Volume 6, Issue 1 MAY 2017

DESIGN AND ANALYSIS OF CONNECTING ROD

1
GANTA.KRISHNARJUNA REDDY 2BADDE NAIK VADITHE

1pg Scholar, Department of Mechanical Engineering, nalanda institute of engineering and technology, satenapalli,
Guntur, Andhra Pradesh 522438
2
Associate Professor of Mechanical Engineering, nalanda institute of engineering and technology, satenapalli,
Guntur, Andhra Pradesh 522438

ABSTRACT Titanium alloy 42CrMo4 (Special alloy steel),

Aluminum metal matrix (KS1275)
Connecting rod is one of the most important part in
automotive engine. Connecting rod is the link By applying these boundary conditions on connecting
between piston and crank shaft. Which it converts rod the unknown variables such as stress,
reciprocating motion of piston into rotary motion of deformation, strain, and maximum shear stress are
crank shaft. In internal engines connecting rod is found using the FEA based software (ANSYS).
mainly made of steel and aluminum alloys (for light 1. INTRODUCTION
weight and absorb high impact loads) or titanium (for In a reciprocating position engine to the connecting
higher performance engines and for higher cost).As a rod or conrod connects the piston to the crank or
connecting rod is rigid, it may transmit either a push crankshaft, alongside the crank they form a simple
or a pull and so the rod may rotate the crank through mechanism converts reciprocating motion into
both halves of a revolution, i.e. Piston pushing and rotating motion. Connecting rod might also converts
piston pulling. Earlier mechanisms, such as chains, rotating motion into reciprocatory motion.
could only pull. In a few two-stroke engines, the Traditionally to development of engines they were
connecting rod is only required to push. first using this manner.

In which it undergoes structural deformations. Thus
in this project we are modeling a connecting rod in
solid works 2016 design software and doing static
structural analysis in ansys work bench 14.5
software.
Thus the part which is modeled is converted into igs
file to import in ansys work bench and static
structural analysis is carried out at 16 MPAof
pressure load by applying various materials including
composite materials, materials used in this project are
such as aluminum alloy (which is already existing),
As a connecting rod is rigid, might transmit either
push or pull and then the rod might rotate each halves
of a revolution i.e. Piston pushing and piston pulling.
Earlier mechanisms used like chains, may solely pull
in a very few two-stroke engines, the connecting rod
is barely needed to push. Now days, connecting rods
are best well-known through their use in a internal
combustion piston engines like automotive engines.
These are clearly different forms earlier types of the
connecting rods utilized in stream engines and steam
locomotives.

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Figure1.1 connecting rod with piston
1.1 Importance of Con Rod In Engine
The connecting rod is that the main a part of the
engine, additionally backbone of the engine. There is
most significant of the connecting rod in an engine.
Figure1.2 connecting rod in engine
Connecting rod rotates the crank shaft that helps the
engine to maneuver on or any of the vehicles to rotate
its wheels. It is designed to resist stresses from
combustion and piston movement.
Connecting rods is toward lighter weight
components. It should withstand with greater power
loads though it is lower in weight. The main purpose
of a connection rod is to provide fluid movement
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Volume 6, Issue 1 MAY 2017
between pistons and a crankshaft and therefore the
connecting rod is beneath tremendous stress from the
load represented by the piston.
When building a high performance engine, great
attention is paid to the connecting rods. The most
effective feature of a connecting rod ought to be the
uniform shape.
The cross section of rod beam design ought to be
spread and minimize stress load over massive
uniformly shaped areas. In operation stress are
generated and radiate from one or more source on a
component because the rod functions.
Top dead center (TDC) is the point at which the
piston is closest to the cylinder head. Bottom dead
center (BDC) is the point at which the piston is
farthest from the cylinder head. Displacement is the
volume that a piston displaces in an engine when it
travels from TDC to BDCduring the same piston
stroke.
2. LITERATURE SURVEY
Hippoliti (1993) reported design methodology in use
at piaggio for connecting rod design, which
incorporates an optimization session moreover
neither the details of optimization nor the load under
which optimization was performed were discussed.
Two parametric fe using 2d plane stress and 3d
approach developed by the author were compared
with experimental results and have good agreements
and optimization procedure they developed was
based on the 2d approach.
Pai (1996) explains an approach to optimize shape of
connecting rod subjected to a load cycle and
consisting of the inertia load deducted from gas load
as one extreme and peak inertia load exerted by the
piston assembly mass as the other extreme, with
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fatigue life constraint. Fatigue life defined as the sum
of the crack initiation and crack growth lives, was
obtained using fracture mechanics principles. The
approach used finite element routine to first calculate
the displacements and stresses in the rod; these were
then used in a separate routine to calculate the total
life. The stresses and the life were used in an
optimization routine to evaluate the objective
function and constraints. The new search direction
was determined using finite difference approximation
with design sensitivity analysis. The author was able
to reduce the weight by 28%, when compared with
the original component.
Sonsino and esper (1994) his discussed the fatigue
based on sintered connecting rods design and it’s not
performing optimization of the connecting rod. They
also designed a connecting rod with a load amplitude
fa = 19.2 kn and with different regions being
designed for different load ratios (r), such as, in the
stem fm = -2.2 kn and r = -1.26, at the piston pin end
fm = -5.5 kn and r = -1.82, at the crank end fm = 7.8
kn and r = -0.42. Based on this measurements
performed preliminary fea followed by production of
a prototype.
Ishida et al. (1995) measured the stress variation at
the column center and column bottom of the
connecting rod, as well as the bending stress at the
column center. The plots, shown in figures 1.5 and
1.6 indicate that at the higher engine speeds, the peak
tensile stress does not occur at 360o crank angle or
top dead center. It was also observed 8 that the r ratio
varies with location, and at a given location it also
varies with the engine speed. The maximum bending
stress magnitude over the entire cycle (0o to 720o
crank angle) at 12000 rev/min, at the column
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centerwas found to be about 25% of the peak tensile
stress over the same cycle.
While investigating a connecting rod failure that led
to a disastrous failure of an engine, rabb (1996)
performed a detailed fea of the connecting rod. He
explains as well as modeled the threads of the
connecting rod, the threads of connecting rod screws,
the pre-stress in the screws, the diametral interference
between the bearing sleeve and the crank end of the
connecting rod, the diametral clearance between the
crank and the crank bearing, the inertia load acting on
the connecting rod, and the combustion pressure. The
analysis clearly indicated the failure location at the
thread root of the connecting rod, caused by improper
screw thread profile. The connecting rod failed at the
location indicated by the fea. An axi-symmetric
model was initially used to obtain the stress
concentration factors 9 at the thread root. These were
used to obtain nominal mean and alternating stresses
in the screw. A detailed fea including all the factors
mentioned above was performed by also including a
plasticity model and strain hardening. Based on the
comparison of the mean stress and stress amplitude at
the threads obtained from this analysis with the
endurance limits obtained from specimen fatigue
tests, the adequacy of a new design was checked.
Load cycling was also used in inelastic fea to obtain
steady state situation.
In a published sae case study (1997), a replacement
connecting rod with 14% weight savings was
designed by removing material from areas that
showed high factor of safety. Factor of safety with
respect to fatigue strength was obtained by
performing fea with applied loads including bolt
tightening load, piston pin interference load,
compressive gas load and tensile inertia load. The
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study lays down certain guidelines regarding the use
of the fatigue limit of the material and its reduction
by a certain factor to account for the as-forged
surface. They also indicate that buckling and bending
stiffness are important design factors that must be
taken into account during the design process. On the
basis of the stress and strain measurements performed
on the connecting rod, close agreement was found
with loads predicted by inertia theory. The study also
concludes that stresses due to bending loads are
substantial and should always be taken into account
during any design exercise.
3. PROBLEM STATEMENT
3.0 problem statement:
Connecting rod is one of the most critical
components internal combustion. Connecting rod is
connected in between the piston and crank shaft.
While the crank shaft rotates piston moves from
bottom dead centre to top dead centre vice versa. In
this process connecting rod undergoes stress and
deformation. Hence for the connecting rod when the
load is applied, how the stresses and strain are
induced in the component and deformation value, due
to applied load are analysed.
Decreasing these stresses and increasing stability
depends upon the materials applied. Thus in
industrial purpose optimization of connecting rod had
already started. Optimization is really important for
automotive industry especially. Optimization of the
component is to make the less time to produce the
product that is stronger, lighter and less total cost
productions. The design and weight of the connecting
rod influence on car performance. Hence, it effects
on the car manufacture credibility. Change in the
design and material results a significant increment in
weight and also performance of the engine. The
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structural factors considered for weight reduction
during the optimization include the buckling load
factor, stresses under the loads, bending stiffness, and
axial stiffness. Thus, the component can give the
higher strength, efficient design and lighter that
would create a major success in the automotive and
manufacturing industry. Among the main objectives
are to improves the engine performance and also to
strengthen the product that is ensure the safety of
human being.
Connecting rod failed due to insufficient strength to
hold the load. Increasing the strength, automatically it
will longer the life cycles of the connecting rod. In
this study, the design of the connecting rod will be
modeled and at the same time increase the strength.
And different materials are applied for gaining more
stability. The study will be focus on the finite
element modeling and analysis. From the analysis
results, the decision whether connecting rod needs to
change in material, load, design etc factors which
induces stress in the component.
3.1 objectives of project
The objectives of the project are as follows
(i) To develop structural modeling of connecting rod
(ii) To perform finite element analysis of connecting
rod
(iii) Suitable material study
(iv) Study of load factors
(v) Study of stress, strain deformation induced in the
connecting rod
(vi) To develop structural optimization model of
connecting rod
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4. DESIGNING OF A CONNECTING ROD BY

USING SOLID WORKS
4.1 Introduction To Solidworks :
Solidworks mechanical design automation software is
a feature-based, parametric solid modeling design
tool which advantage of the easy to learn windows TM
graphical user interface. We can create fully associate
3-D solid models with or without while utilizing
automatic or user defined relations to capture design
intent. Sketch & extrude

Parameters refer to constraints whose values

determine the shape or geometry of the model or
assembly. Parameters can be either numeric
parameters, such as line lengths or circle diameters,
or geometric parameters, such as tangent, parallel,
concentric, horizontal or vertical, etc. Numeric
parameters can be associated with each other through
Extrude cut it to 2mm
the use of relations, which allow them to capture
design intent
A Solid Works model consists of parts, assemblies,
and drawings.
 Typically, we begin with a sketch, create a
base feature, and then add more features to
the model. (One can also begin with an
imported surface or solid geometry).
 We are free to refine our design by adding,
Make Holes
changing, or reordering features..
4.2 Design procedure of Connecting Rod
For designing the Connecting Rod the following
procedure has to be follow

draw a sketch on front plane for bolting holes

2d sketch of a connecting rod

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mirror is used for making for symmetry on both sides
fillet the edges for smooth surfacing
Different Views of Connecting Rods
5. ANALYSIS DEFINATION & STEPS:
The steps needed to perform an analysis depend on
the study type. You complete a study by performing
the following steps:
 Create a study defining its analysis type and
options.
 If needed, define parameters of your study.
A parameter can be a model dimension,
material property, force value, or any other
input.
 Define material properties.
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 Specify restraints and loads.
 The program automatically creates a mixed
mesh when different geometries (solid,
shell, structural members etc.) exist in the
model.
 Define component contact and contact sets.
 Mesh the model to divide the model into
many small pieces called elements. Fatigue
and optimization studies use the meshes in
referenced studies.
 Run the study.
 View results.
5.1 Analysis on connecting rod by using ansys 14.5
work bench software
The analysis of connecting rod models are
carried out using ANSYS software using Finite
Element Method. Firstly the model files prepare in
the SOLIDWORKS SOFTWARE.
Then are exported to ANSYS software as an IGES
files as shown in figure
Figure5.1 structural analysis
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5.2 Materials and their properties relevant governing equations numerically at each of
the nodes of the mesh. The governing equations are
almost always partial differential equations,
and Finite element method is used to find solutions to
such equations. The pattern and relative positioning
of the nodes also affect the solution, the
computational efficiency & time.

5.3 Load & fixed support

• Fixed support

Mesh Type: Tetrahedral

No. of nodes: 16190
No. of elements: 8821
6. STRUCTRUAL ANALYSIS RESULTS
6.1 Material: Aluminium Alloy
Maximum Stress

• Load
Load at 16 MPA

Total Deformation

5.3 Meshing
Meshing is probably the most important part in any
of the computer simulations, because it can show
drastic changes in results you get. Meshing means
you create a mesh of some grid-points called 'nodes’.
It's done with a variety of tools & options available in
the software. The results are calculated bysolving the

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Maximum Strain 6.3 Material: 42CrMo4

Maximum Stress

6.2 Material: Titanium Alloy Total Deformation

Maximum Stress

Total Deformation Maximum Strain

6.4 Material: Al Metal Matrix

Maximum Strain Maximum Stress

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Total Deformation Mode 3

Maximum Strain

7.2 Material: Titanium Alloy

Mode 1

7. MODAL ANALYSIS RESULTS

7.1 Material: Aluminium Alloy
Mode 1 Mode 2

Mode 2 Mode 3

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7.3 Material: 42CrMo4

Mode 1

Mode 2

For comparisons of the results obtained From the

static analysis result tables it is concluded that
Mode 3 42CrMo4 show least stress and least deformation &
strain value on same static load condition.

From the Modal analysis result tables it is concluded

that 42CrMo4 shows Less deformation results for
given frequency. Hence for both Structural and
Modal Analysis 42CrMo4 (Special Alloy Steel) it is
best suitable material for connecting rod.

RESULT TABLE CONCLUSION

 Brief study about connecting rod & it’s

working is done in this project
 Modeling and analysis of connecting rod is
done.
 Modeling of connecting rod is done in solid
works 2016 design software
 The file is saved as igs to import in ansys
workbench
 The analysis in ansys is extremely important
prior to the fabrication of connecting rod.

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 The static structural, & Dynamic analysis approach”. Isor journal of mechanical and
(modal analysis) has carried out in the ansys civil engineering, volume 10, issue 1(nov –
14.5 software package for connecting rod by dec. 2013), pp 47-51.
different materials like aluminum alloy,  Ram bansal et al.”Dynamic simulation of a
Titanium alloy , 42crmo4 (special steel connecting rod made of aluminium alloy
alloy) and Aluminum metal matrix using finite element analysis approach”. Isor
(KS1275) journal of mechanical and civil engineering,
 The material properties and brief volume 5, issue 2 (jan – feb. 2013), pp 01-
explanation about composites has given. 05.
 The utmost stress, strain and deformation  Kuldeep b et al. ”analysis and optimization
values of static analysis are tabulated on of connecting rod using alfasic
load condition of 16 MPA. composites”. Journal of ijirset, vol. 2, issue
 From result we conclude that on given load 6, june 2013.
condition of 16MPA Titanium alloy  Pravardhan s. Shenoy et al. “dynamic load
showing less deformation, while special analysis and optimization of connecting
alloy steel 42CrMo4 showing less rod”. In his thesis.
deformation value.  Gvsssharma andp.srinivasrao”process
 Hence the materials with low stress values capability improvement of an engine
are also preferable for the fabrication of connecting rod machining process.”
connecting rod.  K. Sudershnkumar, dr. K. Tirupathireddy,
 As titanium is very costly material its syedaltafhussain, ‘modeling and analysis of
application is limited can only use for aero two wheeler connecting rod’international
space industries. journal of modern engineering research vol
 Aluminum metal matrix which is less costly -2, issue-5, pp-3367-3371,sep-oct 2012
and less weight ratio showing nearly same  Suraj pal, sunilkumar,”design evaluation and
stress value of titanium and less deformation optimization of connecting rod paramaters
value after 42CrMo4 can consider best using fem” international journal of
material for automobile other than general engineering and management research vol -2
material. ,issue-6,dec 2012.
 Model analysis (Dynamic) is performed on  Vivek c. Pathade ,bhumeshwarpatle
three different modes; deformation values ,ajayn.ingale “stress analysis of ic engines
with respect to different frequencies are connecting rod by fem “international
noted and tabulated for each material. journal of engineering and innovative
technology, vol-1,issue-3,march 2012
REFERENCES
 Priyank d. Toliya, ravi c. Trivedi, prof.
 Abhinavgutam et al. “static stress analysis of Nikhil j. Chotai,”design and finate element
connecting rod using finite element analysis of aluminium-6351 connecting rod

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international journal of engineering and AUTHORS

management research and technology vol-
2,issue 5 may 2013
1. Ganta.Krishnarjuna Reddy
 S.shaari, m.m.rahman, m.m.noor, k.
Department of Mechanical Engineering,
Kadirgama and a.k. amirruddin “design of
connecting rod of internal combustion College name:Nalanda institute of
engine: a topology optimization
engineeringand technology , Village:
kantepudi
approachm”. National conference in
mechanical engineering research and post Mandal: sattenpalli, Dist: guntur
graduate studies( 2ndncmer 2010) 3-4 dec A.P, India, Pin:522438
2010, pp 155-166. Email id: gkrishnarjunareddy@gmail.com
 Bhuptanik.m “ structural analysis of bush
2.Baddenaik.vadithe
bearing for small end connecting rod using –
pro mechanica” issn 0975-0668x nov 12 to
Associate Professor of Mechanical Engineering,
oct 13, vol- 02, 2344-02
College name:Nalanda institute of
engineeringand technology ,Village: kantepudi
Mandal: sattenpalli, Dist: guntur
A.P, India, Pin:522438

Email id: bharathnaik117@gmail.com

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