Design Evaluation Of Connecting Rod - IJRERD
International Journal of Recent Engineering Research and Development (IJRERD) ISSN: 2455-8761 www.ijrerd.com Volume 02 – Issue 07 July 2017 PP. 203-213 Design Evaluation of Connecting Rod Dipalee S. Bedse1 1 Department of Mechanical Engineering, Savitribai Phule Pune University Gokhale Education Society’s R.H. Sapat College of Engineering, Management Studies and Research, Nasik – 5,India. Abstract: The connecting rod (CR) is the main moving part and an important component of an internal combustion (IC) engine. The connecting rod is the intermediate member between the piston and the Crankshaft. It’s primary function is to transmit the push and pull from the piston pin to the crank pin, thus converting the reciprocating motion of the piston into rotary motion of the crank. The main objective of this paper is to Design evaluation through Finite Element Analysis for fatigue life of connecting rod used in Hero Honda Motor Cycle. Structural systems of connecting rod can be analyzed using Finite Element techniques. So firstly a proper Finite Element Model is developed using Cad software CATIA. Then the Finite element analysis is carried out to determine the stresses and displacement in the present design of the connecting rod for the given loading conditions using Finite Element Analysis software (HYPERMESH). Structural strength for the connecting rod will be verified over an Universal Testing Machine (UTM) for tensile loading. Based on the observations of the static FEA and the load analysis results, recommend the best alternative design for the connecting rod. Keywords: Connecting Rod, Finite Element Analysis, Modeling, Static I. Introduction The intermediate component between crank and piston is known as connecting rod. Connecting rod is also known as conrod and is used to connect the piston to crankshaft. As a connecting rod is rigid, it may transmit either a push or a pull and so the rod rotates the crank through both halves of a revolution, i.e. piston pushing and piston pulling. Earlier mechanisms, such as chains, could only pull. In a few two stroke engines, the connecting rod is only required to push. Today, connecting rods are best known through their use in internal combustion piston engines, such as automotive engines. These are of a distinctly different design from earlier forms of connecting rods, used in steam engines and steam locomotives. One source of energy in automobile industry is internal combustion engine. Internal combustion engine converts chemical energy into Mechanical energy in the form of reciprocating motion of piston. Crankshaft and Connecting rod convert reciprocating motion into rotary motion. Connecting rod is one of the important driving parts of Light vehicle engine it forms a simple mechanism that converts linear motion into rotary motion that means the connecting rod is used to transfer linear, reciprocating motion of the piston into rotary motion of the crankshaft.[6] IJRE RD II. Literature Survey P S Shenoy and A Fatemi (2006) are focused on detailed load analysis under service loading conditions was performed for a typical connecting rod, Priyank D. Toliya et al. (2013) Static analysis is done to determine the von Misses stress, elastic strain, total deformation in the present design, M.N. Mohammed et al. (2011)are focused on to analyze the connecting rod failure. The study applied a finite element analysis and metallographic examination ,M. Omid et al.(2008) in this case Finite element was first used to calculate the static displacement and stresses uder the maximum tension and compression and tension loading in the connecting rod of universal tractor, which when there used for critical points evaluation ,S.B.Chikalthankar et al.(2012)In this case the work complete connecting rod Finite Element Analysis (FEA) methodology. It was also performed a fatigue study based on Stress Life (SxN) theory, considering the Modified Goodman diagram ,Adila Afzal et al.(2011) is investigates and compares fatigue behavior of forged steel and powder metal connecting rods ,R,Luria, et al. (2013) are focused on the design of a set of dies employed to manufacture a connecting rod by forging a billet of nanostructured aluminum alloy ,Atish Gawale, et al.(2012) are focused on The design and weight of the connecting rod, Yongqi Liu and Ruixiang Liu (2013) are focused on the stress distribution and fatigue life of CR in light vehicle engine were analyzed using the commercial 3D finite element software, ANSYSTM III. Research Gap From the literature survey we conclude that most of the studies are done on IC Engines connecting rod, Heavy Vehicle connecting rod had focus on stress, critical surface of connecting rod ,weight of connecting rod, the connecting rod failure & structural analysis of connecting rod and all these results are carried out by 203 P a g e www.ijrerd.com
International Journal of Recent Engineering Research and Development (IJRERD) ISSN: 2455-8761 www.ijrerd.com Volume 02 – Issue 07 July 2017 PP. 203-213 FEA software and there is no any experimentation and validation results are found .In other side very less research work done on the stress distribution and fatigue life of CR in light vehicle engine are analyzed using the commercial 3D finite element software. The new analysis will examine the calculations for the stresses and fatigue failure of the component IV. Specification of the Problem The objective of the present work is to design a connecting rod based upon its fatigue life. CAD model of connecting rod will be created in CATIA and it’ll be analyzed in HYPERMESH and FEMFAT software. The Finite element analysis is done to determine the stresses and displacement in the present design of the connecting rod for the given loading conditions using Finite Element Analysis software (HYPERMESH). Structural strength for the connecting rod will be verified over an Universal Testing Machine (UTM) for tensile loading. As for the fatigue life determined by the FE analysis the same shall be compared with historical data with the sponsoring company. Recommend the best alternative design for the connecting rod through experimentation and validation. V. Objectives a) Find out the problem areas by studying the existing system of linkages in which identify the different parameters such as stresses, deflection and fatigue failure of the component for redesign of the connecting rod. b) CAD model of connecting rod will be created in CATIA and it’ll be analyzed in HYPERMESH software. c) To conduct test on Universal Testing Machine to find stress and deflection of existing connecting rod. d) To analyze the alternative geometry for connecting rod using suitable tools such as HYPERMESH software. e) To recommend the best alternative design for the connecting rod through experimentation and validation. VI. Specification of Existing Connecting Rod Specifications of Splendor 100CC Engine Displacement : 97.2CC Bore X Stroke : 50 X 49.5 (in mm) Max. Power : 5.5kW@8000rpm Max. Torque : 7.95Nm @5000rpm Compression Ratio : 9:1 Sr. no. 1. IJRE RD TABLE I Dimensions of Connecting Rod Parameters Value Length of connecting rod 123mm 2. Outer Diameter of Big end 39.02mm 3. Inner Diameter of Big end 30.19mm 4. Outer Diameter of small end 17.75mm 5. Inner Diameter of Small end 13.02mm TABLE III Material Properties of Connecting Rod[11] Material Selected Carbon Steel 204 P a g e Young’s Modulus(E) 210 Gpa Poisson’s Ratio 0.27- 0.3 Density 7860 Kg/mm3 www.ijrerd.com
International Journal of Recent Engineering Research and Development (IJRERD) ISSN: 2455-8761 www.ijrerd.com Volume 02 – Issue 07 July 2017 PP. 203-213 Tensile Strength 400-500 Mpa Compressive Strength 400 to 1000 Mpa Tensile Strain 10-20(%) VII. Mathematical Calculation A. Pressure Calculation Density of Petrol (C8H18), ρ 750 Kg/m3 750 x 10 -9Kg/mm3 Operating Temperature, T 293.15 K Mass Density x Volume m 750x10 -9 x 97.2x10 72.9x10-3 Kg Molecular weight of petrol, M 114.228x10 -3 Kg/mole Gas constant for petrol, R 8314.3/114.228x10-3 From Gas law equation PV mRT 72.79x10 3J/Kg.mol.K P mRT/V 72.9x10 -3x72.79x10 3x293.15/ (97.2x10 3) 16 MPa B. Design Calculation Gas Force Pressure x Cross section area of piston Fl P x π/4 x D2 16xπ/4x502 31415.93 N Inertia Force Stroke length, l 123mm Max. Angular speed, ω 2πNmax/60 Crank radius, r 49.5/2 24.75 mm n l/r 123/24.75 4.97 IJRE RD 2xπx8000/60 837.76 rad/s C. Inertia force FI m ω 2r(cosθ cos2θ/n) 72.9x10 -3x837.76 2x24.75x10 -3x (1 1/4.97) 1521.1 N D. Bending Stress due to inertia force Mmax mω 2r X (l/9 3) 72.9x10 -3x837.76 2x24.75x10 -3x(0.123/9 3) 9.9918 Nm 9991.8 Nmm From connecting rod drawing Ixx 1/12 (10.4x133 – 2x2.6x7.83) 1698.43 mm4 Zxx Ixx/5.2 1698.43/5.2 326.62 mm3 σmax Mmax / Zxx 9991.8/326.62 30.59 MPa E. Fatigue Calculation σmax 30.59 MPa σmin - 30.59 MPa F. Amplitude Stress σa (σmax - σmin) / 2 (30.59 – (-30.59))/2 30.59 MPa 205 P a g e www.ijrerd.com
International Journal of Recent Engineering Research and Development (IJRERD) ISSN: 2455-8761 www.ijrerd.com Volume 02 – Issue 07 July 2017 PP. 203-213 G. Mean Stress σm (σmax σmin) / 2 (30.59 (-30.59))/2 0 MPa H. For Forged Steel Yield strength, Sy 625 MPa Ultimate strength, Sut 827 MPa Fatigue endurance strength, Se’ 0.5 σut 0.5X827 413.5 MPa I. Endurance limit Se ka* kb* kc *kd* ke* kf* Se’ 0.8*1.2*1*1*1*1*413.5 396.96 MPa From modified Goodman line σa/Se σm/Sut 1/n (30.59/396.96) (0/827) 1/n 0.077 n 12.98 As σm 0 J. Finite Life N (σa / a)1/b a (f Sut)2 / Se where f 0.82 a (0.82x827)2/396.96 1158.49 b - [log(f Sut) / Se]/3 - [log(0.82x827/396.96]/3 - 0.077 N (30.59/1158.49)-1/0.077 3.145 x 1020 Cycles IJRE RD VIII. Methodology A. Finite Element Analysis Method Connecting rod was modeled by taking the designed parameter of rod and then by using the CATIA software solid modeling has done which is shown in Fig.1 And saved within this program in *.IGES format. The model is imported in HYPERMESH and then the mechanical characteristics of the connecting rod are established: density - 7860 Kg/mm3, Young’s modulus – 210 GPa, Poisson’s ratio - 0.3, etc. Fig.1 Connecting Rod Using CATIA software 1) Meshing The next stage of the modeling is to create meshing of the created model. The mesh should be finer and accurately represent the geometry in the critical areas i.e. the areas where stress, strain, deformation and loading is going to be important. Here we done solid meshing because A part with all the three dimensions (x, y, z in a Cartesian coordinate) comparable are usually meshed with solid elements. The mesh model of connecting rod is 206 P a g e www.ijrerd.com
International Journal of Recent Engineering Research and Development (IJRERD) ISSN: 2455-8761 www.ijrerd.com Volume 02 – Issue 07 July 2017 PP. 203-213 as shown in fig.2 Fig. 2 Mesh at fillet zone IJRE RD Fig. 3 Meshing of Connecting Rod 2) Load Diagram of Connecting Rod A CATIA model of connecting rod is used for analysis in HYPERMESH. Analysis is done with the pressure of 16 Mpa load applied at the piston end of the connecting rod which is calculated by using mathematical calculations and fixed at the crank end of the connecting rod. It is shown in Fig.4 Fig. 4 Load of Connecting Rod 207 P a g e www.ijrerd.com
International Journal of Recent Engineering Research and Development (IJRERD) ISSN: 2455-8761 www.ijrerd.com Volume 02 – Issue 07 July 2017 PP. 203-213 3) Results and Discussion For the finite element analysis 16Mpa of pressure is used. The analysis is carried out using CATIA and HYPERMESH software. The pressure is applied at the small end of connecting rod keeping big end fixed. The maximum and minimum von-misses stress, strain, shear stress, and factor of safety are noted from the HYPERMESH Fig. 5 Stress Component IJRE RD Fig. 6 Displacement Plot Name Von-misses stress Displacement Maximum Minimum 2 431.11N/mm 0.28 N/mm2 0.18 mm 0.0 mm B. Experimentation 1) Experimental Setup Information The specs for the UTM (Universal Testing Machine) used for the Test are as below Make: Star Testing System (India) - Software based Model No: SPS 248 Type: DC Servo Control Speed for loading: 5mm/min to 500mm/min 208 P a g e www.ijrerd.com
International Journal of Recent Engineering Research and Development (IJRERD) ISSN: 2455-8761 www.ijrerd.com Volume 02 – Issue 07 July 2017 PP. 203-213 Fig. 7 UTM Machine IJRE RD Fig 8 Tensile Test Set Up [EthikaEngg. Solution pvt ltd. Pune ] 2) Observation Chart Load (N) Deflection (mm) 31000 0.1812 Max stress(N/mm2) 431.153 IX. FEA and Experimentation Result From FEA and Experimentation test we get the same result for stresses and deflection. Analyze the alternative geometry for connecting rod using CAE software. Recommend the best alternative design for the connecting rod through experimentation and validation Test Deflection (mm) Max stress(N/mm2) Experimentation 0.1812 FEA 0.18 431.153 431.11 X. Need of Modified Geometry After studying existing model of connecting rod we found that the stress concentration is more at neck radius portion of crank and pin end so to reduce this stress and improve its fatigue life we modify the geometry by making some changes in the present design. 209 P a g e www.ijrerd.com
International Journal of Recent Engineering Research and Development (IJRERD) ISSN: 2455-8761 www.ijrerd.com Volume 02 – Issue 07 July 2017 PP. 203-213 XI. MODIFIED GEOMETRY Geometry changes: Change in web thickness and radius in neck portion Fig .9 Base Model Base model having Neck radius at Crank and Pin end are 20 and 12 mm respectively. IJRE RD Fig .10 Modified Model New modified model having Neck radius at Crank and Pin end are slightly greater than base model as 22and 15 mm respectively and we do again FEA process on redesign model we get results as given below in fig. Fig. 11 Redesign Connecting Model 210 P a g e www.ijrerd.com
International Journal of Recent Engineering Research and Development (IJRERD) ISSN: 2455-8761 www.ijrerd.com Volume 02 – Issue 07 July 2017 PP. 203-213 Fig. 12 Redesign Displacement Plot IJRE RD Fig. 13 Redesign Stress Component XII. Fatigue Life Analysis We find out Fatigue life of connecting rod by using FEMFAT Software. Following fig. shows the FEMFAT results, Firstly we give the Material properties for forged steel and after which we get S-N Curve for the same Material Fig. 14 FEMFAT Material Properties 211 P a g e www.ijrerd.com
International Journal of Recent Engineering Research and Development (IJRERD) ISSN: 2455-8761 www.ijrerd.com Volume 02 – Issue 07 July 2017 PP. 203-213 Fig. 15 S-N curve of Connecting Rod From S-N Curve we get the value of Number of load cycle at stress 1000(N/mm 2 ) IJRE RD Fig. 16 Scalar value of Base Model Fig. 17 Scalar value of Modified Model 212 P a g e www.ijrerd.com
International Journal of Recent Engineering Research and Development (IJRERD) ISSN: 2455-8761 www.ijrerd.com Volume 02 – Issue 07 July 2017 PP. 203-213 Model Average Fatigue Life (No. Of cycles) 7 Base model 8.9 *10 19 Modified Model XIII. 3.333*10 Discussion & Conclusion According to this study, Finite element method is used to find out the stress, strain , deflection critical points and fatigue life time of reciprocating components like connecting rod . In this case present Hero Honda Motor Cycle connecting rod fatigue life is 8.9*107 no. of cycles. In order to improve fatigue life of connecting rod we make small changes in geometry of connecting rod ie. We increase neck radius thickness from 20mm to 22mm at crank end and 12mm to 15mm at pin end and after finding fatigue result on FEMFAT software we can increase life up to 3.333*10 19 no. of cycles. ACKNOWLEDGMENT The authors of this present work acknowledge the technical support given by Ethika Engg. Solutions India pvt ltd. REFERENCES [1]. [2]. [3]. [4]. [5]. [6]. [7]. [8]. [9]. [10]. [11]. Afzal, “Fatigue Behavior and Life prediction of Forged Steel and PM Connecting Rods”, Master’s Thesis, University of Toledo, 2004 Ahad Ridzun Bin Ibrahim, “Analysis of Connecting Rod Fracture Using Finite Element Analysis”,pp.110-112. Ali Fatemi and Mehrdad Zoroufi, “Fatigue Performance Evaluation of Forged Versus Competing Process Technologies: A Comparative Study”, 24th Forging Industry Technical Conference, Cleveland, Ohio, 2002. Atish Gawale, A. A.Shaikh1 and Vinay Patil, “Nonlinear static finite element analysis and optimization of connecting rod.” World Journal of Science and Technology 2012, 2(4):01-04. ISSN: 2231 – 2587. Mr. H. B. Ramani, Mr. Neeraj Kumar, Mr. P. M. Kasundra, “Analysis of Connecting Rod under Different Loading Condition Using Ansys Software”. International Journal of Engineering Research & Technology (IJERT),Vol. 1 Issue 9, November- 2012 ISSN: 2278-0181 Swapnil B. Ikhar, “Modeling and Analysis of Connecting Rod of Two Wheeler (Hero Honda Splendor)” Discovery, Volume 24, Number 83, October 4, 2014 P. G. Charkha, S. B Jaju, “Analysis & Optimization of Connecting Rod”, Second International Conference on Emerging Trends in Engineering and Technology,2009,IEEE, pp. 86-91. Pravardhan S. Shenoy, “Dynamic load analysis and optimization of connecting rod”, 2004,pp. 30-42. P. S. Shenoy and A. Fatemi, “Connecting Rod Optimization for Weight and Cost Reduction”, University of Toledo, SAE Technical Paper Series, Paper No- 2005-01-0987. Schreier, L, “Tension and compression in connecting rods”, 1999. V.B.Bhandari Design Data book 213 P a g e IJRE RD www.ijrerd.com
FEA and the load analysis results, recommend the best alternative design for the connecting rod. Keywords: Connecting Rod, Finite Element Analysis, Modeling, Static I. Introduction The intermediate component between crank and piston is known as connecting rod. Connecting rod is also known as conrod and is used to connect the piston to crankshaft.
its original connecting rod before another connecting rod bearing cap is removed. 5. Remove the connecting rod bearing cap with the connecting rod bearing. 6. Inspect the connecting rod bearing for damage. If the connecting rod bearing is damaged, replace all main and connecting rod bearings. a. Acceptable bearing wear (1). b.
Jan 10, 2012 · Private Pilot Handbook Machado www.rodmachado.com Rod Machado 5. Rod Machado Rod Rod Machado 6. lift weight thrust drag 1-1 Rod Machado 7 B A C D. Rod Machado 8. 65 1-2 Rod Machado 9 A B. 1-3 . Private Pilot Handbook 2002 Library and Help 30% 100 Cessna 172 Rod Machado 35. Cessna 172 74 3-4 85 74 74 75 75 13 3-5 5 5 10 15 20 13 Rod Machado 36 .
The objective of the present work is to design and analyses of connecting rod made of Forged steel. Steel materials are used to design the connecting rod. In this project the material (carbon steel) of connecting rod replaced with Forged steel .Connecting rod was created in CATIAV5 R19. Model is imported in ANSYS 13.0 for analysis.
CONTINUED - WOODWORKS: BEGINNER PROJECT FISHING POLE RACK –2– TOOLS REQUIRED SHOPPING LIST WOOD FINISHING PRODUCTS CUTTING LIST Hand Tools – Crosscut handsaw or miter saw – Rip handsaw – Bar clamps Power Tools – Electric drill with 2" hole saw, 3/8" drill bit and countersink drill bit – Table saw Miscellaneous – Tape measure .File Size: 219KBPage Count: 7Explore furtherWoodworking Plans for a Fishing Rod Rack Home Guides .homeguides.sfgate.com14 Fishing Rod Rack Plans ideas fishing rod rack, rod .www.pinterest.comHow to build a fishing rod rack HowToSpecialist - How to .howtospecialist.comFishing Rod Rack Plans, Fishing Rod Holder Plansfreeww.comFishing Rod Racks and misc Woodworking Plans .woodworkersworkshop.comRecommended to you b
Plate Style 5/8 to 1-1/8 inch Sucker Rod 553-820-506 Solid Style 5/8-3/4 inch Sucker Rod 553-820-607 Solid Style 3/4-7/8 inch Sucker Rod 553-820-800 . Never use an elevator with an incorrect sized rod upset or rod size. Never exceed the maximum working load of the Elevator.
The failure of tie rod may cause instability of vehicle and cause an accident.so it is important to check the strength of tie rod. The load coming on tie rod is mostly . For this analysis the tie rod with diameter 19 mm and length 405 mm of bolero car is considered. The tie rod is made up of steel material. For material analysis we are .
Cable to Busbar Tape - LJ 23 Copper Lugs - LA 24 Copper Lugs - GL 25 Cable to Ground Rod - GR 26 Cable to Ground Rod - GT 27 Cable/Tape to Ground Rod - GY/LQ 28 Tape to Ground Rod - CP/CN 29 Cable to Ground Rod CADWELD ONE SHOT - GR/GT 30 Ground Rod Splice - GB 31 Cable to Rebar - RR 32 Cable to Rebar - RD 33
« On attend par additif alimentaire : toute substance habituellement non consommée comme aliment en soi et habituellement non utilisée comme ingrédient caractéristique dans l’alimentation, possédant ou non une valeur nutritive, et dont l’adjonction intentionnelle aux denrées alimentaires, dans un but technologique au stade de leur fabrication, transformation, préparation .
