International Journal of Research p-ISSN: 2348-6848

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October2016

Analysis and Implementation of Parametric model of a

Piston rod
A.Uma Maheshwara Reddy1,G.Naresh Babu2, D.LokanaGouda3
1
M.Tech Scholar, Dept. of Mechanical, Siddhartha institute of technology and sciences, Telangana, India
2
Assistant Professor, Dept. of Mechanical, Siddhartha institute of technology and sciences, Telangana, India
3
Assistant Professor, Dept. of Mechanical, Siddhartha institute of technology and sciences, Telangana, India

Abstract:Connecting rod is the power transmission cast iron for applications such as motor scooters. The
element which is used to transfer power form piston small end attaches to the piston pin, gudgeon pin (the
to the crank shaft in Internal Combustion Engine (IC usual British term) or wrist pin, which is currently
Engine).This paper describes modeling and most often press fit into the con rod but can swivel in
evaluationof connecting rod. In this task connecting the piston, a "floating wrist pin" design. The
rod ischanged with the assistance of Aluminum connecting rod is under tremendous stress from the
strengthened with Boron carbidefor Suzuki GS150R reciprocating load represented by the piston, actually
motorbike. A second drawing isdrafted from the stretching and being compressed with every rotation,
calculations. A parametric model ofconnecting rod is and the load increases to the third power with
modeled making use of professional-E5.0 software. increasing engine speed. Failure of a connecting rod,
Analysis is carried out by way of utilizing usually called "throwing a rod" is one of the most
ANSYSsoftware. Finite element analysis of common causes of catastrophic engine failure in cars,
connecting rod iscarried out by using considering two frequently putting the broken rod through the side of
substances, viz. Aluminumreinforced with Boron the crankcase and thereby rendering the engine
Carbide and Aluminum 360.The first-rate combo of irreparable; it can result from fatigue near a physical
parameters like Von missesstress and pressure, defect in the rod, lubrication failure in a bearing due
Deformation, aspect of defense andweight discount to faulty maintenance or from failure of the rod bolts
for two wheeler piston have been performed from a defect, improper tightening, or re-use of
inANSYS software. Compared to carbon already used (stressed) bolts where not
steel,aluminum boron carbide and aluminum recommended.
360,Aluminum boron carbide is found to have
workingelement of security is nearer to theoretical II. LITERATURE SURVEY
component ofsecurity, 33.17% to shrink the load, to
Pushpendra kumar Sharma et al. (2012) performed
expand thestiffness by way of 48.55% and to
the static FEA of the connecting rod using the
diminish the stressby10.35% and most stiffer.
softwareand said optimization was performed to
Keywords-Piston Rod, Crankshaft, Connecting Rod,PRO- reduce weight. Weight can be reduced by changing
E 5.0, ANSYS the material of thecurrent forged steel connecting rod
to crack able forged steel (C70). And the software
I. INTRODUCTION gives a view of stressdistribution in the whole
connecting rod which gives the information that
In a reciprocating piston engine, the connecting rod
which parts are to be hardened orgiven attention
connects the piston to the crank or crankshaft. In
during manufacturing stage. [12]
modern automotive internal combustion engines, the
connecting rods are most usually made of steel for K. Sudershn Kumar et al. (2012) analyzed Two
production engines, but can be made of aluminum Wheeler Connecting Rod. In this project connecting
(for lightness and the ability to absorb high impact at rod wasreplaced by Aluminum reinforced with Boron
the expense of durability) or titanium (for a carbide for Suzuki GS150R motorbike. A 2D
combination of strength and lightness at the expense drawing wasdrafted from the calculations. A
of affordability) for high performance engines, or of

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 International Journal of Research p-ISSN: 2348-6848
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October2016

parametric model of connecting rod was modeled crankpressure as the other extreme load.
using PRO-E 4.0 software. Furthermore, the existing connecting rod could be
replaced with a newconnecting rod made of Genetic
Analysis was carried out by using ANSYS software. Steel. [6]
Finite element analysis of connecting rod was done
byconsidering two materials, viz... Aluminum Kuldeep B et al. (2013) optimized connecting rod
Reinforced with Boron Carbide and Aluminum 360. using alfasic composites. In the work connecting rod
The bestcombination of parameters like Von misses wasreplaced by aluminum based composite material
stress and strain, Deformation, Factor of safety and reinforced with silicon carbide and fly ash. FEA
weight reductionfor two wheeler piston were done in analysis wascarried out by considering two materials.
ANSYS software. Compared to carbon steel, The parameter like von misses stress, von misses
aluminum boron carbide andaluminum 360, strain anddisplacement was obtained from ANSYS
Aluminum boron carbide is found to have working software. Compared to the former material the new
factor of safety is nearer to theoretical factorof safety, material found tohave less weight and better stiffness.
33.17% to reduce the weight, to increase the stiffness It resulted in reduction of 43.48% of weight, with
by 48.55% and to reduce the stress by10.35%and 75% reduction indisplacement. [8]
most stiffer. [7]
Ambrish Tiwari et al. (2014) presented the paper for
B. Anusha et al. (2013) compared the materials For connecting rod Finite Element Analysis for weight
Two-Wheeler Connecting Rod Using Ansys. In the andcost reduction opportunities for a production of
analysistwo materials were selected and analyzed. forged steel connecting rod. It was also performed a
The software results of two materials were compared fatiguestudy based on Stress Life (SxN) theory,
and utilized fordesigning the connecting rod. By considering the Modified Goodman diagram. [2]
comparing the different results obtained from the
analysis, it was concludedthat the stress induced in Table.1 shows the specifications of the connecting
the structural steel was less than the cast iron. [3] rod for carbon steel (Suzuki GS). The typical
chemical composition of the material is 0.61%C,
G. Naga Malleshwara Rao et al. (2013) carried out 0.095% Al, 0.82%Mn, 0.00097%Br, 0.145% C,
analysis of connecting rod using ANSYS. The 7.8Co, 75.56Fe and 3.25 Mo.
mainObjective of the work was to explore weight Table: 1Specifications of connecting rod
reduction opportunities in the connecting rod of an
I.C. engine byexamining various materials such as
Genetic Steel, Aluminum, Titanium and Cast Iron.
This was entailed byperforming a detailed load
analysis. Therefore, the study has dealt with two
subjects, first, static load and stressanalysis of the
connecting rod and second. Design Optimization for
suitable material to minimize the deflection.

In the first of the study the loads acting on the

connecting rod as a function of time are obtained.
The relationsfor obtaining the loads for the
connecting rod at a given constant speed of crank
shaft are also determined. Itcould be concluded from
this study that the connecting rod could be designed
and optimized under a comprisingtensile load
corresponding to 360o crank angle at the maximum
engine speed as one extreme load, and the

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 International Journal of Research p-ISSN: 2348-6848
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A. PRESSURE CALCULATION FOR 150CC

ENGINE Suzuki GS 150 R
Specifications
Engine type air cooled 4-stroke Bore × Stroke (mm)
= 57×58.6
Displacement = 149.5CC
Maximum Power = 13.8bhp@8500rpm
Maximum Torque = 13.4Nm@6000rpm
Compression Ratio = 9.35/1
Density of Petrol C8H18 = 737.22kg/m3 =
737.22E-9kg/mm3
Temperature = 60F = 288.855K
Mass = Density × Volume = 737.22E-9×149.5E3
= 0.11Kg
Molecular Weight of Petrol 114.228 g/mole
From Gas Equation,
PV=Mrt R = R*/Mw = 8.3143/.114228 = 72.76 P
= (0.11x72.786x288.85) / 149.5E3 P = 15.469 Mpa.

III. THEORETICAL CALCULATIONS B. DESIGN CALCULATION FOR CARBON

OF PISTON ROD
STEEL
A connecting rod is a machine member which is
subjected to alternating direct compressive and Thickness of flange & web of the section = t
tensile forces. Since the compressive forces are much Width of B= 4t
higher than the tensile force, therefore the cross- The standard dimension of Height of section H = 5t
section of the connecting rod is designed as a strut Area of section A= 2(4t×t) +3t×t
and the Rankin formula is used. A connecting rod A = 11t²
subjected to an axial load W may buckle with x-axis M.O.I of section about x axis:
as neutral axis in the plane of motion of the I xx = 112 [4 {5 }3−3 {3 }3]
connecting rod, {or} y-axis is a neutral axis. The = 41912[ 4]
connecting rod is considered like both ends hinged MI of section about y axis:
for buckling about x-axis and both ends fixed for Iyy = 2×112×t×{4t}3+112{3t}t3
buckling about y-axis. A connecting rod should be = 13112[t4]
equally strong in buckling about either axis. IxxIyy = 3.2
LetA = cross sectional area of the connecting rod. Length of connecting rod (L) = 2 times the stroke
L = length of the connecting rod. L = 117.2 mm
C = compressive yield stress. Buckling load WB = maximum gas force × F.O.S
Wcr = crippling or buckling load. WB = ( × )(1+a (L/Kxx)2
Ixx = moment of inertia of the section about x-axis = 37663N
Iyy = moment of inertia of the section about y-axis = compressive yield stress = 415MPa
respectively. K xx = I xxA
Kxx = radius of gyration of the section about x- K xx = 1.78t
axis a= 2
Kyy = radius of gyration of the section about y- a = 0.0002
axis respectively. By substituting , A, a, L, Kxx on WB then
D = Diameter of piston
= 4565t4-37663t2-81639.46 = 0
r = Radius of crank

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t2 = 10.03 = 6277.16712.5×1.5d1
t = 3.167mm = 17.94mm
t = 3.2mm Where,
Width of section B = 4t Design bearing pressure for small end pb1=12.5 to
= 4×3.2 15.4N/mm2
= 12.8mm Length of the piston pin l1= (1.5to 2) d1
Height of section H = 5t Outer diameter of the small end = d1+2tb+2tm
= 5×3.2 = 17.94 + [2×2] + [2×5]
= 16mm = 31.94mm
Area A = 11t2 Where,
=11×3.2×3.2 Thickness of the bush (tb) = 2 to 5 mm
= 112.64mm2 Marginal thickness (tm) = 5 to 15 mm
Height at the big end (crank end) = H2 Inner diameter of the big end d2= FgPb2 ×l2
= 1.1H to 1.25H = 6277.16710.8×1.0d1
= 1.1×16 =23.88mm
H2 =17.6mm Where,
Height at the small end (piston end) = 0.9H to Design bearing pressure for big end pb2 = 10.8 to
0.75H 12.6N/mm2
= 0.9×16 Length of the crank pin l2 = (1.0 to 1.25) d2
H1 =12mm Root diameter of the bolt = ( (2Fim)(πxSt))1/2
= (2×6277.167π×56.667)1/2
C. 2D Drawing for Connecting Rod = 4mm
Stroke length (l) =117.2mm Outer diameter of the big end = d2 + 2tb + 2db
Diameter of piston (D) =57mm +2tm
Stroke length (l) =117.2mm = 23.88+2×2+2×4+2×5
Diameter of piston (D) =57mm = 47.72mm
P=15.5N/mm2 Where,
Radius of crank(r) =stroke length/2 Thickness of the bush [tb] = 2 to 5 mm
=58.6/2 Marginal thickness [tm] = 5 to 15 mm
=29.3 Nominal diameter of bolt [db] = 1.2 x root
Maximum force on the piston due to pressure diameter of the bolt
Fl = π4xD2xp = 1.2×4 = 4.8mm
=π/4 x (57)2x15.469
=39473.16N IV. STEPS IN MODELING OF
CONNECTING ROD
Maximum angular speed Wmax= [2πNmax]60
= [2π×8500]60 = 2 Optimized Connecting Rod has been modeled with
=768 rad/sec the help of PRO/E Wildfire 4.0 software. The
Ratio of the length of connecting rod to the radius Orthographic and Solid Model of optimized
of crank connecting rod is shown in figures below.
N= lr =112/ (29.3) = 3.8
Maximum Inertia force of reciprocating parts
F im = Mr (Wmax) 2 r (cosθ + COS2θn) (Or)
F im = Mr (Wmax)2 r (1+1n)
= 0.11x (768)2 x (0.0293) x (1+ (1/3.8))
F im = 2376.26N
Inner diameter of the small end d1 = ×

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Piston pin End: Po = 4319/ (7.8 x 14 x _3) = 22.84

MPa
CAD Model of connecting rod in PRO Engineer.
Tensile Loading:
The following is the list of steps that are used to
create the required model: Crank End: Po = 4319/ [17.5 x 10.708 x (_/2)] =
1. Choose the reference plane. 14.68 MPa
2. Set the dimension in mm. Piston pin End: Po = 4319/ [7.8 x 14 x (_/2)] = 25.18
3. Go to sketcher and sketch circular entities. MPa
4. Then extrude these entities for making the Following are Figures shows the optimized results
both ends of connecting rod. along with the results of figures in reference paper
5. Again reference plane is selected for shank and comparison for static analysis of connecting rod
of connecting rod. at load 4319N.
6. Entities is made that should be tangential to
both ends.
7. Extrude the entities symmetrically.
8. Plane is selected for making entities of
groove.
9. Groove is made on the shank and mirrored
for creating groove on both side.
10. Datum plane is selected for creating small
holes on piston end then holes are made on
the periphery of piston end.

V. ARESULTS OF FINITE ELEMENT

Above figures shows the comparison equivalent
ANALYSIS AND COMPARISION WITH
von misses stress at 4319N.
EXISTING RESULTS

In this study four cases of finite element models are

analyzed. FEA for both tensile and compressive loads
are conducted. Two cases are analyzed for each case,
one with load applied at the crank end and restrained
at the piston pin end, and the other with load applied
at the piston pin end and restrained at the crank end.
In the analysis carried out, the axial load was 4319 N Above figures shows the comparison of shear
(Gas Force) in both tension and compression. In stress at 4319N
addition to this the analysis carried out taking
Buckling Load of 21598N. Finally the comparisons
are done for optimization purpose.
The pressure constants for 4319 N are as follows
used for applying Boundary Condition:

Compressive Loading:

Crank End: Po = 4319/ (17.5 x 10.708 x _3) = 13.31

MPa

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Above figures shows the comparison of equivalent

elastic strain at 4319N

Table shows the result comparison for static analysis

Above figure shows the comparison of safety factor

at 21598N.

Following are Figures shows the optimized results

along with the results of figures and comparison for
static analysis of connecting rod at load 21598N.

Above figure shows the comparison of safety factor

at 21598N.
Following are Figures shows the optimized results
along with the results of figures in reference paper
and comparison for fatigue analysis of connecting rod
at load 21598N.

Above figure shows the comparison of safety factor

at 4319N.

(1)

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Above (3) and (4) figures shows the damage at

4319N and 21598N.
Table shows the comparison of Weight

Above table shows the weight optimization of

connecting rod, in existing model weight of
(2) connecting rod was 131.5g. After optimization
Above (1) and (2) figures shows the life at 4319N weight of connecting rod is126.73, the percentage
and 21598N weight reduction is 3.62.

VI. CONCLUSION

Finite element analysis of the connecting rod of

aSuzuki GS150R has been finished using FEA
deviceANSYS Workbench. From the outcome
received fromFE evaluation, many discussions had
been made. Theresults got are well in agreement with
theequivalent available current consequence. The
modelprovided right here, is good trustworthy and
below permissiblerestrict of stresses.

1. Conclusion is based on the current work that

thedesign parameter of connecting rod with
changeoffers ample development in the present
(3)
results.

2.The burden of the connecting rod can also be

lowered by0.477g. Thereby, reduces the inertia force.

3.Fatigue strength is the principal drivingfactor for

the design of connecting rod and it's determinedthat
the fatigue results are in good agreement with
thepresent outcomes.

4.The stress is determined maximum on the piston

finish sothe material is improved within the stressed
portion toshrink stress.

REFERENCES

[1] Afzal, A. and A. Fatemi, 2004. "A comparative

(4) study of fatigue behavior and life predictions of

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