Presentation Title - 1

Subject: Machine design

style : Design of I C Engine Parts
• FontChapter
• ComicTopic Design of Connecting rod
Sans:MS
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Prof Vishal T Patel

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 Connecting rod of I C Engine
The connecting rod is the intermediate member between the piston and the
crankshaft.

Its primary function is to transmit the push and pull from the piston pin to
the crankpin and thus convert the reciprocating motion of the piston into the
rotary motion of the crank.

It consists of a long shank, a small end and a big end. The cross-section of
the shank may be rectangular, circular, tubular, I-section or H-section.

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 Connecting rod of I C Engine
Forces acting on the connecting rod

The various forces acting on the connecting rod are as follows:

(1) Forces on the piston due to gas pressure and inertia of the reciprocating
parts

(2) Forces due to inertia of the connecting rod

(3) Forces due to friction of the piston rings

(4) Forces due to friction of the piston pin bearing and crank pin bearing

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Design of connecting rod

Design of Shank with I section

Design of shank with Bending stress

Design of Small end

Design of Big end

Design for Bolts of Big end Bearing cap

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Selection of Cross section
Area of Section, A1 – A2
A = 11 t2
Moment of Inertia about X-X,
Ixx = (419/12) * t4
Moment of Inertia about Y-Y,
Iyy = (131/12) * t4

Ixx / IYY = 3.2

Radius of Gyration,
Kxx = 1.78 * t
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Forces due to gas pressure and inertia of reciprocating parts

FP = Forces due to gas pressure on piston

FN = Side thrust force

Fc = Resultant force on connecting rod

Φ = angle of inclination of connecting rod

with the line of stroke

Θ = angle of inclination of crank from top

dead center position

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Forces due to gas pressure and inertia of reciprocating parts

Maximum gas load occurs shortly after the dead center position and at this
instant ( φ = 3.3 ),

φ = 3.3 and cos φ = cos 3.3 = 0.9983 = 1

𝜋
Fc = 𝐷2 * Pmax
4

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 Buckling of connecting rod in the plane of rotation

Rankine’s formula

𝝈𝒄 ×𝑨
Fcr = 𝒍
𝟏+𝐚 ( )𝟐
𝑲𝒙𝒙

Where, Fcr = Fc * Nf
𝝈𝒄 = Compressive yield stress (N/mm2)
A = Cross sectional area of connecting rod
a = constant = 1/7500

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 Check for transverse bending (whipping) stress

Transverse bending or whipping stress is calculated at speed N,

ωmax = 2πN/60, rad/s.

σbw = Mx / Zxx

Where, Mx = m1 * ω2 * r * l2 / 9 3

m1 = ρ * A

Where, m1 = mass of connecting rod per unit length kg/m

ρ = density of material of connecting rod = given or 3800 kg/mm3

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Check for transverse bending (whipping) stress

σbw = Mx / Zxx

Zxx = Ixx / H/2

= 13.97 t2

now from σall check the design is safe or not.

If σbw < σall then design is safe otherwise design is unsafe.

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 Design of Small End

1. Diameter of piston pin (dp)

𝝅
Fc = 𝑫𝟐 * Pmax
𝟒

Fc = dp * lp * (Pb)p

Where, lp = length of piston pin = 1.5 to 2 dp, mm

(Pb)p = permissible bearing pressure for piston pin

2. Internal Diameter of small end (dpi)

dpi = dp + 2 * thickness of Bearing bush

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 Design of Big End

1. Diameter of crank pin (dc)

𝝅
Fc = 𝑫𝟐 * Pmax
𝟒

Fc = dc * lc * (Pb)c

Where, lc = length of Crank pin = 1.25 to 1.5 dc

(Pb)c = permissible bearing pressure for Crank pin

2. Internal diameter of Crank pin (dci)

dci = dc + 2 * thickness of Bearing bush

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 For Big end cap and Bolts (Diameter of bolts)

Total reciprocating mass

mr = mass of position + (mass of connecting rod)/3

mr = mp + (mc / 3)

Now, Maximum Inertia force,

Fimax = mr * ω2 * r [ 1 + (1/n)]

Where n = l / r = length of connecting rod / crank radius

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 For Big end cap and Bolts (Diameter of bolts)

𝜋
From this equation, Fimax = 2 * ( ∗ dcb2 ) σbt
4

where, dcb = core diameter of bolts

From core diameter of Bolt,

We can find bolt diameter

db = dcb / 0.84

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 For Big end cap and Bolts (Thickness of cap)
Thickness of cap (tc),

σ b = Mb * y / I

Mb = Fimax * x / 6
𝜋
Fimax = 2 * ( ∗ dc2 ) σbt
4

Where, x = center distance between bolts = dc + 6 + db + 3

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 For Big end cap and Bolts (Thickness of cap)
Thickness of cap (tc),

σbw = Mb * y / I

where, y = tc / 2

I = (bc * tc3) / 12

means subject the tc and you will get the answer of it.

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