IRJET - Modeling & Analysis of Connecting Rod of Composite Material using E-Glass, Epoxy, MWCNT & Aluminum

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 07 Issue: 02 | Feb 2020 www.irjet.net p-ISSN: 2395-0072
© 2020, IRJET | Impact Factor value: 7.34 | ISO 9001:2008 Certified Journal | Page 1817
Modeling & Analysis of Connecting Rod of Composite material using E-
Glass, Epoxy, MWCNT & Aluminum
Pawar P. N.1, Pawar R. S.2, Pawar R. V.3, Jadhav S. S.4, Mr. Deshpande G. G.*,
Mr. Gunjegaonkar V.P.*
1-4Student, Department of Mechanical Engineering, SIET (Poly.), Paniv, Maharashtra, India
*Lecturer, Department of Mechanical Engineering, SIET (Poly.), Paniv, Maharashtra, India
---------------------------------------------------------------------***----------------------------------------------------------------------
Abstract - The main purpose of this paper is to present the
idea of designing connecting rod with minimumcostaswellas
by using different materials such as E-Glass, Epoxy, MWCNT
and Aluminum. Here we are using these materials for
improving various properties which are better than existing
material. In general, forged steel has a wild scope of
application for manufacturingofconnectingrod. Butthere are
few of the limitations of forged steel which can be recovered
with the help of these materials. The overall result of this
project is to provide an alternative for existing material.
Key Words: Design, Manufacturing, Compositematerial,
properties of material, connecting rod.
1. INTRODUCTION
Connecting rod isa mechanical elementusedtotransfer
energy from piston to crank. Generally it consists of two
ends namely bigger end and small end. Small end is used to
connect piston by using gudgeon pin and bigger end is used
to connect camshaft.
During each rotation of thecrankshaft,a connecting rod
is often subject to large and repetitive forces: shear
forces due to the angle between the piston and the
crankpin, compression forces as the piston moves
downwards, and tensile forces asthepistonmovesupwards.
These forces are proportional to the engine speed (RPM)
squared.
Failure of a connecting rod, often called "throwing a
rod,” is one of the most common causes of catastrophic
engine failure in cars, frequently driving the broken rod
through the side of the crankcase, and therebyrenderingthe
engine irreparable. Common causesofconnectingrodfailure
are tensile failure from high engine speeds, the impact force
when the piston hits a valve (due to a valve train problem),
rod bearing failure (usually due to a lubrication problem, or
incorrect installation of the connecting rod.).
2. LITERATURE REVIEW
Suraj Pal [1] “Design Evaluation and Optimization of
Connecting Rod Parameters Using FEM” In this paper Finite
element analysis of single cylinder four stroke petrolengines
is taken for the study; Structural systems of Connecting rod
can be easily analyzed using Finite Element techniques. So
firstly a proper Finite Element Model is developed using Cad
software Pro/E Wildfire 4.0.Then static analysis is done to
determine the von Misses stress, shear stress, elastic strain,
total deformation inthepresentdesignconnectingrodforthe
given loading conditions using Finite Element Analysis
Software ANSYS .In the first part of the study, the static loads
acting on the connecting rod, After that the work is carried
out for safe design.
G. Naga Malleshwara Rao [2] “Design Optimization and
Analysis of a Connecting Rod using ANSYS” The main
Objective of this work is to explore weight reduction
opportunities in the connecting rod of an I.C. engine by
examining various materials such as Genetic Steel,
Aluminium, Titanium and Cast Iron. This was entailed by
performing a detailed load analysis.
K. Sudershan Kumar [3] “Modeling and Analysis of Two
Wheeler Connecting Rod” Thispaperdescribesmodelingand
analysis of connecting rod. In this project connecting rod is
replaced by Aluminium reinforced with Boron carbide for
SuzukiGS150R motorbike. A 2D drawing is drafted from the
calculations. A parametric model of connecting rod is
modeled using PRO-E 4.0 software. Analysis iscarried out by
using ANSYS software.
B. Anusha, C. VijayaBhaskar Reddy [4] “Modeling and
Analysis of Two-wheeler Connecting Rod byUsingANSYS”In
this paper a static analysis is conducted on a connecting rod
of a single cylinder 4-stroke petrol engine. The model is
developed using Solid modeling software i.e. PRO/E (Creo-
parametric). Further finite element analysis is done to
determine the von-misses stresses shear stress and strains
for the given loading conditions.
B. Anusha, Dr. C. VijayaBhaskar Reddy [5] “Comparison Of
Materials For Two- Wheeler Connecting Rod Using ANSYS”
The modeled connecting rod imported to the analysis
software i.e. ANSYS. Static analysis isdonetodeterminevon-
misses stresses, strain,shearstressandtotal deformation for
the given loading conditions using analysis software i.e.
ANSYS. In this analysis two materials are selected and
analyzed. The software results of two materials are
compared and utilized for designing the connecting rod.
Mr. H. B. Ramani [6] “Analysis of Connecting Rod under
Different Loading Condition Using ANSYS Software” In this
study, detailed load analysis was performed on connecting
rod, followed by finite element methodinAnsys-13medium.

In this regard, In order to calculate stress in Different part of
connecting rod, the total forces exerted connectingrod were
calculated and then it was modeled, meshed and loaded in
ANSYS software. The maximum stresses in different parts of
connecting rod were determined by Analysis.Themaximum
pressure stress was between pin end and rod linkages and
between bearing cup and connecting rod linkage. The
maximum tensile stress was obtained in lower half of pin
end and between pin end and rodlinkage.Itissuggestedthat
the results obtained can be useful to bring about
modification in Design of connecting rod.
Dr. N. A. Wankhede, Suchita Ingale [7], admits a paper
attempts to design and analyze the connecting rod used in a
diesel engine in context of the lateral bending forces acting
along its length during cycle of it The lateral bending stress
are commonly called as whipping stress and this whipping
stress forms the base ofevaluationofperformanceofvarious
materials that can be used for manufacturing of connecting
rod. The conventional material used is steel which is design
using CAD tool which is CATIA V5 and subsequently
analyzed for bending stress acting on it in the arena of finite
element analysis using ANSYS workbench 14.5 and this
procedure is followed for different material which are
aluminum 7075 , aluminum 6061 and High StrengthCarbon.
Bansal [8], conducted a dynamic simulation on a connecting
rod made of aluminum alloy using FEA. In this analysis of
connecting rod were performed under static load for stress
analysis and optimization. Static load analysis was
performed to determine the in von-mises stresses of the
connecting rod.
3. POPOSED WORK:
In this project we are going to perform following
activities,
 Existing material of connecting rod and their
properties
 Failure Analysis
 Suggest Alternative material for connectingrodand
their properties
 Design of connectingrodby usinganalytical method
 Modeling of proposed connecting rod with suitable
material by using Solidworks
 Analysis of proposed model by using ANSYS.
4. MODELING & ANALYSIS OF PROPOSED DESIGN
Solidworks is a 3D solid modeling package which allows
users to develop full solid models in a simulated
environment for both design and analysis. InSolidworks, we
sketch ideas and experiment with different designstocreate
3D models. Solidworks is used by designers, engineers, and
other professionals to produce simple and complex parts,
assemblies, and drawings. Designing in a modeling package
such as Solidworks is beneficial because it saves time, effort,
and money that would otherwise be spent prototyping the
design.
Fig-1: Model of Connecting Rod (Sample Design)
The basis of FEA relies on the decomposition of the
domain into a finite number of sub domains (elements) for
which the systematic approximatesolutionisconstructed by
applying the variationorweightedresidual method.In effect,
FEA reduces the problem to that of a finite number of
unknown by dividing the domains into elements and by
expressing the unknown field variable in terms of the
assumed approximatingfunctionwithin eachelement.These
functions (also called interpolation functions) are defined in
terms of the values of the field variables at specifics points,
referred to as nodes. Nodes are usually located along the
element boundaries and are connectedtoadjacent elements.
ANSYS Mechanical is a Workbench application that can
perform a variety of engineering simulations, including
stress, thermal, vibration, thermo-electric, and magneto
static simulations. A typical simulation consists of settingup
the model and the loads applied to it, solving for the model's
response to the loads, the design has 20929 nodes and
11628 elements.
4. MATERIAL SELECTION
In previous chapters, we have seen the properties
and analysis of forged steel. Other thanforgedsteel there are
few different alloys are used for the production of
connecting rod such as;AlloySteel,Aluminiumalloy,Powder
Metals etc.
We are going to discuss about comparison of different
materials in this chapter,
Properties
Forged
Steel
Powder
Metal
C-70
Alloy
Steel
Young’s Modulus 201 199 212
Yield Strength 700 588 574
Ultimate Tensile
Strength
938 866 966
Strength Coefficient 1400 1379 1763
Strain Hardening 0.122 0.152 0.193

Exponent
Density 7.806 7.850 7.700
Poisson’s Ratio 0.30 0.29 0.30
Fatigue Strength
Coefficient
1188 1493 1303
Fatigue Strength
Exponent
-0.0711 -0.1032 -0.0928
Fatigue Ductility Coeff 0.3576 0.1978 0.5646
Fatigue Ductility
Exponent
-0.5663 -0.5304 -0.5861
Cyclic Strength
Coefficient
1397 2005 1739
Cyclic Strain Hardening
Exponent
0.1308 0.1917 0.1919
These are the common materials used for
connecting rod. But as we already discussed in previous
chapters, these materials have limitations so we aregoing to
select different material with similarpropertiesandstrength
too. In considerations of above properties we are going to
choose a composite material having components like E –
Glass, Epoxy, Fly Ash etc. These components have an ability
to meet the specifications and properties with desired
manner.
The compositionofthecomponentsistobedeciding
after successful testing and analysis of the composite.
There are various materials are to be taken in
account for manufacturing of connecting rod by using
composite material. We are going to use E Glass, Epoxy,
MWCNT, and Aluminium for the production of connecting
rod. So let us take a review over the properties of these
materials,
Material: E – Glass Fiber
Composition: 54% SiO2 – 15% Al2O3 – 12% CaO
Property
Minimum
Value
Maximum
Value
Units (S.I.)
Atomic Volume
(average)
0.0088 0.009 m3/kmol
Density 2.55 2.6 Mg/m3
EnergyContent 100 120 MJ/kg
Bulk Modulus 43 50 GPa
Compressive
Strength
4000 5000 MPa
Ductility 0.026 0.028
Elastic Limit 2750 2875 MPa
Endurance
Limit
2970 3110 MPa
Fracture
Toughness
0.5 1 MPa.m1/2
Hardness 3000 6000 MPa
Modulus of
Rupture
3300 3450 MPa
Poisson's Ratio 0.21 0.23
Shear Modulus 30 36 GPa
Tensile
Strength
1950 2050 MPa
Young's
Modulus
72 85 GPa
Glass
Temperature
820 850 K
Maximum
Service
Temperature
620 630 K
Specific Heat 800 805 J/kg.K
Thermal
Conductivity
1.2 1.35 W/m.K
Thermal
Expansion
4.9 5.1 10-6/K
Breakdown
Potential
15 20 MV/m
Dielectric
Constant
6.13 6.33
Material: MWCNT (Multi Walled Carbon Nanotubes)
Properties of MWNTs
 Electrical: MWNTs are highly conductive when
properly integrated into a composite structure,
however, the outerwall alonehasconductiveproperties,
but the inner walls are not instrumental to conductivity.
 Morphology: MWNTs have a high aspect ratio with
lengths typically more than 100 times the diameter,and
in certain cases much higher. Their performance and
application are based not just on their aspect ratio, but
also on the degree of entanglement and the straightness
of the tubes; which in turn is a function of both the
degree and dimension of defects in the tubes.
 Physical: Defect–free, individual, MWNTs have an
excellent tensile strength and when integrated into a
composite, such as a thermoplastic or thermosets
compound can significantly increase its strength.
 Thermal: MWNTshavea thermal stabilityabove600°C,
as a result of the level of defects - and to a certain extent
on the purity; as a residual catalyst in the product can
also accelerate decomposition.
 Chemical: MWNTs are an allotrope of sp2 hybridized
carbon similar to graphite and fullerenes, and therefore
have high chemical stability. However, the Nanotubes
can be functionalized to enhance both the strength and
dispersibility of composites.
Material: Epoxy
 Low Shrinkage
 High strength
 Excellent adhesion to various substrates
 Effective electrical insulation
 Chemical and solvent resistance, and
 Low cost and low toxicity
 The tensile strength ranges from 90 to 120 MPa

 A tensile modulus ranging from 3100 to 3800 MPa
 Glass transition temperatures (Tg) that range from
150 to 220 ◦C
Epoxies are easily cured, and they are also compatible
with most substrates. They tend to wet surfaces easily,
making them especially suitable for composite applications.
Epoxy resin is also used to modify several polymers such
as polyurethane or unsaturated polyesters to enhance their
physical and chemical attributes.
Aside from the properties mentioned above, epoxy resins
have two main drawbacks which are their brittleness and
moisture sensitivity.
Material: Aluminum
Property Value
Atomic Number 13
Atomic Weight (g/mol) 26.98
Crystal Structure FCC
Melting Point (°C) 660.2
Boiling Point (°C) 2480
Mean Specific Heat (0-100°C) (cal/g.°C) 0.219
Thermal Conductivity (0-100°C) (cal/cms. °C) 0.57
Co-Efficient of Linear Expansion (0-100°C) (x10 -
6/°C)
23.5
Electrical Resistivity at 20°C (Ω.cm) 2.69
Density (g/cm3) 2.6898
Modulus of Elasticity (GPa) 68.3
Poisson’s Ratio 0.34
5. RESULT & DISCUSSION
Connecting rod is a major link whichconnectsthepiston
to the crankshaft and is responsible for transferring the
power from the piston to the crankshaft. In this project
Finite element analysis of connecting rod used in single
cylinder four stroke petrol engines is taken for the study.
Static stress analysis will be conducted on connecting rod
made up of two different materials viz. E-glass/Epoxy and
Aluminium composite reinforced with Carbon nano tubes.
Modeling and comparative analysis of connecting rod is
carried out in commercially used FEM software ANSYS
Workbench. Static structural analysis will do by fixing the
piston end and applying load at the crank end of the
connecting rod. Output parameters in static stress analysis
are von-Mises stress, Shear stress, total deformation, and
equivalent elastic strain for the given loading conditions.
We are going to put the recorded data by testing using
ANSYS in the manner of comparison with the previous ones.
In this project, we are going to do simple comparison and
other relevant analysis for providing the detailed
investigation about the topic.
6. CONCLUSION
Solid modeling of connecting rod for four stroke single
cylinders has been done using FEA tool ANSYS Workbench.
On the basis of this study following conclusion has been
made:
o Maximum von-Mises stress for E-Glass/Epoxy and Al-2
CNTs composite should be higher than that of forged
steel and powder metal.
o Connecting rod made from Al-MWCNTs will have less
weight than that of E-Glass/Epoxy.
This will get after comparing the results obtained
from the analysis for two different materials it has been
found that the stress induced in the Al-MWCNTs composite
is less than the E-Glass/Epoxy.
7. REFERENCES
[1] Suraj Pal, “Design Evaluation and Optimization of
ConnectingRodParametersUsingFEM”,International
Journal of Engineering and Management Research,
Vol.-2, Issue-6, December 2012, ISSN No.:2250-0758,
Pages: 21-25.
[2] G. Naga Malleshwara Rao, “Design Optimization and
Analysis of a Connecting Rod using ANSYS,”
International Journal of Science and Research (IJSR),
India Online ISSN: 2319-7064.
[3] K. Sudershan Kumar et al., “Modeling and Analysis of
Two Wheeler Connecting Rod,” International Journal
of Modern Engineering Research (IJMER), Vol.2,
Issue.5, Sep-Oct. 2012, pp-3367-3371.
[4] B. Anusha, C.Vijaya Bhaskar Reddy, Modeling and
Analysis of Two Wheeler Connecting Rod by Using
Ansys, IOSR Journal of Mechanical and Civil
Engineering (IOSR-JMCE), Volume 6, Issue 5 (May. -
Jun. 2013), PP 83-87.
[5] Mr. H. B. Ramani, 2 Mr.Neeraj Kumar, 3 Mr. P. M.
KasundraW. Li, D. Li and J. Ni, “Analysis of Connecting
Rodunder Different Loading Condition Using Ansys
Software” International Journal of Engineering
Research & Technology (IJERT) Vol. 1 Issue 9,
November- 2012 ISSN: 2278-0181
[6] Leela Krishna Vegi, Venu Gopal Vegi."Design And
Analysis of Connecting Rod Using Forged steel
“.International Journal of Scientific & Engineering
Research, Volume 4, Issue 6, June-2013. 2081 ISSN
2229-5518
[7] Prof. Vivek C. Pathade1, Dr. Dilip S. Ingole, “Stress
Analysis of I.C.Engine Connecting Rod by FEM and
Photoelasticity” IOSR Journal of Mechanical and Civil
Engineering (IOSRJMCE) e-ISSN: 2278-1684 Volume
6, Issue 1 (Mar. - Apr. 2013), PP 117-125.
[8] Kuldeep B, Arun L.R, Mohammed Faheem “Analysis
and Optimization of Connecting Rod Using ALFASiC
Composites”, ISSN: 2319- 875, International Journal
of Innovative Research in Science, Engineering and
Technology, Vol. 2, Issue 6, June 2013.

[9] Prof. N. P. Doshi, 1 Prof .N. K. Ingole “Analysis of
Connecting Rod Using Analytical and Finite Element
Method.”International Journal ofModernEngineering
Research” (IJMER) Vol.3, Issue.1, Jan-Feb. 2013,ISSN:
2249-6645.
[10] Ram Bansal, “Dynamic simulation of connecting rod
made of aluminum alloy using finite element analysis
approach”, IOSR Journal of Mechanical and Civil
Engineering, Volume 5, Issue 2, pp. 01-05, Jan. - Feb.
2013.

IRJET - Modeling & Analysis of Connecting Rod of Composite Material using E-Glass, Epoxy, MWCNT & Aluminum

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