MODELLING AND STATISTICAL

ANALYSIS OF EN 18 CONNECTING ROD

USING FEA
REPORT
SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENT FOR
Six Month Industrial Training
AT
EMSON TOOLS MFG. CORP. LTD.

SUBMITTED BY

Harjeet Singh
Mechanical Engineering
College Roll No. 112142
Univ. Roll No. 1136844

Mechanical Engineering Department

BABA BANDA SINGH BAHADUR ENGG. COLLEGE

ACKNOWLEDGEMENT
The authors would like to express a deep sense of gratitude and thanks profusely to Dr. M.S.
Saini, (Director, Baba Banda Singh Bhadur Engg. College, Fatehgarh Sahib). Without the wise
counsel and able guidance, it would have been impossible to complete the report in this manner.
The constant guidance and encouragement received from Mr. H.S Sethi (HOD ME) and Dean
T&P, GNDEC Ludhiana has been of great help in carrying out the project work and is
acknowledged with reverential thanks.
The author would like to express a deep sense of gratitude and thanks profusely to Mr. Rakesh
Kumar (Training Supervisor, EMSON tool manufacturing corporation limited Ludhiana)
Without the wise counsel and able guidance, it would have been impossible to complete the
report in this manner.
The author also expresses gratitude to training co-ordinator Er. Rajeev Sukhija. The author
expresses gratitude to other faculty members of Mechanical Engineering department of Baba
Banda Singh Bhadur Engg. College, Fatehgarh Sahib for their intellectual support throughout the
course of this work.
Finally, the author is indebted to all whosoever have contributed in this report work (friends
name here). Without their encouragement it would not have been possible to complete the
project in such an efficient manner.

Harjeet Singh

Certificate
I hereby certify that the work which is being submitted in this project titled MODELLING
AND STATISTICAL ANALYSIS OF EN 18 CONNECTING ROD USING FEA, in partial
fulfillment of the requirement for the award of degree of Bachelors of Technology in
Mechanical Engineering submitted in Baba Banda Singh Bhadur Engg. College, Fatehgarh
Sahib, is an authentic record of my own work carried out under the supervision of Mr. Rakesh
Kumar (Training Supervisor, EMSON tool manufacturing corporation ltd. Ludhiana.
.

(Harjeet Singh)
Class. Roll No. 112142
Univ. Roll No. 1136844

This is to certify that the statements made above by the candidate are correct and true to the best
of my knowledge.

Mr. Rakesh Kumar

EMSON tools manufacturing corporation ltd. Ludhiana

I as training co-ordinator certify the statement made above by the candidate are acoorect and true
to the best of my knowledge.

Er. Rajeev Sukhija

(Training Co-ordinator)

Abstract
The main objective of this study is to build a Finite Element Model of a piston
connecting rod (also called a conrod) and study the stresses induced due to the forces
exerted on it in use in an internal combustion engine. The deformation of the rod will
also be studied and an optimized simulation obtained. This preliminary report will outline
the approach followed towards the building of the model, the forces applied to the
connecting rod, modelling of the rod and a preliminary static analysis of the connecting
rod using Ansys. First, the loads on the connecting rod were obtained as a function of
crank angle. The dimensions of the rod were measured from an actual conrod, and a
model was created in Solidworks.

This model was then imported into Ansys for

evaluation. Another simulation software, Engine Sim, was used to find the pressure in
the cylinder, along with angular acceleration as a function of
important to know the

crank angle. It is very

acceleration of the conrod/pistion assembly as it will generate

inertia loads on the connecting rod which may be relatively high at high rpm. In this
report, a static finite element analysis was carried out for the maximum force on the
conrod at a constant engine speed. Inertial loads were not considered in the simulation,
but will be included in subsequent analyses and the conrod was considered to be
homogenous with no residual stresses.
The forces on the connecting rod were calculated from the pressure distribution
chart in the cylinder. The maximum pressure at the TDC will result in the maximum
force onto the piston which will get transferred to connecting rod (neglecting friction
force between piston rings and cylinder). Also, we are not considering the inertial
forces due to acceleration change with respect to crank angle, which may further
add to pressure forces. This acceleration was calculated by using kinematics theory.
Angular acceleration values will be used in subsequent analyses to calculate the
inertial loads. It seems that the connecting rod will always be in compression or
bending but it is the inertial loads which will play the most important role in providing
tensile loads at TDC just before the suction stroke. The EN18 material used at EMSON,
Ludhiana is studied under stress and strain conditions. A Better composition material that will
perform better under stress and strain conditions is proposed and statistically analyzed.