Jun 20, 2015 design and construction of a connecting rod 1. This results in a slower rate of pressure drop across the inlet path, therefore causing a reduction in intake flow rate all else being equal. In this months enginology setion circle track contributor jim mcfarland discusses the science behind connecting rods and how their design and geometry is vital to engine performance. This proprietary steel is forged in trenton, michigan, and manufactured 100% in our fostoria, ohio facility. Maximum connecting rod tension loading occurs at tdc at the end of the exhaust stroke and beginning of intake stroke when the connecting rod has to stop and then change the direction of the piston crank angle at 0 or 360 degrees. We will use the flip side of the slot,to cut around into the sides of our model.
Connecting rod design a6200 reengineering the model. Together with the crank, they form a simple mechanism that converts reciprocating motion into rotating motion. Connecting rod of two wheeler 100 cc petrol engine is taken for the analysis, finite element analysis includes the design and modeling of connecting rod using creo 2. A connecting rod is one of the most mechanically stressed components in internal combustion engines. Typical design of automobile engine connecting rod.
The connecting rod is the intermediate member between the piston and the crankshaft. Powder forging process powder forging consists of the rapid densification of a heated powderbased preform using a single forging strike. Blais a thesis submitted in partial fulfillment of the requirements for the degree of masters of science in mechanical engineering approved. Pdf design of connecting rod of internal combustion. Checking with the engine builder and manufacturer is also a. The objectives of this paper are to develop structural modeling, finite element analyze and the optimization of the connecting rod for robust.
August 8, 20 department of mechanical engineering kate gleason college of engineering. Mechanical engineering a rod or bar for transmitting motion, esp one that connects a rotating part to a reciprocating part 2. As a mechanical engineer, what is the design considerations in designing the drive shaft and the axle. Fatigue analysis of connecting rod using finite element. Certain aftermarket performance rods may have a serrated mating surface that registers the cap to the rod. And find the optimal solution after the theoretical calculation.
In this in order to have a connecting rod equally strong in buckling about both the axis, the buckling loads must be equal. The connecting rod is modeled as plane stress problem using 25 quadrilateral pelements. As tolerance chain analysis is an essential activity in process planning for geometry assurance, a tolerance chains study based on monte carlo simulations for the connecting rod line has been performed to develop. Coupling to the crankshaft is achieved through solid journal bearing half shells inserted on both sides of the split large end. Can you tell what the diameter of the large end of the connecting rods should measure. Hippoliti 1993 reported design methodology in use at piaggio for connecting rod design, which incorporates an optimization session. Design and analysis of a connecting rod written by sebastian antony, arjun a. In terms of design, the three pockets at the big end of a boostline rod subtract a little weight at the stress points where the rod has been beefed up. On the other hand, you should replace the connection rod with a stronger one if you want to make the engine work at a higher speed. Design and analysis of connecting rod using forged steel leela krishna vegi1, venu gopal vegi2. What is more important when it comes to choosing a connecting rod for your car. Material design for advanced connecting rod for mass optimization design for light weight connecting rod dnyandeep k. It converts the linear motion of the pistons to the rotary motion of the crankshaft. Important design considerations for window hardware include life cycle serviceability, ability of operating hardware to resist wind loads when the window is in the open position, and resistance to forced entry.
Being one of the most integral parts in an engines design, the connecting rod must be able to withstand tremendous loads and transmit a great deal of power. Tension and compression analysis in reciprocating engine. The connecting rod cr is the main moving part and an important component of an internal com. Design of connecting rod for high speed application in ic engine using two different materials likes aluminum and aluminum alloy alfasic and also mentions the its mechanical properties which are required for design of connecting rod. When the cylinder fires, the piston pushes down on the connecting rod, which inturn, causes the crankshaft to rotate. Manufacturing variations in joint surface flatness and bearing crush were predicted. The connecting rod pushes and pulls the piston into and out of the cylinder. Connecting rods how to prevent engine failures hot rod. Analysis of connecting rod bearing design trends using a. The computeraided design cad files and all associated content posted to this website are created, uploaded, managed and owned by third party users. Steel materials are used to design the connecting rod. Connecting rod design factors such as joint surface flatness, bearing crush, geometric shape, and capscrew torque can significantly affect bore distortion, assembly stresses, and bearing and joint load distribution. Unless compensation is made for this change in piston speed. Aamas window selection guide includes a useful overview of the operating hardware options for the various types of operating windows.
Pride in workmanship, and attention to detail are qualities youll discover during careful examination of our finished product. Analysis of connecting rod bearing design trends using a mode. This is the load that stretches the connecting rod, causes the big end to become oval, and pulls at the fasteners. The connecting rod is under tremendous stress from the reciprocating load represented by the piston, actually stretching and being compressed with every rotation, and the load increases to the third power with increasing engine speed. Connecting rods 101 design,material,modifications,and. As connecting rod length is increased, piston motion both acceleration and velocity away from tdc decreases. Mar 16, 2016 the other constraint was the one on thickness to bound it away from zero. A rod that transmits motion or power from one moving part to another, especially the rod connecting the crankshaft of a motor vehicle to a piston. And from the origin sketch i slot something like this. The rod must be straight, centertocenter rod length must meet design specs, the pin bore and bigend bore must be perfectly round, each bore must be sized appropriately for wrist pin and crank.
The configuration depends upon the type of connecting elements, nature and magnitude of the forces and moments, available equipment, fabrication and erection considerations, cost, etc. Now zoom in to this area to make it easier to select. Primary factors influencing connecting rod design are extreme inertia forces and cylinder pressure as defined by maximum engine speed, rotating assembly geometry, and weight. We have discussed here 4 major parts dimensions and all. The effect of inertia load due to the connecting rod, mentioned above, was analysed separately. Together with the crank, the connecting rod converts the reciprocating motion of the piston into the rotation of the crankshaft. The design was modified slightly from the existing forging designs due to different requirements of the cross. To offer a technically correct and dimensionally accurate representation of an automotive type connecting rod, i think three things need to be addressed. Fracture splitting connecting rods are not broken parts, just to be sure. Connecting rod cap bolts to the bottom of the connecting rod body. The objective of the present work is to design and analyses of connecting rod made of aluminium alloy. Honing to a slight oversize and using oversize bearings is. Design and analysis of connecting rod for high speed.
The maximum stress of the connecting rod monitored and make sure it is not over the allowable stress. If your engine makes only a few revolutions per minute, then you should consider buying an hshaped rod or an ibeam rod that has. Each cad and any associated text, image or data is in no way sponsored by or affiliated with any company, organization or realworld item, product, or good it may purport to portray. This paper presents the design connecting rod of internal combustion engine using the topology optimization.
A comparison of manufacturing technologies in the connecting rod industry. Selection of material, shape, and manufacturing process. You might not know that choosing the right connecting rod will be an important decision to make. If they arent, cap misalignment can reduce clearance between the rod and the crankshaft journal. Causes of failure with a connecting rod it still runs. An optimization study was performed on a steel forged connecting rod with a consideration for improvement in weight and production cost. The structure of connecting rod was modeled utilized solidworks software. The connecting rod connects the pistons to the crankshaft. K published on 20161014 download full article with reference data and citations. In this project the material forged steel of connecting rod replaced with aluminium alloy. And i changed the view orientation to a bottom view. Connecting rods are used in numerous situations, most commonly in the engines of automobiles. The connecting rod or conrod connects the piston to the crank or crankshaft.
Figure 110 connecting rods must be strong enough to remain rigid under load and yet be light enough to reduce the inertia forces that are. Together with the crank, they form a simple mechanism that. This design also cannot be reconditioned by grinding material from the mating surfaces. Choosing the proper connecting rod for your application is as vital as selecting the correct camshaft. The geometric model, finite element mesh, physical dimensions, and. Selection of material, shape, and manufacturing process for a. In this guide to connecting rods we demonstrate how to avoid connecting rod installation mistakes and prevent engine failures in your stock car racing engine circle track magazine.
Linear buckling analysis was performed on the connecting is 26. The connecting rod is required to transmit the compressive and tensile forces from the piston, and rotate at both ends. The traditionally manufactured connecting rods lack in captorod fit, where fracturesplitting connecting rods allows precise. Connecting rod definition of connecting rod by the free. Tension and compression analysis in reciprocating engine connecting rods. As weve talked about in previous articles, all connecting rods have a parting edge. Pdf a repertoire of failures in connecting rods for.
Connecting rod bolts and nut clamps the rod cap and rod together connecting rod small end, or top. The shape of the connecting rod is to be determined to minimize its weight subject to a set of stress constraints. Most are flat surfaces machined into the cap and rod sections. The rod bolts will come apart as the piston travels up on the exhaust stroke, the force and inertia of the rotating assembly rips the rod cap off of the connecting rod. Selection of material, shape and manufacturing process for a connecting rod abstract this activity centers on the courses of strength of materials and production design offered at a sophomore level mechanical engineering curriculum.
Connecting rods callies precision engine components. A connecting rod, also called a con rod, is the part of a piston engine which connects the piston to the crankshaft. Analysis of connecting rod bearing design trends using a modebased elastohydrodynamic lubrication model by travis m. Engine connecting rod an overview sciencedirect topics. A repertoire of failures in connecting rods for internal combustion engines, and indications on traditional and advanced design methods. A connecting rod for an internal combustion engine consists of the big end, rod and small end. In a reciprocating piston engine, the connecting rod or connecting rod connects the piston to the crank or crankshaft. Enter ansys in the working directory specif ied by your instruct or using. The manufacturing process of fracturespliting connecting rods different compared to the traditional ones.
The connecting rods are mounted with connecting rod bearing shells on the crankshaft pins on the crankshaft. The predecessor to the connecting rod is a mechanic linkage used by water mills to convert rotating motion of the water wheel into reciprocating motion. Seshu adluri introduction steel connections many configurations are used for force transfer in connections. Connecting rod, structural analysis, titanium, steel, gas load, fatigue, fea 1. Think of the time when you decide to build or overhaul your next engine. Material design for advanced connecting rod for mass. The cap screw threads into the connecting rod itself.
The connecting rod is the link that transmits forces between the piston and the crankshaft. Connecting rod bolts and nuts clamp the connecting rod and cap together. Design and analysis of a connecting rod for the 117kw six cylinders turbocharged diesel engine. And start a new sketchon the right, flat, bottom face. A con rod for a modern passenger car engine has been studied to show the performance of highdensity pmmaterials manufactured by warm compaction of high compressible low alloyed powders.
The load of the connecting rod optimized is comprised of the tensile load of 26. On every stroke, the connecting rod is stretched and compressed. Wiseco also uses arp rod bolts, and includes instructions for installation and grease for the threads with each set. Refer chapter 25 from the book, design of machine elements by v. Pdf design and analysis of a connecting rod for the 117kw. The introduction of piston cooling nozzles in al engines provides scope for eliminating the oil hole in the connecting rod and thereby reducing the size of the i section. Its also just as involved of a process, one in which you should know several things about your combination prior to making a decision. All connecting rods for automotive use need to be lightweight but strong enough to. Here, the connecting rod is replaced by various materials like stainless steel, aluminium, c70 steel and also a design change by inducing truss member is suggested. They could obtain 20% weight reduction in the neck region of the connecting rod. These surfaces must be straight and perpendicular to the rod sides. Selecting and saving a car will make browsing faster and more fun. The proper condition of a connecting rod is fairly straightforward.
Hello friends here in this video we will learn about the design procedure of connecting rod,which is a part of internal combustion engine. In order to keep the engine from moving while changing a timing belt, can you take out 1 spark plug and put a bunch of rope in the cylinder to. The small connecting rod eye on the piston side serves as a mounting for the piston bolt and is frequently equipped with a bronze connecting rod bearing bush. In october 2009 a 20day nonscheduled outage was initiated at groups i and ii for the replacement of diesel generator bearings, after receiving a letter from the manufacturer warsila informing of the possibility of certain of the connecting rod bearings installed in the diesel generator motors being defective, this potentially leading to seizure of the motor shaft. Connecting rods forged 4340 steel connecting rod material. Bedse1 1department of mechanical engineering, savitribai phule pune university gokhale education societys r.
Connecting rod rotates the crank shaft which helps the engine to move on or any vehicle to rotate its. 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. Design and analysis of connecting rod using forged steel. Connecting rod big end a hole machined in the rod body and cap. If your engine makes only a few revolutions per minute, then you should consider buying an hshaped rod or an ibeam rod that has greater strength than ordinary connection rods. The small end attaches to the gudgeon pin also called piston pin or wrist pin, which can swivel in the piston. Cap alingment method, bearing inset crush and or machined grooves for bearing tabs and finally, piston pin hole diameter press fit pin or sized for a bushing and floating pin in which case. Callies ultra connecting rods are produced from extremely clean timkensteelmade product, that is formulated to our exact specifications. Pdf design and analysis of a connecting rod for the. What is the design procedure for an connecting rod.
Sapat college of engineering, management studies and research, nasik 5,india. Jawaharlal nehru technological university, kakinada, ap, india. The objectives of this paper are to develop structural modeling, finite element analyze and the optimization of the connecting rod for robust design. If the connecting rod fails because it bends this is usually due to engine knock from a.
Connecting rods jim mcfarland discusses connecting rod. International journal for research in applied science. Fatigue analysis of connecting rod using finite element analysis 789 the stress at any point on the connecting rod at this axial load can be interpolated from the axial stress analysis results. This pressure, plus other factors, can cause the connecting rod. They are used respectively depending on their field of application or use.
820 909 84 1455 486 376 577 444 201 880 334 59 185 349 1462 65 514 120 1507 253 1330 147 740 937 466 529 56 1145 295 238 525 1162 588 289 428 471 476 845