CAREER EPISODE 3

PRELOAD AND STATIC ANALYSIS OF A TWO STAGE CONNECTING ROD FOR

AN AIR COMPRESSOR

3.1 Introduction

Project Title: - Preload And Static Analysis Of A Two Stage Connecting Rod For An Air
Compressor
Project Type: - Academic
Chronology: - Insert
Organization: - Ned University of Engineering and Technology
Location: - Karachi
Under guidance of: - Insert
Position: - Team leader

3.2 Background

3.2.1

A two-stage air compressor uses two cylinders and is very powerful. An air compressor is a
machine that increases the flow of air in a confined space. In industrial, commercial, and
personal settings, compressed air creates pressure and generates power. Pumps and compressors
usually use reciprocating engines as their power source. The connecting rod connects the piston
with the crankshaft and transmits power from the piston to the crankshaft. A structural behavior
study of the connecting rod was carried out to the ANSYS program in order to define the
structural behavior under static loads. A structural alloy steel material is taken into consideration
when analyzing connecting rods.

In this project, the preload and static analyses of an air compressor connecting rod were
analyzed. The different parameters and physical properties of the material, structural steel were
selected to perform the project. The model was designed based on the dimensions of the
connecting rod, which included the length, thickness, and diameter. Solid Works software
selected to create the 3D model of the connecting rod. In addition, once the model is finalized, it
is converted to IGES for analysis. Once the design was imported into the ANSYS software, the
connecting rod for the two-stage air compressor was analyzed. In addition, stress and
deformation were studied based on the load applied during analysis.
3.2.2 Objectives

The project aims to study the preload and static analysis of a two-stage connecting rod for an air
compressor. The other objectives were listed below,

 To reduce the failure rate of connecting rods and improve manufacturing methods.
 To analyze the maximum allowable stress by using structural alloy steel.

NED University of
Engineering &
Technology

Mechanical
Engineering
Department

Supervisor

Ashan (Team Other Members

Leader)

Figure 1 Organization chart

3.2.3 Roles and Duties

 To acquire information relating to the air compressors and also gain detailed knowledge
on the connecting rods utilized in air compressors
 To review the components and select the material for the design of the connecting rod.
 To perform theoretical calculations for the determination of the loads experienced by the
rod.
 To design the proposed connecting rod model in SolidWorks software.
 To conduct finite element based structural analysis on the connecting rod

3.3 PEA

3.3.1

In order to gather information related to the topic, I read various articles and research papers
before I began the project. Additionally, I followed the literature review relevant to the topic. I
studied the properties of the static analysis of the connecting rod. I also studied the properties of
the air compressor. I also learned about the uses of the air compressor in a personal life as well as
for the project. Additionally, I gained an understanding of the various parameters and devices
required to design a connecting rod. In addition, I talked with my team members regarding the
topic to get additional information. Also, I gain knowledge of the different sections that are used
in designing the connecting rod. In addition, I learned how to design 3D models using the solid
works software. Moreover, I understood how ANSYS software could be used for mechanical
machine design analysis.

3.3.2

Having studied the literature and learned valuable skills, I was able to move on to selecting the
materials and parameters of the project. For the connecting rod, I considered the LP cylinder, HP
cylinder and length of the connecting rod 185mm, thickness of the connecting rod of 35mm and
density of 3980kg/mm2. For the air compressor, I chose the high and low pressure cylinders, the
crankshaft, belt and motor. Further, I also considered the inlet and outlet conditions of air
compressor for two stages. Additionally, I considered the cast iron material characteristics of the
connecting rod, which included a Young Modulus of 175 MPa, a Poisson's ratio of 0.25, Yield
strength of 650 Mpa and Tensile strength of 900 Mpa. Further, I selected the materials for the
bolt that including the structure steel alloy of grade A 4340, size of the bolt of M8, Yield stress
of 950Mpa, ultimate tensile strength of 1050 Mpa, thread coefficient of the friction of 0.1, head
face coefficient of the friction of 0.1, pitch as 1.2mm, pitch diameter of 7.13mm, root diameter of
6.1mm respectively. Finall, I opted for SolidWorks as the design software and ANSYS for
conducting the structural analysis of the prepared design.
3.3.3

Having collected all the parameters and materials for the project, I turned my attention to
calculating the static and preload analyzes of the connecting rods of the two stages. As part of the
static analysis of the connecting rod, I determined the pressure constant for compressive and
tensile loading at the crank by using empirical equations. In addition, I also determined the
pressure constant for compressive and tensile loading at the piston pin end by using empirical
equations. As a next step I moved for the bolt preload on the connecting rod, I determined the
bolt preload from tensile stress and area of the bolt.

Assuming,

Low pressure cylinder diameter, dlp = 126mm

High pressure cylinder diameter, dhp = 68mm

Stroke length, ls = 86mm

Working pressure, Pmax = 12.5 bar

The normal load on the area of contact:

p= p 0 . cosθ

The uniformly distributed tensile loading over the 180⁰ angle:

π/2
Pt = ∫ [ p0 .(cos ¿ θ). rt ]dθ ¿
2

−π /2

π
¿ p0 .rt .( )
2

Pt
p0 =
π
rt .( )
2

Assuming the compressive load to be applied over an angle of 120o. The relation of this load with the
normal load can be given as:
π/3
Pc = ∫ [ p0 .(cos¿θ) . rt ] dθ ¿
−π / 3
¿ p0 (rt ) √ 3

Then,

Net load acting , P=Pmax × A

2
π × D HP
¿ 12.5 × =45396.014 N
4

Taking the value of compressive load, taking r = 17.5 mm and t = 35 mm for piston end and r = 24 and t =
35 for crank end, I got the tensile and compressive loading as:

For piston end,

45396.014 2
Compressive loading= =42.79 N /mm
17.5 ×35 × √ 3

4 5396.014 2
Tenisle Loading= =47.18 N /mm
π
17.5 ×35 ×
2

For crank end,

45396.014
Compressive loading= =31.2 N /mm 2
24 × 35× √3

45396.014
Tenisle Loading= =34.4 N / mm 2
π
24 × 35 ×
2

For the calculation of bolt pre-load,

I considered M8 size bolt having 0.15 thread coefficient, pitch as 1.25 mm, the pitch diameter, d2 and
root diameter, d3 as 7.16 mm and 6.52 mm. I assumed the initial tensile stress on the bolt to be 62% of
the yield strength. Then I calculated the pre bolt load on the bolt as:

π d 02
F i=( 0.62 ×σ y ) ×
4

( )
2 2
π d 2 +d 3
¿ ( 0.62 ×σ y ) × ×
4 2

¿ 20548.76 N
3.3.4

As I finished the calculations, I moved on to modelling the connecting rod in CAD. For
designing the 3D models of the connecting rod for the two-stage air compressor, I used the Solid
Works software. As a first step, I opened the software and created a 2D drawing according to the
dimensions. By using the circle command as well as the profile tool bars, I created all the steps in
the design process for the connection rod. In addition to using the sketch toolbar, I also
performed the filleting and grooving needed in the connection rod design. At the end of all this
process, I generated the final rendering of the three-dimensional model of the two-stage air
compressor connecting rod. I also converted the soli work drawing to IGES format before
conducting the analysis.

3.3.5

After I completed modeling the connecting rod, I turned my attention to analyzing it. To begin
the analysis, I opened up the ANSYS software and used a static structure analysis software
program. After I imported the model into the ANSYS software, I applied the A403 structural
steel material properties. During the analysis, I began by meshing the design using tetrahedral
elements of different size. I applied constraints in radial direction in the inner sleeve of the rod
and also applied the loading. I studied stress, strain, deformation, and safety factor by letting the
solver analyze these values. For the preload calculations on the bolt, I initially imported the bolt
model and applied steel as the material. I then meshed the model and applied the boundary
conditions to perform an analysis of the bolt preload calculations. I applied bolt preloads to the
connecting rod bolts during the analysis and then started the simulation

3.4 Technical Problems and Solutions

3.4.1

An error occurred while I was analyzing the connecting rod. When I assigned the materials to
ANSYS for the analysis of the connecting rod model. Based on the analysis of the model, I
discovered that the forged steel material had much more deformation than the specified limit. I
then discussed this issue with my team mates, but I did not receive any solutions. Furthermore, I
discussed the issue with my supervisor and he suggested that I resolve the issue by using
structural steel alloy material and performed the analysis. Afterward, I selected the alloy steel
material, assigned it to the model on ANSYS software, and then performed the analysis in the
same way as before. As I observed the results, I noted that the deformation fell below the
required limit this time. I had solved the error when I ran the analysis.

3.4.2

During the analysis of the connecting rod, I encountered another error. When I was analyzing the
connecting rod, I noticed that there were more stress results at the edges. In the next step, I
examined the design and attempted to determine what caused the solution. Having conducted a
few researches, I determined that the design of the connecting rods had a much higher stress at
the edges of the rods due to the sharp edges at the side of the connecting rod. Then, I redesigned
the connecting rod, and I used the fillet toolbar at the sharp edges of the rod, and then I
performed the analysis as before. As a result, I analyzed the results at the edges of the connecting
rod with a specified stress.

3.5 Creative Works

I created the CAD model of the two stage air pressure of the connecting rod. As I entered both
the parameters and dimensions into Solid Work. After that I modeled the 3D of the connecting
rod and converted into the IGES. Additionally, I mesh the design under the hexahedral elements
and then import it into ANSYS for analysis. Once the materials were assigned to ANSYS, I
defined the boundary conditions and ran the analysis.

3.6 Team Management

I assumed the responsibility of the team leader in this project and carried out management work
in addition to the project tasks. I executed the time management strategy for the project and also
the work division among the project members as per the skills and interests of the individual. I
maintained good relation with other professors and seniors and asked for their suggestions when
required. I held regular meeting to discuss the progress of the project with my supervisor and
team members. I noted all the results from the analysis and also the project findings which I used
to prepare the project report and presentations.

3.7 Codes

To know about the safety practices and standards regarding an air compressor, I reviewed IS
11461 (1985). Also, I studied ICS 21.240 for acquiring information relating to rotary-
reciprocating mechanisms.
3.8 Summary

The static structural analysis of a connecting rod used in two stage reciprocating compressor is
done in this project. The connecting rod was designed with cast iron as the material and steel was
used for the bolt design. The design was prepared in SolidWorks and the analysis process was
undertaken in ANSYS. From the analysis results, high amount of deformation and stress was
observed in the mid section of the bolt. The stress observed from the analysis was within the
allowable limit of the material so the design was considered to be safe.

I broadened my knowledge relating to air compressors and the type of connecting rods used in
them. I developed my team working and team management skills after completion of this project.