1158.49
b = - [log(f Sut) / Se]/3
= - [log(0.82x827/396.96]/3 = - 0.077
N = (30.59/1158.49)-1/0.077
= 3.145 x 1020 Cycles
IJRE RD
VIII. Methodology
A. Finite Element Analysis Method
Connecting rod was modeled by taking the designed parameter of rod and then by using the CATIA
software solid modeling has done which is shown in Fig.1 And saved within this program in *.IGES format. The
model is imported in HYPERMESH and then the mechanical characteristics of the connecting rod are estab-
lished: density - 7860 Kg/mm3, Young’s modulus – 210 GPa, Poisson’s ratio - 0.3, etc.
1) Meshing
The next stage of the modeling is to create meshing of the created model. The mesh should be finer and
accurately represent the geometry in the critical areas i.e. the areas where stress, strain, deformation and loading
is going to be important. Here we done solid meshing because A part with all the three dimensions (x, y, z in a
Cartesian coordinate) comparable are usually meshed with solid elements. The mesh model of connecting rod is
206 | P a g e www.ijrerd.com
International Journal of Recent Engineering Research and Development (IJRERD)
ISSN: 2455-8761
www.ijrerd.com || Volume 02 – Issue 07 || July 2017 || PP. 203-213
as shown in fig.2
IJRE RD
207 | P a g e www.ijrerd.com
International Journal of Recent Engineering Research and Development (IJRERD)
ISSN: 2455-8761
www.ijrerd.com || Volume 02 – Issue 07 || July 2017 || PP. 203-213
3) Results and Discussion
For the finite element analysis 16Mpa of pressure is used. The analysis is carried out using CATIA and
HYPERMESH software. The pressure is applied at the small end of connecting rod keeping big end fixed. The
maximum and minimum von-misses stress, strain, shear stress, and factor of safety are noted from the
HYPERMESH
IJRE RD
B. Experimentation
1) Experimental Setup Information
The specs for the UTM (Universal Testing Machine) used for the Test are as below
Make: Star Testing System (India) - Software based
Model No: SPS 248
Type: DC Servo Control
Speed for loading: 5mm/min to 500mm/min
208 | P a g e www.ijrerd.com
International Journal of Recent Engineering Research and Development (IJRERD)
ISSN: 2455-8761
www.ijrerd.com || Volume 02 – Issue 07 || July 2017 || PP. 203-213
IJRE RD
209 | P a g e www.ijrerd.com
International Journal of Recent Engineering Research and Development (IJRERD)
ISSN: 2455-8761
www.ijrerd.com || Volume 02 – Issue 07 || July 2017 || PP. 203-213
XI. MODIFIED GEOMETRY
Geometry changes: Change in web thickness and radius in neck portion
Base model having Neck radius at Crank and Pin end are 20 and 12 mm respectively.
IJRE RD
New modified model having Neck radius at Crank and Pin end are slightly greater than base model as
22and 15 mm respectively and we do again FEA process on redesign model we get results as given below in fig.
210 | P a g e www.ijrerd.com
International Journal of Recent Engineering Research and Development (IJRERD)
ISSN: 2455-8761
www.ijrerd.com || Volume 02 – Issue 07 || July 2017 || PP. 203-213
IJRE RD
211 | P a g e www.ijrerd.com
International Journal of Recent Engineering Research and Development (IJRERD)
ISSN: 2455-8761
www.ijrerd.com || Volume 02 – Issue 07 || July 2017 || PP. 203-213
From S-N Curve we get the value of Number of load cycle at stress 1000(N/mm 2 )
IJRE RD
212 | P a g e www.ijrerd.com
International Journal of Recent Engineering Research and Development (IJRERD)
ISSN: 2455-8761
www.ijrerd.com || Volume 02 – Issue 07 || July 2017 || PP. 203-213
Model Average Fatigue Life
(No. Of cycles)
7
Base model
8.9 *10
19
Modified Model
3.333*10
ACKNOWLEDGMENT
The authors of this present work acknowledge the technical support given by Ethika Engg. Solutions
India pvt ltd.
REFERENCES
[1]. Afzal, “Fatigue Behavior and Life prediction of Forged Steel and PM Connecting Rods”, Master’s
Thesis, University of Toledo, 2004
[2]. Ahad Ridzun Bin Ibrahim, “Analysis of Connecting Rod Fracture Using Finite Element Analy-
sis”,pp.110-112.
[3]. Ali Fatemi and Mehrdad Zoroufi, “Fatigue Performance Evaluation of Forged Versus Competing
Process Technologies: A Comparative Study”, 24th Forging Industry Technical Conference, Cleveland,
Ohio, 2002.
[4]. Atish Gawale, A. A.Shaikh1 and Vinay Patil, “Nonlinear static finite element analysis and optimization
IJRE RD
of connecting rod.” World Journal of Science and Technology 2012, 2(4):01-04. ISSN: 2231 – 2587.
[5]. Mr. H. B. Ramani, Mr. Neeraj Kumar, Mr. P. M. Kasundra, “Analysis of Connecting Rod under Dif-
ferent Loading Condition Using Ansys Software”. International Journal of Engineering Research &
Technology (IJERT),Vol. 1 Issue 9, November- 2012 ISSN: 2278-0181
[6]. Swapnil B. Ikhar, “Modeling and Analysis of Connecting Rod of Two Wheeler (Hero Honda Splen-
dor)” Discovery, Volume 24, Number 83, October 4, 2014
[7]. P. G. Charkha, S. B Jaju, “Analysis & Optimization of Connecting Rod”, Second International Confe-
rence on Emerging Trends in Engineering and Technology,2009,IEEE, pp. 86-91.
[8]. Pravardhan S. Shenoy, “Dynamic load analysis and optimization of connecting rod”, 2004,pp. 30-42.
[9]. P. S. Shenoy and A. Fatemi, “Connecting Rod Optimization for Weight and Cost Reduction”, Universi-
ty of Toledo, SAE Technical Paper Series, Paper No- 2005-01-0987.
[10]. Schreier, L, “Tension and compression in connecting rods”, 1999.
[11]. V.B.Bhandari Design Data book
213 | P a g e www.ijrerd.com