![International Journal of Trend in Scientific Research and Development (IJTSRD) @ www.ijtsrd.com eISSN: 2456-6470
@ IJTSRD | Unique Paper ID - IJTSRD23182 | Volume – 3 | Issue – 3 | Mar-Apr 2019 Page: 1013
LITERATURE SURVEY
D. Gopinathan, Ch V Sushma [2015] did research to explore
weight reduction opportunities for the productionofForged
steel, Aluminum and Titanium connecting rods. First they
did static load analysis of connecting rod for three materials
and then they optimised forged steel connecting rod for
weight reduction. First geometrical model was developed
using CATIA. Then product model was analysed by using
ANSYS software. Then analysis was compared for three
materials for optimisation result.
Pravardhan S. Shenoy and AliFatemi(2005) did thedynamic
load examination and enhancement of connecting rod. The
fundamental goal of this examination was to investigate
weight and cost decrease open doors for a production
manufactured steel connecting rod. Normally, an ideal
arrangement is the Mini or Max conceivable esteem the
target capacity could accomplishunder acharacterized setof
imperatives. The heaviness of the con-rod has little impact
on the cost of the last part. Change in the material, bringing
about a huge diminishment in machining cost, was the key
factor in cost lessening. Thus, in this streamlining issue the
cost and the weight were managed independently. The
auxiliary elementsconsidered forweightdiminishmentamid
the improvement incorporate the clasping load factor,
worries under the heaps, twisting firmness, and hub
solidness. Cost diminishment is accomplished by utilizingC-
70 steel, which is break crack able. It kills sawing and
machining of the rod and top mating faces and is accepted to
lessen the production cos t by 25%. The weight distinction
between the two when adjusted for jolt head weight was
under 1%. This means that the precisionof thestrongmodel.
Setup of the motor to which the con-rod has a place.
Webster et al. (2000) performed three dimensional finite
element analysis of a high diesel engine connecting rod. For
this analysis they used the maximum compressive load
which was measured experimentally, and the maximum
tensile load which is essentially the inertia load of the piston
assembly mass. The load distributions on the piston pin end
and crank end were determined experimentally. They
modeled the connecting rod cap separately, and also
modeled the bolt pretension using beam elements andmulti
point cons equations.
G. M. Sayeed Ahmed [Oct.2014] replaced a broken
connecting rod made of forged steel with aluminum alloys
and carbon fiber. Connecting rods were manufactured by
conventional method. Rods were tested in ideal conditions
by applying variable loads. Authors found that weight of
connecting rods was reduced and all performed to the level
of expectation. Rods performed well at their extreme
conditions.
DIMENSIONAL PARAMETERS
Table 1 Design Specifications
Volume of cylinder 450cc
Height of the bore 95mm
Bore Radius 38.8mm
Gas or Stream Pressure 35bar
Small end Diameter of connecting rod pin 29.70mm
Crank shaft pin diameter of connecting rod 39.14mm
Diameter of big end 53.14mm
Outer diameter of small end 43.71mm
Height of big end 73.62mm
Tensile yield stress 650 (min) – 950 (max)
Load 15kgf (min), 27.19kgf (max)
Maximum inertia force on bolts 6509.393N
Based on the ranges indulged in design data book the minimum and maximum parameters are considered as case1 and case2.
METHODOLGY
4.1 Modelling of connecting rod in CATIA V5
CATIA is started as an in-house developmentin1977 byFrench aircraftmanufacturer AVIONSMARCELDASSAULT, atthattime
customer of the CADAM software to develop Dassault's Mirage fighter jet. It was later adopted by the aerospace, automotive,
shipbuilding, and other industries. CATIA name is an abbreviation for Computer Aided Three-
dimensional Interactive Application. The French Dassault Systemsis theparentcompanyand IBM participateinthe software’s
and marketing, and catia is invades broad industrial sectors.
Based on the design particulars above perished the modelling is carried out. The big end and small end are modelled. Boththe
ends are of connecting rod are assembled by using temporary joints i.e, nut and bolts.
Fig Modelling of parts of connecting rod Fig Assembled connecting rod
The model is converted into “stp” to undergo the analysis](https://image.slidesharecdn.com/221designandanalysisofconnectingrodofdieselengine-190618111026/85/Design-and-Analysis-of-Connecting-Rod-of-Diesel-Engine-2-320.jpg)
![International Journal of Trend in Scientific Research and Development (IJTSRD) @ www.ijtsrd.com eISSN: 2456-6470
@ IJTSRD | Unique Paper ID - IJTSRD23182 | Volume – 3 | Issue – 3 | Mar-Apr 2019 Page: 1017
Here,
The Case 1 is nothing but the modal which is done by using minimal design parameters and load of 15kgf.
The Case 2 is nothing but the model which is done by using maximal design parameters and with the load of 27.19kgf.
By observing the above chart it is clear that the component made up C-70 steel has lesser deformation than Aluminium and
Cast Iron. Therefore it is more feasible to use the C-70 steel for the manufacturing of connecting rod. Being a composite
material C-70 steel has weight deduction by around 10% of the original components, also the cost reduced according to that.
CONCLUSION
In this project the connecting rods are Designed concerning
all the accessible limitations utilizing a data book as the
reference, Later the item’s document are changed over to
".STP" record organize (standard trade of item document)
and imported to Ansys workbenchtodiscoverdisfigurement
and investigative valve regarding the model’s definitions.
In this project the connecting rod was experienced with
different sorts of materials like cast iron, aluminum, and C-
70 to discover total deformation, and equivalent stress by
Using static auxiliary features which are included in Ansys
workbench.
It was observed that connecting Rod made up of Aluminum,
and Cast Iron has higher intensity of stress induced as
compared to connecting Rod made up of C-70. Alsothereisa
great opportunity to improve the design. Hence C-70 is
better choice for connecting rods.
REFERENCES
[1] D. Gopinathan, Ch V Sushma, (2015) “Design And
Optimisation Of Four Wheeler Connecting Rod Using
Finite Element Analysis” Materials Today Proceedings
2(2015)2291-2299
[2] G. M. Sayeed Ahmed,(oct. 2014)” Design, Fabrication
And Analysis Of a Connecting Rod with Aluminum
Alloys and Carbon Fiber” International Journal of
Innovative Research in Science, Engineering and
technology(IJIRSET),Vol.3,Issue 10, ISSN:2319-8753
[3] Pravardhan S. Shenoy , (2005), “Connecting Rod
Optimization for Weight and Cost Reduction”, The
University of Toledo, SAE intemational. 2005-01-0987.
[4] Abhinav Gautam, K Priya Ajit, (Nov – Dec 2013) “Static
Stress Analysis of ConnectingRodUsingFiniteElement
Approach”, IOSR Journal of Mechanical and Civil
Engineering (IOSR-JMCE), Volume 10, Issue 1 ISSN:
2278-1684](https://image.slidesharecdn.com/221designandanalysisofconnectingrodofdieselengine-190618111026/85/Design-and-Analysis-of-Connecting-Rod-of-Diesel-Engine-6-320.jpg)
Design and Analysis of Connecting Rod of Diesel Engine
- 1. International Journal of Trend in Scientific Research and Development (IJTSRD) Volume: 3 | Issue: 3 | Mar-Apr 2019 Available Online: www.ijtsrd.com e-ISSN: 2456 - 6470 @ IJTSRD | Unique Paper ID – IJTSRD23182 | Volume – 3 | Issue – 3 | Mar-Apr 2019 Page: 1012 Design and Analysis of Connecting Rod of Diesel Engine A. Vijay Kumar1, K. Mihir2, M. Mrudul2, P. Pavan Kumar2 1Assistant Professor, 2UG Scholar Department of Mechanical Engineering, GNIT, Rangareddy, Telangana,India How to cite this paper: A. Vijay Kumar | K. Mihir | M. Mrudul | P. Pavan Kumar "Design and Analysis of Connecting Rod of Diesel Engine" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456- 6470, Volume-3 | Issue-3, April 2019, pp.1012-1017, URL: https://www.ijtsrd.c om/papers/ijtsrd231 82.pdf Copyright © 2019 by author(s) and International Journal of Trend in Scientific Research and Development Journal. This is an Open Access article distributed under the terms of the Creative Commons Attribution License (CC BY 4.0) (http://creativecommons.org/licenses/ by/4.0) ABSTRACT The main objective of this study is to review the weight optimization and cost reduction of a connecting rod in a Diesel engine. To get the idea about designing the connecting rod, various stresses to be considered while designing the connecting rod .This has entailed performing a detailed load analysis. The most important factors that are concentrated are stress distribution and deflections. In this project the connecting-rod is designed with respect to all the available constraints using advanced cad software CATIA. Later the product file is converted to ".stp" file format (standard exchange of product file) and imported to ANSYS workbench to find deformation and analytic valve with respect to the model or product definitions. KEYWORDS: Connecting-rod, CATIA, ANSYS INTRODUCTION The connecting rod in automobile engine is a connection between the piston and the crank shaft. The joiningof piston pin with the crankpin, Small end of connecting rod to piston pin and big end to the crank pin. Connecting rod ensure that piston has linear motion and with respect to that rotation motion is acquired by the crankshaft. The connecting rod is employed to transmit the power thrust from piston to the crank pin and hence it must be very strong, rigid and also as light as possible. Hence connecting rod materials possess good fatigue and shock resistances. Connecting rods for automotive applications are typically manufactured by forging from either wrought steel or powdered metal. They could also be cast. However, castings could have blow-holeswhich aredetrimentalfromdurability and fatigue points of view. The fact that forgings produce blow-hole-free and betterrodsgivesthemanadvantageover cast rods. Between the forging processes, powder forged or drop forged, each process has its own prosandcons.Powder metal manufactured blankshavetheadvantageofbeing near net shape, reducing material waste. However, the cost of the blank is high due to the high material cost and sophisticated manufacturing techniques. With steelforging,thematerialis inexpensive and the rough part manufacturing process is cost effective. Bringingtheparttofinaldimensions underthe tight tolerance results in high expenditure for machining, as the blank usually contains more excess material. Fig 1 Connecting Rod 1.1 SELECTION OF MATERIAL In general the connecting rods are made up of Cast iron, Aluminum, and Steels. According to survey Annual North American production is approximately 100 million rods. A new steel, C-70, has been introduced from Europe as a crack able forging steel. Alloying elements in the material enable hardening of forged connecting rods when they undergo controlled cooling after forging. This material fractures in a fashion similar to powder forged materials. Using finite element analysis (FEA) techniques, it was found thatthereis a reduction of weight by 10% and also by using “crackable” C-70, the costs is reduced by 25% over in general forged steel connecting rods and ostensibly15% lessthanaP/F rod with similar or better fatigue behaviour. IJTSRD23182
- 2. International Journal of Trend in Scientific Research and Development (IJTSRD) @ www.ijtsrd.com eISSN: 2456-6470 @ IJTSRD | Unique Paper ID - IJTSRD23182 | Volume – 3 | Issue – 3 | Mar-Apr 2019 Page: 1013 LITERATURE SURVEY D. Gopinathan, Ch V Sushma [2015] did research to explore weight reduction opportunities for the productionofForged steel, Aluminum and Titanium connecting rods. First they did static load analysis of connecting rod for three materials and then they optimised forged steel connecting rod for weight reduction. First geometrical model was developed using CATIA. Then product model was analysed by using ANSYS software. Then analysis was compared for three materials for optimisation result. Pravardhan S. Shenoy and AliFatemi(2005) did thedynamic load examination and enhancement of connecting rod. The fundamental goal of this examination was to investigate weight and cost decrease open doors for a production manufactured steel connecting rod. Normally, an ideal arrangement is the Mini or Max conceivable esteem the target capacity could accomplishunder acharacterized setof imperatives. The heaviness of the con-rod has little impact on the cost of the last part. Change in the material, bringing about a huge diminishment in machining cost, was the key factor in cost lessening. Thus, in this streamlining issue the cost and the weight were managed independently. The auxiliary elementsconsidered forweightdiminishmentamid the improvement incorporate the clasping load factor, worries under the heaps, twisting firmness, and hub solidness. Cost diminishment is accomplished by utilizingC- 70 steel, which is break crack able. It kills sawing and machining of the rod and top mating faces and is accepted to lessen the production cos t by 25%. The weight distinction between the two when adjusted for jolt head weight was under 1%. This means that the precisionof thestrongmodel. Setup of the motor to which the con-rod has a place. Webster et al. (2000) performed three dimensional finite element analysis of a high diesel engine connecting rod. For this analysis they used the maximum compressive load which was measured experimentally, and the maximum tensile load which is essentially the inertia load of the piston assembly mass. The load distributions on the piston pin end and crank end were determined experimentally. They modeled the connecting rod cap separately, and also modeled the bolt pretension using beam elements andmulti point cons equations. G. M. Sayeed Ahmed [Oct.2014] replaced a broken connecting rod made of forged steel with aluminum alloys and carbon fiber. Connecting rods were manufactured by conventional method. Rods were tested in ideal conditions by applying variable loads. Authors found that weight of connecting rods was reduced and all performed to the level of expectation. Rods performed well at their extreme conditions. DIMENSIONAL PARAMETERS Table 1 Design Specifications Volume of cylinder 450cc Height of the bore 95mm Bore Radius 38.8mm Gas or Stream Pressure 35bar Small end Diameter of connecting rod pin 29.70mm Crank shaft pin diameter of connecting rod 39.14mm Diameter of big end 53.14mm Outer diameter of small end 43.71mm Height of big end 73.62mm Tensile yield stress 650 (min) – 950 (max) Load 15kgf (min), 27.19kgf (max) Maximum inertia force on bolts 6509.393N Based on the ranges indulged in design data book the minimum and maximum parameters are considered as case1 and case2. METHODOLGY 4.1 Modelling of connecting rod in CATIA V5 CATIA is started as an in-house developmentin1977 byFrench aircraftmanufacturer AVIONSMARCELDASSAULT, atthattime customer of the CADAM software to develop Dassault's Mirage fighter jet. It was later adopted by the aerospace, automotive, shipbuilding, and other industries. CATIA name is an abbreviation for Computer Aided Three- dimensional Interactive Application. The French Dassault Systemsis theparentcompanyand IBM participateinthe software’s and marketing, and catia is invades broad industrial sectors. Based on the design particulars above perished the modelling is carried out. The big end and small end are modelled. Boththe ends are of connecting rod are assembled by using temporary joints i.e, nut and bolts. Fig Modelling of parts of connecting rod Fig Assembled connecting rod The model is converted into “stp” to undergo the analysis
- 3. International Journal of Trend in Scientific Research and Development (IJTSRD) @ www.ijtsrd.com eISSN: 2456-6470 @ IJTSRD | Unique Paper ID - IJTSRD23182 | Volume – 3 | Issue – 3 | Mar-Apr 2019 Page: 1014 4.2 Analysis of Connecting Rod by ANSYS 18.1 ANSYS a product of ANSYS Inc. Is a world's leading, widely distributed and popular commercial CAE package. It is widely used by designers/analysis in industries such as aerospace, automotive, manufacturing, nuclear, electronics,biomedical, and much more. ANSYS provides simulation solution that enables designers to simulate design performance directly on the desktop. In this way, it provides fast efficient and cost efficient product development from design conceptstagetoperformance validation stage of product development cycle. It helps to acceleration and streamlines the product development process by helping designers to resolve issues relation to structural thermal fluid flow electromagnetic effect a combination of these phenomena acting together and soon. In ANSYS, the basics of FEA concepts, modelling and theanalysingof engineeringproblemusingANSYSworkbench. In addition, describe of importance tools and concepts given whenever required .this following simulation streams of ANSYS. 1. Structural Analysis Static Structural Analysis Transient Structural Analysis The geometry is imported into the workbench which is storedin“stp” format earlier.Theimportedmodelissegregatedintoset of finite elements by meshig Fig Mesh Generated With Default Mesh Controls The supports and loads are to be specified based on those boundary conditions the analysis is carried out. Also the material specification should be done Fig Choosing the Supports and Loads from Drop-Down 4.2.1 For C-70 Steel Static Structural CASE 1: Fig Total Deformation and Equivalent Stress of connecting rod at first interval Fig Total Deformation and Equivalent Stress of connecting rod at second interval
- 4. International Journal of Trend in Scientific Research and Development (IJTSRD) @ www.ijtsrd.com eISSN: 2456-6470 @ IJTSRD | Unique Paper ID - IJTSRD23182 | Volume – 3 | Issue – 3 | Mar-Apr 2019 Page: 1015 CASE 2: Fig Total Deformation and Equivalent Stress of connecting rod at first interval Fig Total Deformation and Equivalent Stress of connecting rod at second interval Transient structural CASE 1: Fig Total Deformation and Equivalent Stress of connecting rod CASE 2: Fig Total Deformation and Equivalent Stress of connecting rod Here, The Case 1 is nothing but the modal which is done by using minimal design parameters and load of 15kgf. The Case 2 is nothing but the model which is done by using maximal design parameters and with the load of 27.19kgf.
- 5. International Journal of Trend in Scientific Research and Development (IJTSRD) @ www.ijtsrd.com eISSN: 2456-6470 @ IJTSRD | Unique Paper ID - IJTSRD23182 | Volume – 3 | Issue – 3 | Mar-Apr 2019 Page: 1016 RESULTS AND DISCUSSIONS 5.1 C-70 Steel: Table 1 Results of C-70 Steel Static Structural Transient Structural First Interval Second Interval Total Deformation (mm) Equivalent Stress (Mpa) Total Deformation (mm) Equivalent Stress (Mpa) Total Deformation (mm) Equivalent Stress (Mpa) Case 1 (Minimum) 0.00020167 0.00022261 0.017118 Case 1 (Maximum) 0.359 289.39 0.39617 319.35 1.5597 Case 2 (Minimum) 0.00016014 0.00029027 0.19648 Case 2 (Maximum) 0.28156 177.06 0.51037 320.96 5.9941 5.2 Cast Iron: Table 2 Results of Cast Iron Static Structural Transient Structural First Interval Second Interval Total Deformation (mm) Equivalent Stress (Mpa) Total Deformation (mm) Equivalent Stress (Mpa) Total Deformation (mm) Equivalent Stress (Mpa) Case 1 (Minimum) 0.00021791 0.00024051 0.017118 Case 1 (Maximum) 0.65066 289.6 0.71803 319.59 1.5597 Case 2 (Minimum) 0.00016059 0.00029111 0.19648 Case 2 (Maximum) 0.51028 177.19 0.92499 321.2 5.9941 5.3 Aluminum: Table 1 Results of Aluminum Static Structural Transient Structural First Interval Second Interval Total Deformation (mm) Equivalent Stress (Mpa) Total Deformation (mm) Equivalent Stress (Mpa) Total Deformation (mm) Equivalent Stress (Mpa) Case 1 (Minimum) 0.00012773 0.00014094 0.017118 Case 1 (Maximum) 1.0033 287.3 1.1072 317.05 1.5597 Case 2 (Minimum) 0.00014416 0.00026134 0.19648 Case 2 (Maximum) 0.78685 175.74 1.4263 318.56 5.9941 5.4 Comparison of Total Deformation for different materials Chart 1 Comparison in between different materials
- 6. International Journal of Trend in Scientific Research and Development (IJTSRD) @ www.ijtsrd.com eISSN: 2456-6470 @ IJTSRD | Unique Paper ID - IJTSRD23182 | Volume – 3 | Issue – 3 | Mar-Apr 2019 Page: 1017 Here, The Case 1 is nothing but the modal which is done by using minimal design parameters and load of 15kgf. The Case 2 is nothing but the model which is done by using maximal design parameters and with the load of 27.19kgf. By observing the above chart it is clear that the component made up C-70 steel has lesser deformation than Aluminium and Cast Iron. Therefore it is more feasible to use the C-70 steel for the manufacturing of connecting rod. Being a composite material C-70 steel has weight deduction by around 10% of the original components, also the cost reduced according to that. CONCLUSION In this project the connecting rods are Designed concerning all the accessible limitations utilizing a data book as the reference, Later the item’s document are changed over to ".STP" record organize (standard trade of item document) and imported to Ansys workbenchtodiscoverdisfigurement and investigative valve regarding the model’s definitions. In this project the connecting rod was experienced with different sorts of materials like cast iron, aluminum, and C- 70 to discover total deformation, and equivalent stress by Using static auxiliary features which are included in Ansys workbench. It was observed that connecting Rod made up of Aluminum, and Cast Iron has higher intensity of stress induced as compared to connecting Rod made up of C-70. Alsothereisa great opportunity to improve the design. Hence C-70 is better choice for connecting rods. REFERENCES [1] D. Gopinathan, Ch V Sushma, (2015) “Design And Optimisation Of Four Wheeler Connecting Rod Using Finite Element Analysis” Materials Today Proceedings 2(2015)2291-2299 [2] G. M. Sayeed Ahmed,(oct. 2014)” Design, Fabrication And Analysis Of a Connecting Rod with Aluminum Alloys and Carbon Fiber” International Journal of Innovative Research in Science, Engineering and technology(IJIRSET),Vol.3,Issue 10, ISSN:2319-8753 [3] Pravardhan S. Shenoy , (2005), “Connecting Rod Optimization for Weight and Cost Reduction”, The University of Toledo, SAE intemational. 2005-01-0987. [4] Abhinav Gautam, K Priya Ajit, (Nov – Dec 2013) “Static Stress Analysis of ConnectingRodUsingFiniteElement Approach”, IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE), Volume 10, Issue 1 ISSN: 2278-1684