Analysis of Stress Induced in Connecting Rod of Two Wheeler Engine
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IJRASETPublicationsAnalysis of Stress Induced in Connecting Rod of Two Wheeler Engine
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IJRASETPublicationsInternational Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 6.887
Volume 6 Issue VIII, August 2018- Available at www.ijraset.com
Analysis of Stress Induced in Connecting Rod of
Two Wheeler Engine
1
Mithilesh Kumar, Jitendra Jadon2
1
M.Tech Scholar, 2Assistant Professor, Department of Mechanical Engineering, Shobhit University, Meerut
Abstract: A connecting Road mainly connect crankshaft and piston during combustion from the combustion chamber. A
connecting rod is made of different material like carbon steel or any alloy. My aim of this project is to design a connecting rod of
standard dimension using PRO E software and to analyze the design by using analysis software ANSYS like stress, strain, factor
of safety. Different forces to be calculated by using analysis software. KEYWORDS ansys, connecting rod, static analysis, carbon
steel, aluminium
I. INTRODUCTION
A connecting rod transfer power to the crank during combustion to generate rotational energy. A connecting rod may be of two
different type, H type of I type or both used according to their field. An I-beam is light in weight and strong but it has limitation to
handle the load due to type of material used where H-type is better than I type which handle more stress so, H-Beam type can be
used in heavy engines.
1) Why Aluminum ?
I have selected aluminium alloy for this project. Aluminium is light in weight, easily available , and low cost. So, our choice is
ALUMNIUM 2024 the chemical compositon of Al 2024 is tabulated below in Table.
AL Chromium, Copper, Iron, Fe Magnesium, Manganese, Silicon, Titanium, Zinc, Zn
Cr Cu Mg Mn Si Ti
90.4 - 95 0.10 % 3.9 - 5.0 0.70 % 0.20 - 0.80 0.40 - 1.2 0.50 - 1.2 0.15 % 0.25 %
% % % % %
ENGINE SPECIFICATIONS
Here i have used A Bajaj Pulsar 150 engine which is a four stroke engine with 149 cc of displacement.
Below the specification of Engine:
Bore*Stroke=58.00 mm* 56.00 mm
The compression ratio of the engine = 9.5:1
Maximum power= 15.06 Ps@9000 rpm
Maximum Torque= 12.28 Ps@6500 rpm
Density of petrol= 737.22 kg/m3
Temperature=60F=288.855 K
Displacement= 149 cc
Mass of petrol=Density*Volume
=737.22*E^-9 * 149*10^3
=0.11 kg
Molecular weight of petrol=114.228 g/mole
Gas equation,
PV=MrT {R=R*/Mw=8.3143/0.114228=72.786}
P=0.11*72.786*288.855/149E^3=15.521 Mpa
©IJRASET: All Rights are Reserved 493
International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 6.887
Volume 6 Issue VIII, August 2018- Available at www.ijraset.com
2) Designing Process
Pro E software is used to design the connecting rod of two wheeler Engine according to the standard dimensions. Thereafter the
design is imported into Ansys to analyse the stress, and displacement.
II. LITERATURE SURVEY
There are many literature related to Finite Element Analysis of connecting rod. Many research publications, journals, reference
manuals. books are available of national and international editions dealing with basic concepts of FEA. For the current study it is
necessary to study about the stress analysis of connecting rod. A connecting rod should be durable , due to this connecting rod is an
Important topic in the field of research.
1) Webster et al. IN (1983) performed 3D finite element analysis of a high diesel engine connecting rod. For this analysis they
used the maximum compressive load which was measured experimentally, and the maximum tensile load which is essentially
the inertia load of the piston assembly mass.[1] The load distributions on the piston pin end and crank end were determined
experimentally. They modeled the connecting rod cap separately, and also modeled the bolt pretension using beam elements
and multi point consequations. [2].
2) Hitesh Kumar [3] et al. did analysis of connecting rod stress producing compressive loading. And then give idea about weight
reduction opportunities in connecting rod of an I.C. engine by examining two materials, AISI 1040 carbon steel and AISI 4340
alloy steel. Therefore, this study has deal with two subjects, first, static load and stress analysis of the connecting rod and
second optimization for weight reduction and shape. With the use of FEA von-misses stress, strain, shear stress, deformat ion,
and weight reduction etc, were calculated for a part circular loading conditions using FEA Software ANSYS WORKBENCH
14.0.Compared to the former material the new material found to have less weight, stress reduction and better stiffness. 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.
3) Shahrukh Shamim et al studied finite element analysis of connecting rod used in single cylinder four stroke petrol engines.
Static stress analysis is conducted on connecting rod made up of two different materials viz. E-glass/Epoxy and Aluminum
composite reinforced with Carbon nano tubes. Modeling and comparative analysis of connecting rod is carried out in
commercially used FEM software ANSYS 14.0. Static structural analysis was done by fixing the piston end and applying load
at the crank end of the connecting rod. Output parameters in static stress analysis are von-Mises stress, Shear stress, total
deformation and equivalent elastic strain for the given loading conditions. [4]
III. PROBLEM STATEMENT
The design of the Connecting rod starts with the definition of the connecting rod geometry using 3D CAD program. The idea behind
finite analysis is to divide a model into a constant finite number of elements. The system software generates and forecasts the
complete stiffness of the total rod. evaluating the data is possible forecast how the connecting rod will behave in a real loading
condition and allows the engineer to see where the FEA is carried out by using the ANSYS programmable software. Based on the
analysis of optimal result, the stress concentrates on the model has become evaluate, which provides a better hint for rebuilt of
connecting rod.
A. Problem Formulation
The objective of present study is carried out the analysis of a two wheeler connecting rod of different materials and making a
meaningful comparison among results of analysis, which can be helpful for getting suitable material for the manufacturing of
connecting rod. Study also incorporates the fabrication of material by changing the chemical constituents to find the new material.
In the present study 3D model of connecting rod is developed using CAE software (PRO-E SOFTWARE) and the static analysis is
done by ANSYS WORKBENCH 13.0. The results of analysis are noted for making helpful comparison.
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International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 6.887
Volume 6 Issue VIII, August 2018- Available at www.ijraset.com
IV. MODELING & ANALYSIS
PRO E is Used to create the Model according to the standard dimension. First 2D model is developed and then 3d Model is
generated.
Figure 1: Model of connecting Rod Figure 2 : Model of Crank end Bearing Lower half
Finite Element Analysis Using Ansys
Figure 3 :Model of Connecting Rod Figure 4 :model of the Lower Bearing
The meshed models of the connecting rod and lower are as shown in above figure.
Once meshing is done the boundary conditions i.e. DOF constrains, forces, loads are to be applied on the model. As shown in above
figure the pressure is applied on the Crank end bearing of the connecting rod, while keeping piston end fixed.The pressure of 15
Mpa is used.
Figure 5 Meshed Model of Connecting Rod Figure 6 : Meshed model of Lower Bearing
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International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 6.887
Volume 6 Issue VIII, August 2018- Available at www.ijraset.com
Figure 7 Load constrained section of connecting rod Figure 8 :Load Constrained Section of Lower Bearing
V. RESULTS & DISCUSSION
The Analysis is done for two different materials, Al 2024 and Stailness Steel at 15 Mpa pressure.
Figure 9 : Displacement Output of the Lower Bearing of Stainless Steel Figure 10 : Displacement Output of the Connecting Rod
Figure 11 : Von-Misses Stress Output of the Lower Bearing of Stainless Steel Figure 12 :Von-Misses Stress Output of the
Stainless Steel Connecting Rod
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International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 6.887
Volume 6 Issue VIII, August 2018- Available at www.ijraset.com
Figure 13 : Displacement Output of the Aluminium Alloy Connecting Rod
Figure 14 :Displacement Output of the Aluminium Alloy Connecting Rod
Figure 15 :Von-Misses Stress Output of the Aluminium Alloy Connecting Rod
©IJRASET: All Rights are Reserved 497
International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 6.887
Volume 6 Issue VIII, August 2018- Available at www.ijraset.com
Figure 16 : Von-Misses Stress Output of the Lower Bearing of Aluminium Alloy
According to the results obtained by the ANSYS software for the displacement, Von-Misses Stress at the pressure of 15 MPa the
values for the output obtained can be represented as shown in the tables below.
FOR 15 MPA PRESSURE Stainless Aluminium
Steel Alloy 2024
Displacement 0.0194161 0.024894
Von-Misses Stress 0.149E+09 0.151E+09
FOR 15 MPA PRESSURE Stainless Aluminium
Steel Alloy 2024
Displacement 0.012094 0.03381
Von-Misses Stress 0.123E+09 0.115E+09
VI. CONCLUSION
The results or conclusion thus that can made on the bases of the output results by ANSYS can be as followed: The analysis was
completed and we got the Strong and weak points of the design upon which improvements can be done. Other materials can be used
to compare with Al 2024 and further weight and cost reduction can be done to optimize the design. The design similar to existing
ones and much research needs to be done to make a ground-breaking design that is very efficient as compared to existing ones. The
areas of the design which buckle most under stress need require more attention to obtain a more efficient design.
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[3] Hitesh Kumar, 2, Vijay Kumar Sharma, Department of Mechanical Engineering Stress Analysis and Optimization of I. C. Engine Connecting Rod by Finite
Element Analysis ,IJERT Vol. 4 Issue 04, April-2015\
[4] Shahrukh Shamim,Design and Comparat ive Analysis of Connecting Rod usin g Finite Element Method,IJERT, Vol. 3 Issue 9, September- 201
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