DESIGN, STATIC AND MODAL ANALYSIS OF CONNECTING ROD OF

FOUR STROKE SPARK IGNITION ENGINE

A Project report submitted in partial fulfillment of the requirements for the award

BACHELOR OF TECHNOLOGY

IN

MECHANICAL ENGINEERING

By

CHINNARI NATRAJ (319126520L02)

BANTU SANDHYA (319126520L03)

SEERA NAVEEN KUMAR (318126520046)

AGATHA NAVEEN (318126520001)

SEERA VIVEK (318126520047)

Under the esteemed guidance of

Mrs. M. Sailaja M.TECH., (Ph.D.)

Assistant Professor

DEPARTMENT OF MECHANICAL ENGINEERING

ANIL NEERUKONDA INSTITUTE OF TECHNOLOGY & SCIENCES(A)

(Permanently Affiliated to Andhra University, Approved by AICTE,

Accredited by NBA & NAAC with ‘A’ grade)

Sangivalasa - 531162, Bheemunipatnam (Mandal), Visakhapatnam (Dist.),

Andhra Pradesh, India. 2021-2022
THIS PROJECT WORK IS APPROVED BY THE FOLLOWING
BOARD OF EXAMINERS

INTERNAL EXAMINER:

EXTERNAL EXAMINER:
 ACKNOWLEDGEMENT

We express immensely our deep sense of gratitude to Ms. M. SAILAJA, M.E, (Ph .D),
Assistant Professor, Department of Mechanical Engineering, Anil Neerukonda
Institute of Technology & Sciences, Sangivalasa, Bheemunipatnam (Mandal),
Vishakhapatnam District for her valuable guidance and encouragement at every stage
of the work made it a successful fulfilment.

We were very thankful to Prof. T.V. Hanumantha Rao, Principle, Anil Neerukonda
Institute of Technology & Sciences for their valuable suggestions.

We were very thankful to Dr. B. Naga Raju, Professor, and Head of the Department,
Mechanical Engineering, Anil Neerukonda Institute of Technology & Sciences for his
valuable guidance and encouragement at every stage of the work made it a successful
fulfilment.

We express our sincere thanks to the members of non-teaching staff of Mechanical

Engineering for their kind co-operation and support to carry on work.

Last but not the least we like to convey our thanks to all who contributed either directly
or indirectly for the completion of our work.

CHINNARI NATRAJ (319126520L02)

BANTU SANDHYA (319126520L03)

SEERA NAVEEN KUMAR (318126520046)

AGATHA NAVEEN (318126520001)

SEERA VIVEK (318126520047)

 ABSTRACT

In this project we are going to do static, modal analysis and of a

Connecting rod. Different materials are used for the analysis like
structural steel , Titanium alloy, Aluminium alloy. Connecting rod is one
of the most vital part of an I.C. engine and used to transfer the
reciprocating motion of piston into the rotatory motion of crankshaft. It is
heavily stressed during the operation subjected to compressive stress due
to the gas pressure and tensile stress due to the Inertia force. The actual
dimensions of the connecting rod are considered and the model of the
connecting rod is designed in solid works and ANSYS is used for static
and modal analysis for finding von misses stresses, frequencies for three
materials and compared to choose the best material suitable for connecting
rod.
 CONTENTS

S.NO DESCRIPTION Page NO.

LIST OF FIGURES i
LIST OF TABLES iii
LIST OF GRAPHS iv
NOMENCLATURE v
METHODOLOGY ADOPTED vi
CHAPTER 1: INTRODUCTION
1.1 CONNECTING ROD 1
1.2 TYPES OF CONNECTING ROD 2
1.2(a) Connecting rod with nut and bolt 2
1.2(b) Connecting rod without nut and bolt 3
1.2(c) I-beam Connecting rod 3
1.2(d) connecting rod with H-beam 3
1.2(e) X-beam, cross beam 4
1.3 FAILURES IN CONNECTING ROD 4
1.3(a) fatigue 4
1.3(b) pin failure 4
1.3(c) over revving 4
1.3(d) hydrolock 5
1.4 PROBLEM STATEMENT 6
1.5 PROBLEM OBJECTIVE 6
CHAPTER 2: LITRETURE REVIEW 7
CHAPTER 3: THEORETICAL CALCULATIONS 11
3.1 DESIGN FOR PRESSURE CALCULATIONS 11
3.2 DESIGN CALCULATIONS FOR THE 12
CONNECTING ROD
3.2(a) Design of small end 14
3.2(b) Design of big end 14
3.3 FINAL DIMENSIONS OF CONNECTING ROD 17
CHAPTER 4: MODELLING 18
4.1 INTRODUCTION TO SOLID WORKS 18
 4.1(a) features 20
4.2 STEP BY STEP DESIGN OF THE CONNECTING ROD 23
CHAPTER 5: ANALYSIS 25
5.1 INTRODUCTION TO FINITE ELEMENT ANALYSIS 25
5.2 BASIC STEPS IN THE FINITE ELEMENT ANALYSIS 25
5.3 INTRODUCTION TO ANSYS WORKBENCH 26
5.3(a) Ansys Workbench features 27
5.4 STRUCTUAL ANALYSIS
5.4(a) Types of structural analysis 28
5.5 PROCEDURE FOR PERFORMING
STATIC STRUCTURAL ANALYSIS 29
5.5(a) material: Structural steel 33
5.5(b) material ALLUMINIUM ALLOY 34
5.5(c) material: TITANIUM ALLOY 36
5.6 PROCEDURE FOR PERFORMING
MODAL ANALYSIS 40
5.6(a) material: STRUCTURAL STEEL 43
5.6(b) material: ALLUMINIUM ALLOY 45
5.6(c) material: TITANIUM ALLOY 47
5.6(d) Interpretation of results 49
CHAPTER 6: CONCLUSIONS AND REFRENCES 50
 I

LIST OF FIGURES
S.NO DESCRIPTION PAGE NO.
Fig 1.1: Connecting rod 1
Fig 1.2: Connecting rod with nut and bolt 2
Fig 1.3: Connecting rod without nut and bolt 3
Fig 1.4: Connecting rod that initially failed through fatigue 5
Fig 4.1: Solid works interface 18
Fig 4.2: SolidWorks drawing interface 19
Fig 4.3: SolidWorks dimensions in 2D 23
Fig 4.4: Solid works extruding of small end, big end, shank and slot-cut 23
Fig 4.5: SolidWorks dimensions in 3D 24
Fig 5.1: ANSYS work bench 27
Fig 5.2: Structural analysis interface 29
Fig 5.3: Engineering data interface 30
Fig 5.4: Import of Geometry 30
Fig 5.5: Meshing interface 31
Fig 5.6: Mesh Details 31
Fig 5.7: Connecting rod meshing model 31
Fig 5.8: Static Structural interface adding fixed supports and loads 32
Fig 5.9: Support and loading 32
Fig 5.10: Solutions 33
Fig 5.11: Steel properties 33
Fig 5.12: Equivalent stress 33
Fig 5.13: Max shear stress 33
Fig 5.14: Safety factor 34
Fig 5.15: Total deformation 34
Fig 5.16: Properties of aluminium alloy 34
Fig 5.17: Equivalent stress 35
Fig 5.18: Max shear stress 35
Fig 5.19: Safety factor 34
Fig 5.20: Total deformation 35
Fig 5.21: Properties of titanium alloy 36
Fig 5.22: Equivalent stress 36
 II

Fig 5.23: Max shear stress 36

Fig 5.24: Safety factor 37
Fig 5.25: Total deformation 37
Fig 5.26: Modal analysis Interface 40
Fig 5.27: Engineering data interface 40
Fig 5.28: Import of Geometry 41
Fig 5.29: Meshing Interface 41
Fig 5.30: Mesh Details 42
Fig 5.31: Modal Interface adding fixed supports and loads 42
Structural steel
Fig 5.32: Total Deformation 1 43
Fig 5.33: Total Deformation 2 43
Fig 5.34: Total Deformation 3 43
Fig 5.35: Total Deformation 4 43
Fig 5.36: Total Deformation 5 44
Fig 5.37: Total Deformation 6 44
Aluminium alloy
Fig 5.38: Total Deformation 1 45
Fig 5.39: Total Deformation 2 45
Fig 5.40: Total Deformation 3 45
Fig 5.41: Total Deformation 4 45
Fig 5.42: Total Deformation 5 46
Fig 5.43: Total Deformation 6 46
Titanium alloy
Fig 5.44: Total Deformation 1 47
Fig 5.45: Total Deformation 2 47
Fig 5.46: Total Deformation 3 47
Fig 5.47: Total Deformation 4 47
Fig 5.48: Total Deformation 5 48
Fig 5.49: Total Deformation 6 48
 III

LIST OF TABLES
S.NO DESCRIPTION PAGE NO.
Table 3.1: Parameters of connecting rod 17
Table 5.1: Results of structural analysis of structural steel 34
Table 5.2: Results of structural analysis of aluminium alloy 36
Table 5.3: Results of structural analysis of titanium alloy 37
Table 5.4: Results of structural analysis 37
Table 5.5: Results of modal analysis of structural steel 44
Table 5.6: Results of modal analysis of aluminium alloy 46
Table 5.7: Results of modal analysis of titanium alloy 48
 IV

LIST OF GRAPHS
S.NO DESCRIPTION PAGE NO.
Fig 5.1: Mass vs Materials 38
Fig 5.2: Max. shear stress vs Materials 38
Fig 5.3: Equivalent stress vs Materials 39
Fig 5.4: Factor of safety vs Materials 39
Fig 5.5: Frequency vs modes analysis of structural steel 44
Fig 5.6: Frequency vs modes analysis of aluminium alloy 46
Fig 5.7: Frequency vs modes analysis of titanium alloy 48
 V

NOMENCLATURE
A = cross-sectional area of the connecting rod.

L = length of the connecting rod.

T = thickness of the connecting rod.

B = width of the connecting rod.

H = height of the connecting rod,

C = compressive yield stress.

Wcr = crippling or buckling load.

Ixx = moment of inertia of the section about the x-axis

Iyy = moment of inertia of the section about y-axis respectively.

Kxx = radius of gyration of the section about the x-axis:

Kyy = radius of gyration of the section about y-axis respectively.

D = Diameter of piston

r = Radius of crank

D1 = Diameter of small end or piston end. LEX

D2 = Diameter of big end or crank end.

FP = Force acting on the piston.

FI = Force of inertia.

σc = Compressive yield stress.

F = Buckling load.

a = Constant depending upon material and end fixity coefficient.

Ø =Angle between connecting rod and piston axis.

 VI

METHODOLOGY ADOPTED

1. Literature Review

2. Material Selection

3. Design of connecting rod

4. Model preparation in Solid works

5. Simulation

6. Results & Discussion

7. Conclusions

8. References

SOFTWARE REQUIRED

1. SOLID WORKS for preparing model

2. ANSYS for simulation.

 1

CHAPTER 1

INTRODUCTION
1.1 CONNECTING ROD

A Connecting rod is the part which connects the piston and the crank shaft. It
is the link between both parts. Small end part of the rod is connected to piston with the
help of the pin and the big end part of the rod is connected to the crank shaft. The
purpose of the Connecting rod is to provide fluid movement between piston and crank.

Fig 1.1: Connecting rod

Now a days the need of connecting rod is used in every type of automotive engines.
Like Diesel Engine, Straight or inline Engines, V-Type Engines, Boxer or flat engines.
These are type of automotive engine and all the engines cannot be used without the
use of Connecting rod.

Connecting rod is the backbone of the engine

A Connecting rod is the link between the reciprocating piston and rotating crank shaft.
Small end of the connecting rod is connected to the piston by means of gudgeon pin.
The big end of the connecting rod is connected to the crankshaft. The function of the
connecting rod is to convert the reciprocating motion of the piston into the rotary
motion of the crankshaft. The connecting rods are usually forged out of the open hearth
steel or sometimes even nickel steel or vanadium steel. For low to medium capacity
high speed engines, these are often made of duraluminium or other aluminum alloys.
However, with the progress of technology, the connecting rods these days are also cast
from malleable or spheroid graphite cast iron. In general, forged connecting rods are
compact and light weight which is an advantage from inertia view point, whereas cast
 2

connecting rods are comparatively cheaper, but on account of lesser strength their use
limited to small and medium size petrol engines.

It has mainly three parts namely- a pin end, a shank region and a crank end. Pin end is
connected to the piston assembly and crank end is connected to crankshaft. A
combination of axial and bending stresses act on the rod in operation. The axial
stresses are product due to cylinder gas pressure and the inertia force arising on
account of reciprocating motion. Whereas bending stresses are caused due to the
centrifugal effects. To provide the maximum rigidity with minimum weight, the cross
section of the connecting rod is made as and I – section end of the rod is a solid eye or
a split eye this end holding the piston pin. The big end works on the crank pin and is
always split. In some connecting rods, a hole is drilled between two ends for carrying
lubricating oil from the big end to the small end for lubrication of piston and the piston
pin.

1.2 TYPES OF CONNECTING ROD

There are many types of connecting rod with different I section and H section. But
there are basically two types of connecting rod.

1.2(a) Connecting rod with nut and bolt - The connecting rod with cap at the larger
end is joined by means of bolt and nut. This type of connecting rod is most widely
used in multi cylinder engines. For example: trucks, tractor etc.

Fig 1.2: Connecting rod with nut and bolt

 3

1.2(b) Connecting rod without nut and bolt - This type of connecting rod consist of
single parts itself. And mostly used in single cylinder engine. For example: bikes,
scooter etc.

Fig 1.3 connecting rod without nut and bolt

1.2(c) I-beam connecting rod:

I-beam connecting rods owe their name to their resemblance to a capital 'I'
when you cut them apart. Connecting rods with an I-beam are the most common typeof
connecting rods and thus the ones most often used in serial production. They are cheap
to manufacture and generally withstand more than they would actually need to in
standard engines. Standard I-beam connecting rods are often heavier than those with
an H-beam. These are very lightweight and often sustain up to 1,000 hp, which is
mainly due to the fact that they are milled out of solid, high-strength steel.

1.2(d) Connecting rod with H-beam:

The cross-section of connecting rods with an H-beam resembles a capital 'H',

which is where they get their name from. They are designed for engines that run with
a lot of hp at low speeds, usually charged engines with a turbocharger or compressor.
These are optimal to withstand the pressure from compression. One example of this is
our H-beam connecting rod for the 2.5L TFSI (Turbo fuel stratified injection) like in
the Audi RS3.
 4

1.2(e) X-beam, cross beam:

Connecting rods with an X-beam are the latest achievement from connecting
rod manufacturers. They are like a sort of hybrid between I-beam and H-beam and
combine the best properties of their predecessors. These connecting rods have a large
cross-section, thereby distributing the tension across the entire connecting rod.
Because of their high rigidity and crack resistance as well as minimal weight, they are
basically made for racing.

1.3 FAILURES IN CONNECTING ROD:

The connecting rod connects the pistons to the crankshaft. It converts the linear
motion of the pistons to the rotary motion of the crankshaft. On every stroke, the
connecting rod is stretched and compressed. This pressure, plus other factors, can
cause the connecting rod to break. The broken rod can go through the engine block
completely, ruining the engine--a condition known as "throwing a rod."

1.3(a) Fatigue:

Fatigue is the main cause of broken connecting rods--especially in older

engines. The constant compression during the power stroke and stretching during the
exhaust stroke, over thousands of times a minute, eventually wears the metal out and
it becomes brittle and finally breaks. If the oil is low or dirty it can speed up. this
process. Running the engine hot can also speed up the process.

1.3(b) Pin Failure:

The pin that connects the connecting rod to the piston (called the piston pin, or
gudgeon pin) gets a lot of wear. If this pin snaps the connecting rod is no longer
connected to the engine. For some engines this results in catastrophic engine failure,
the connecting rod goes through the engine block or the crankshaft is bent, but for
some engines it just causes a dramatic loss of power.

1.3(c) Over Revving:

Over revving is the main cause of connecting rod failures in new and high
performance engines. If the tachometer hits the red, even briefly, then the connection
 5

rods are in danger of breaking. This is because the forces acting on a connecting rod
increase dramatically at high revolutions. It does not matter if the tachometer is going
into the red because the car is travelling at a high speed, is going too fast in a low gear
or is simply going too fast because the accelerator is pressed too far while the car is in
neutral, the stress is simply too high at extremely high RPM's.

1.3(d) Hydrolock:

Hydrolock is a deformation of the connecting rod caused when water gets into
the piston chamber. This usually happens after the car has been driven through deep
water such as a flooded street. If only a little water gets into the cylinder the car makes
a knocking or tapping sound and it can be repaired but if enough water gets in the
cylinder that it takes up all the space available at spark time, the connecting rod will
bend or snap

Fig 1.4: Connecting rod that initially failed through fatigue, the further damaged
from impact with crankshaft
 6

1.4 PROBLEM STATEMENT

The objective of the present work is to design and optimize a connecting rod
based upon its material properties by using different materials (aluminium alloy,
titanium alloy, structural steel). The material of connecting rod will be optimized
depending upon the analysis result output. CAD model of connecting rod will be
modelled in SOLID WORKS and then analysed in ANSYS Software. After analysis
a comparison will be made between existing material and alternate material which will
be suggested for the connecting rod in terms of stresses, factor of safety and the desired
output results can be achieved.

1.5 PROBLEM OBJECTIVE

1. Design and Analysis of the connecting rod based on the input parameters and then
modelling of the connecting rod in the SOLID WORKS software.

2. FEM tool software ANSYS workbench is given model and material input based on
the parameters obtained.

3. To determine the Von-Misses stresses, Shear stress, Total Deformation and to

optimize in the existing Connecting rod design.

4. To calculate stresses in critical areas and to identify the spots in the connecting rod
where there are more chances of failure.

5. To determine the structural analysis and modal analysis of the connecting rod with
different materials.

The main aim of the project is to determine the Von-Misses Stresses, Shear stress, on
which the new material can be compared with the existing material used for
Connecting Rod.
 7

CHAPTER 2

LITERATURE REVIEW

1) Kuldeep B, Arun L.R and Mohammed Faheem In their work connecting

rod is replaced by aluminium based composite material reinforced with silicon
carbide and fly ash. And it also describes the modelling and analysis of
connecting rod. FEA analysis was carried out by considering two materials.
The parameters like von misses stress, von misses strain and displacement
were obtained from ANSYS software. Compared to the former material the
new material found to have less weight and better stiffness. It resulted in
reduction of 43.48% of weight, with 75% reduction in displacement
2) D. Soorya Prabakaran and P. Ramachandran -The objective of their project
is to Evaluation of composite material connecting rod by using Aluminium
boron carbide. The connecting rods are commonly used in the internal
combustion engines and are subjected to millions of varying stress cycles
leading to fatigue failure. While the Composite connecting rods are lighter and
may offer better compressive strength, stiffness and fatigue resistance than
conventional connecting rods and their design still represents a major technical
challenge.
3) Sameer Nasir Momin and R.J. Gawande -This study incorporates FEA
modal analysis and experimental modal analysis of connecting rod. A
parametric model of Connecting rod is modelled using CATIA V5 R19
software and finite element analysis is carried out by using ANSYS Software.
Finite element method is used to determine natural frequencies of a connecting
rod and compare results with FFT analyzer. FFT analysis is done by hanging
the connecting rod at small end and experimental results were compared with
FEM.
4) Kumbha Sambaiah , Dr. A Rama Rao and Dr. M Mahesh they studied
about the optimization for connecting rod of internal combustion engine by
using two different materials like forged steel and C-70 connecting rods. For
fulfilling that need here we have selected typical forged steel or ultra-high
strength steel. This steel has strength level above 900MPa and this steel
generally have carbon content ranging from 0.01-0.45%. As strength increases,
 8

critical length/size of defect decreases. Once the critical length of the defect is
reached during processing or application, the material fails catastrophically
without any prior warning. Ultra high strength steels are classified according
to their composition microstructure. The steel C-70 has been introduced from
Europe as crack able forging steel.
5) ASHISH KUMAR and Er. SHUBHAM PARMAR The main aim of this
study is to analyze and optimize the Connecting Rod of Mahindra Pijo. This
research demonstrates the performance of a connecting rod basically depend
on its size optimization and material selection. The dimensions of the existing
connecting rod are measured with the help of a vernier caliper and micrometer.
The model of the connecting rod is designed in SOLIDWORKS with the
measured dimensions and the material of the existing connecting rod is SAE
8620 Finite Element Analysis (FEA) is used for the static structural and steady-
state thermal analysis of the connecting rod by considering the parameters such
as equivalent stress, von misses strain, maximum principal elastic strain, safety
factor and heat flux.
6) Adnan Ali Haider and Akash Kumar In this work, design and structural
analysis of connecting was performed. This work addresses the computation
of strength and deformation characteristics of a connecting rod. Finite element
method is used to analyse the connecting rod’s stress and deformation using
ANSYS Software. For this case, a fatigue and structural analysis will be
performed. The axial compressive load is greater than the axial tensile load.
Therefore, the design is only analyzed for the axial compressive loads. This
analysis shows the importance of the solution of the connecting rod
deformation in view of the changes in materials at the most important variants
of the stress. This variant is frequently overlooked and primary importance is
analyzed with the strength. Factor of Safety and the design of connecting rod
is checked and analyzed.
7) DR.B.K.Roy They have discussed about Various designs of connecting rod
have been analyzed in this report and finally an optimal design has been
selected for Finite Element Analysis. Using ANSYS-12.0 Workbench and
CATIA V5R19,Various results are found out and compared with the existing
results. It has been found out that the study presented here has came up with
 9

better results as well as safe design of connecting rod under permissible limits
of various parameters and safe stresses.

8) Aisha Muhammad and Ibrahim Haruna Shanono In this paper, Finite

Element Method (FEM) using ANSYS workbench was used to carry out the
weight optimization of the connection rod with target weight reduction of 20%,
30%, 40%, 50%, and 60% under a loading force of 30KN to determine the
mass that needs to be remove to minimize both weight and cost. Furthermore,
structural optimization is done to determine an optimized structure with new
deformation, Von-misses stress, and equivalent elastic strain values followed
by the comparison of these values before and after the structural optimization
to verify the effect of the analysis.
9) Mulukuntla Vidya Sagar and Kanjarla Shyam Kumar this work is mainly
discussed about how new material may be preferred and their uses. common
examples include materials which are stronger, lighter, or less expensive when
compared to traditional materials. As a connecting rod is rigid, it may transmit
either a push or a pull and so the rod may rotate 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. In which it undergoes structural deformations.
Thus the part which is modeled is converted into IGES file to importin ANSYS
work bench and static structural analysis is carried out at 16MPa of pressure
load by applying various materials such as Aluminum Alloy, Al6061
+B4C(Aluminum boron carbide) and 42Cr2Mo4 (special alloy steel) materials
used in this project. By applying these boundary conditions on connecting rod
the unknown variables such as stress, deformation, and strain are found using
the FEM Analysis based software.
10) MR. HD NITTUKAR AND MR. A R. NADAF In their work they describes
the designing and Analysis of connecting rod. Which is manufactured by using
Forged steel. In this, drawing is drafted from the calculations. A parametric
model of Connecting rod is modeled using NX 10 software and to that model,
analysis is carried out by using ANSYS Workbench Software. Finite element
analysis of connecting rod is done by considering the materials, such as
Titanium Alloy, Beryllium Alloy – 25, Magnesium Alloy and Aluminum 360.
 10

The best combination of parameters like Von misses Stress and strain,
Deformation, Factor of safety and weight reduction for two wheeler piston
were done in ANSYS software. Aluminium Alloy has more factor of safety,
reduce the weight, reduce the stress and stiffer than other material like Forged
Steel. With Fatigue analysis we can determine the lifetime of the connecting
rod.

SCOPE OF THE WORK FROM LITERATURE SURVEY

These research papers are very useful in design, analysis and optimization of
connecting rod. Researchers used many different methods and software for design,
analysis and optimization. Researches used different 3D modelling software like Solid
works Catia etc., and for stress analysis they used Ansys, Abacus analysis,
Optimization can be done by changing the material of Connecting rod.
 11

CHAPTER 3
THEORITICAL CALCULATIONS

3.1 DESIGN FOR PRESSURE CALCULATION

Consider 150cc Engine Specifications

Engine type = Air cooled 4-stroke

Bore x Stroke (mm) = 57 × 58.6mm2

Displacement = 149.5 CC

Maximum Power = 13.8 bhp @ 8500 rpm

Maximum Torque = 13.4 Nm @ 6000 rpm

Compression Ratio = 9.35:1

Density of Petrol (C8H18) = 737.22 kg/𝑚3

Auto ignition temp. = 60°𝐹 =288.85°𝐾

Mass = Density x volume = 737.22× 10-9× 149.5× 103 = 0.110214 kg

Molecular weight of petrol = 114.228 g/mole = 0.11423 kg/mole

From gas equation,

PV=𝑚 × 𝑅𝑠𝑝𝑒𝑐𝑖𝑓𝑖𝑐 × 𝑇

Where,

P = Gas Pressure, MPa

V = Volume

m = Mass, kg

T = Temperature, °k

𝑅𝑠𝑝𝑒𝑐𝑖𝑓𝑖𝑐 = Specific gas constant = R/M

𝑅𝑠𝑝𝑒𝑐𝑖𝑓𝑖𝑐 = 8.3144/0.114228
 12

𝑅𝑠𝑝𝑒𝑐𝑖𝑓𝑖𝑐 = 72.788 Nm/kg K

P = 𝑚 × 𝑅𝑠𝑝𝑒𝑐𝑖𝑓𝑖𝑐 × 𝑇⁄𝑉

P = 0.110214 x 72.788 x (288.85 / 149.5) = 15.49 MPa ≅ 16 MPa

Calculation is done for maximum Pressure of 16 MPa.

3.2 DESIGN CALCULATION FOR THE CONNECTING ROD

Thickness of the flange & web of the section = t

Width of the section, B = 4t

Height of the section, H = 5t

Area of the section, A = 11𝑡2

Moment of inertia about x-axis, 𝐼xx = 34.91𝑡4

Moment of inertia about y-axis, Iyy =10.91𝑡4

Therefore 𝐼xx/Iyy = 3.2

Length of the connecting rod (L) = 2 times stroke L = 117.2 mm

Total Force acting F = 𝐹𝑃 −𝐹𝐼

Where,

𝐹𝑃= force acting on the piston

𝐹𝐼 = force of inertia

𝐹𝑃 = ( 𝜋 /4 )𝐷2 ×Gas pressure

Where,

D = Bore Diameter

𝐹𝑃 = ( 𝜋 4 ) 572 × 15.49 = 38275 N

F𝐼 = 𝑚 × 𝜔2 × 𝑟 (𝑐𝑜𝑠∅ + 𝑐𝑜𝑠2∅ /𝑛 )

Where,
 13

M = Mass

𝜔 = 2𝜋8500/60 = 890.118 𝑟𝑎𝑑/𝑠𝑒𝑐

𝑛 = length of connecting rod(l) / crank radius(r)

=(2 × 𝑠𝑡𝑟𝑜𝑘𝑒)/(𝑠𝑡𝑟𝑜𝑘𝑒⁄2)

=117.2/29.3

∴𝑛=4

The maximum gas load occurs shortly after the dead centre position at ∅ = 3.3 °
cos(3.3) = 0.9983 ≅ 1

∴ 𝐹I = 0.110214 × 890.1182 × 0.0293 (1 + 1/4 )

=3200

So,

F = 38275-3200 = 35075 N

According to Rankin’s – Gordon formula,

𝐹 = (σc𝐴) /1+𝑎( 𝑙 𝐾𝑥𝑥)2

Where,

A = c/s area of connecting rod

l = Length of connecting rod

σc= Compressive yield stress

F = Buckling load

𝑎 = Constant depending upon material and end fixity coefficient

Kxx and Kyy = Radius of gyration of the section about x – x and y – y axis
respectively.

On substituting to Rankin’s formula

35075 = 170×11𝑡2 /1+0.002(117.2⁄1.78𝑡)2

By solving this,
 14

t =5.5 mm

Therefore,

Width B = 4t = 22 mm

Height H = 5t = 27.5 mm

Area A = 11𝑡 2 = 332.75 𝑚𝑚2

3.2(a) Design of small end:

Load on the small end (𝐹𝑝) = Projected area ×Bearing pressure

=dplp × Pbp

Where,

F𝑝 = 38275 N load on the piston pin

𝑑𝑝 = Inner dia. of the small end

𝑙𝑝 = length of the piston pin

= 1.5𝑏𝑝 to 2𝑏𝑝

P𝑏𝑝 = Bearing pressure

= 10.0 for oil engines.

= 12.5 to 15.4 for automotive engines.

We assume it is a 150cc engine, thus

P𝑏𝑝 = 15.4 Mpa

3.2(b) Design of Big end:

Load on the big end (𝐹𝑐 ) = Projected Area ×Bearing pressure

= 𝑑𝑐𝑙𝑐 ×Pbc

Where,

𝐹𝑐 = 38275 N load on the crankpin

𝑑𝑐 = Inner dia. of the big end

 15

𝑙𝑐 = length of the crank pin

= 1.25 𝑑𝑐 to 1.5 𝑑𝑐

𝑃𝑏𝑐 = 5 to 12.6 Mpa

Height at the small end H1 = 0.75H to 0.9 H

H1 = 0.9× 27.5= 24.75 mm

Height at the big end

H2 = 1.1H to 1.25H

H2 = 1.25× 27.5 = 34.375 mm

Substituting,

38275 = 2𝑑𝑝 × 𝑑𝑝 × 15.4

∴ 𝑑𝑝 = 35 mm

𝑙𝑝 =2𝑑𝑝= 70 mm

Outer diameter of small end = 𝑑𝑝 + 2𝑡𝑏 + 2𝑡𝑚

= 35 + [2×2] + [2×5]

= 49 mm

Where,

Thickness of bush (𝑡𝑏) = 2 to 5 mm

Marginal thickness (𝑡𝑚) = 5 to 10 mm

Substituting,

38275 = 1.5𝑑𝑐 × 𝑑𝑐 × 12.6 ∴ 𝑑𝑐 = 45 mm

𝑙𝑐 = 1.5𝑑𝑐= 67.5 mm

Outer diameter of big end = 𝑑𝑐 + 2𝑡𝑏 + 2𝑡𝑚 + 2𝑑𝑏

= 45 + [2×2] + [2×5] + [2×2]

= 63 mm
 16

Where,

Thickness of bush (𝑡𝑏) = 2 to 5 mm

Marginal thickness (𝑡𝑚) = 5 to 10 mm

Marginal thickness of bolt (𝑑𝑏 )= 2 to 5 mm

 17

3.3 FINAL DIMENSIONS

Table 3.1 Parameters of Connecting Rod

Parameters Size (mm)

Thickness of the connecting rod 5.5

(t)
Width of the section (B = 4t) 22

Height of the section (H = 5t) 27.5

Height at the big end (H1) 24.75

Height at the small end (H2) 34.375

Inner diameter of the small end 35

Outer diameter of the small end 49

Inner diameter of the big end 45

Outer diameter of the big end 63

 18

CHAPTER 4

MODELLING

4.1 INTRODUCTION TO SOLIDWORKS

SolidWorks is a solid modelling computer-aided design (CAD) and computer

aided engineering (CAE) program that runs primarily on Microsoft Windows.
SolidWorks is published by Dassault Systems.SolidWorks released its first product
SolidWorks 95, in November 1995. In 1997 Dassault, best known for its CATIA CAD
software, acquired SolidWorks. SolidWorks is a solid modeler, and utilizes a
parametric feature-based approach which was initially developed by PTC (Creo/Pro-
Engineer) to create models and assemblies. The software is written on Parasolid-
kernel.

Fig 4.1: SolidWorks interface

Parameters refer to constraints whose values determine the shape of geometry of the
model or assembly. Parameters can be either numerical parameters, such as line
lengths or circle diameters, or geometric parameters, such as tangent, parallel,
concentric, horizontal or vertical, etc. Numeric parameters can be associated with each
other through the use of relations, which allows them to capture design intent.
 19

Design intent is how the creator of the part wants it to respond to changes and updates.
For example, you would want the hole at the top of a beverage can to stay at the top
surface, regardless of the height or size of the can. SolidWorks allows the user to
specify that the hole is a feature on the top surface, and will then honour their design
intent no matter what height they later assign to the can.

Building a model in SolidWorks usually starts with a 2D sketch (although 3D sketches

are available for power users). The sketch consists of geometry such as points, lines,
arcs, conics (except the hyperbola), and splines. Dimensions are added to the sketch
to define the size and location of the geometry. Relations are used to define attributes
such as tangency, parallelism, perpendicularity, and concentricity. The parametric
nature of SolidWorks means that the dimensions and relations drive the geometry, not
the other way around. The dimensions in the sketch can be controlled independently,
or by relationships to other parameters inside or outside the sketch.

Fig 4.2 SolidWorks drawing interface

In an assembly, the analog to sketch relations are mates. Just as sketch relations define
conditions such as tangency, parallelism, and concentricity with respect to sketch
geometry, assembly mates define equivalent relations with respect to the individual
parts or components, allowing the easy construction of assemblies. SolidWorks also
includes additional advanced mating features such as gear and cam follower mates,
which allow modelled gear assemblies to accurately reproduce the rotational
movement of an actual gear train.
 20

Finally, drawings can be created either from parts or assemblies. Views are
automatically generated from the solid model, and notes, dimensions and tolerances
can then be easily added to the drawing as needed. The drawing module includes most
paper sizes (ANSI, ISO, DIN, GOST, JIS, BSI and SAC).

4.1(a) FEATURES:

3D Interconnect

Open proprietary 3D CAD data directly in SOLIDWORKS, allowing you to work

seamlessly with anyone, and incorporate design changes dramatically faster.

Wrap Feature

Create geometry on any face. You are no longer limited to cylindrical surfaces when
wrapping a sketch.

Advanced Hole Wizard

Allows for the creation of holes with multiple elements, allowing for definition on
either side. You now no longer need to use multiple hole wizard features to create
holes with different elements.

Sweep Profile

Previously you had to create a new sketch convert entities to create the same profile.
Now you can select faces, edges, and curves to create the same profile.

Magnetic Mates

Whether you're working in large layouts or common parts, just grab the part or
assembly until the magnet snaps it into place. It's as easy as click and drag.

Latest Version Overwrite

Allows you to check in your current version over your previous version, helping you
save space on your server by not saving every incremental version.

Offset On Surface

Make your life easier when working with complex geometry with the Offset on
Surface feature. It simplifies the creation of thickens, cut outs, and junctions.
 21

Animation Import

Create life-like animations without additional effort or time. Save time by importing
existing motion studies and animations to create amazing videos.

FASTER 2D DRAWING CREATION

Reference and link to BOM table cell elements in annotations. Parametrically mirror
drawing views without the model. Pre-defined layers in the layout tab etc.

Shaded Sketch Contours

A handy new option in SOLIDWORKS 2019 called Shaded Sketch Contours. It is

common for SOLIDWORKS users to sometimes unintentionally leave small gaps
between endpoints when creating sketched profiles. If a gap is small enough, it can
easily go undetected. this a new time-saving setting call Shaded Sketch Contours has
been introduced which makes any closed contour, shaded. This is great feedback for
users as they can immediately know the status of a sketch.

Extrude from Any Size Planar Face

SOLIDWORKS 2019 lets you create boss, cut, and surface extrudes from any size
surface, face, or plane. This same functionality is also available for Extruded Cut and
Extruded Surface. Of course, the surface or face must be planar. But it is limited to
just parts.

Simulation Results Processing

This feature in SOLIDWORKS 2019 makes for easier communication and results
visualization, but there are many other features that can help communicate the
simulation results as well. By setting a maximum value for our stress plot, we can
specify the color that we want values above that to be. This is done by clicking the top
of the color gradient on our plot key.

Convert Static Study to Non-Linear or Dynamic

When copy study is selected, we can copy our previous study into a new static study
or we can choose to change the type of study to either a non-linear or dynamic study.
As before when using duplicate study, we can choose new configurations and/or
choose a new name. Once non-linear is selected, we can choose either sub-type; static
 22

non-linear or dynamic non-linear. The same is true for the dynamic study, except
dynamic has 4 sub-types; modal type history, harmonic, random vibration, and
response spectrum analysis.

Sweep Profile selection of Faces, Edges and Curves

Previously to complete a sweep from existing geometry, a sketch was required for the
sweep profile. This would require to start a sketch and convert edges or faces to
complete the profile. Now a Face, Edge or Curve can be selected for time saving.

Dimensions

With the are extension line or opposite side selected you can attach the leader to an
extended radius. If it is not possible, the leader will attach to the opposite side of the
arc. Mirrored holes are included in the total instance count when using hole callout.

DimXpert

The DimXpert tools within SOLIDWORKS are used to add details for the model.
fabrication by adding tolerance features and associated 3D annotations. These 3D
annotations (datums, dimensions, and geometric tolerances) are used to partially or
fully document the geometry. As the annotations are created, they are automatically
oriented in 3D space to match the source feature orientation and the standard views
(Front. Top, Right, etc.) of a drawing.

(a) Select edges rather than planes Now in SOLIDWORKS 2019 basic location
dimensions can be created by selecting edges (like Smart Dimension) rather than
rotating the model to select planes.

(b) Basic size dimension-radi

Adding a basic size location for radii in SOLIDWORKS 2019 is as easy as using

the Smart dimension in sketching

(c) Dimension to reference features

Location dimensions may now be created from reference features like Planes,

Axis, Centre of Mass and Coordinate system.

 23

4.2 STEP BY STEP DESIGN OF A CONNECTING ROD

STEP 1

Drawing small end and big end of connecting rod and rod

Fig 4.3: SolidWorks dimensions in 2D

Fig 4.4: Extruding of small end, big end, shank and slot-cut in shank
 24

Fig 4.5: 3D structure of connecting rod

 25

CHAPTER 5

ANALYSIS

5.1 INTRODUCTION TO FINITE ELEMENT ANALYSIS

A rough answer to a wide range of engineering issues. Although it

was originally designed to investigate stresses in complex aircraft structures, it has
now been expanded and applied to the broader field of continuum mechanics.
Engineering institutions and business are paying close attention to it because of its
versatility and adaptability as an analysis tool. The finite element method has evolved
into a formidable tool for solving a wide range of engineering problems numerically.
Because complex issues may be modelled and released with relative ease, advances in
computer technology and CAD systems have led to growing usage of FEM in research
and industry.

5.2 Basic steps in the Finite Element Analysis :

a) Pre processing phase:

create and discretize the solution domain into finite elements i.e subdivide the real
continuum into nodes and elements.

• Assume a shape function to represent the physical behavior of an element; that

is an approximate continuous function is assumed to represent the solution of
an element.
• Develop equations for all the elements in the mesh..
• These generally take form
• [K][U] = [F]
• Where [K]' is a square matrix, known as stiffness matrix
• (U) is the vector of (unknown) nodal displacements or temperature
• {F}' is the vector of applied nodal forces • Assemble the elemental equations to
obtain the equations of the whole problem. Construct the global stiffness
matrix.
• Apply boundary conditions, initial conditions, and loading.
 26

b) Solution Phase:

Solve a set of linear or nonlinear algebraic equations simultaneously to obtain nodal

results of primary degrees of freedom or unknowns, such as displacement values at
different nodes in structural problem or temperature values at different nodes in heat
transfer problem.

c) Post processing phase:

• Computation of any secondary unknowns or variables e.g., the gradient of the

solution.
• Interpretation of the results to check whether the solution makes sense.
• Tabular and/or graphical presentation of the results.

5.3 Introduction to ANSYS Workbench:

ANSYS Workbench is the framework upon which the industry's broadest suite
of advanced engineering simulation technology is built. An innovative project
schematic view ties together the entire simulation process, guiding the user every step
of the way. Even complex multi physics analysis can be performed with drag and-drop
simplicity.

The ANSYS Workbench platform creates an automatic connection to share geometry

for both the fluid and structural analyses, reducing data storage and making it easier
to investigate the implications of geometry changes on both analyses. Furthermore, a
link is established to automatically transfer pressure loads from the fluid to the
structural analyses.

The toolbox and the project Schematic are the two main parts of the ANSYS
Workbench interface. The system templates in the toolbox can be used to create a
project. The project Schematic is the interface section where we may manage our
project. The new project schematic view provides a broad overview of the simulation
project. Even for complex studies using many physics, engineering purpose, data
relationships, and the status of the entire project are accessible at a glance. A
navigation bar and a toolbar with frequently used functionalities will also be visible.
Context menus on schematic items and cells can also be accessed by right-clicking on
them. Context menus allow you to add to and change your list.
 27

Fig 5.1: ANSYS work bench

5.3(a) ANSYS Workbench Features:

• Bidirectional, parametric links with all major CAD systems.

• Integrated, analysis-focused geometry modeling, repair, and simplification via
ANSYS Design Modeler.
• Highly-automated, physics-aware meshing.
• Automatic contact detection.
• Unequalled depth of capabilities within individual physics disciplines.
• Unparalleled breadth of simulation technologies.
• Complete analysis systems that guide the user start-to-finish through an
analysis.
• Comprehensive multi physics simulation with drag-and-drop ease of use.
• Flexible components enable tools to be deployed to best suit engineering
intent.
• Innovative project schematic view allows engineering intent, data
relationships, and the state of the project to be comprehended at a glance.
Complex project schematics can be saved for re-use.
• Pervasive, project-level parameter management across all physics.
• Automated what-if analyses with integrated design point capability.
 28

• Adaptive architecture with scripting and journaling capabilities and API's

enabling rapid integration of new and third-party solutions.

5.4 Structural Analysis

Structural analysis is probably the most common application of the finite

element method. The term structural (or structure) implies not only civil engineering
structures such as bridges and buildings, but also naval, aeronautical, and mechanical
structures such as ship hulls, aircraft bodies, and machine. housings, as well as
mechanical components such as pistons, machine parts, and tools.

5.4 (a) types of structural analysis

The types of structural analyses available in the ANSYS family of products are
explained below. The primary unknowns (nodal degrees of freedom) calculated in a
structural analysis are displacements. Other quantities, such as strains, stresses, and
reaction forces, are then derived from the nodal displacements. Structural analyses is
available in the ANSYS/Multi physics, ANSYS/Mechanical, ANSYS/Structural, and
ANSYS/Linear Plus programs only.

One can perform the following types of structural analyses

1) Static Analysis:

Used to determine displacements, stresses, etc., under static loading

conditions. It comprises of both linear and non-linear static analysis. Non linearity can
include plasticity, stress stiffening, large deflection, large strain, hyper elasticity,
contact surfaces, and creep.

2) Modal Analysis:

Used to calculate the natural frequencies and mode shapes of a structure. Different
mode extraction methods are available.

3) Harmonic Analysis:

Used to determine the response of a structure to harmonically time-varying loads.

 29

4) Transient Dynamic Analysis:

Used to determine the response of a structure to arbitrarily time-varying loads. All

non-linearity mentioned under Static Analysis above are allowed.

5) Spectrum Analysis:

An extension of the modal analysis, used to calculate stresses and strains due to a

response spectrum or a PSD input (random vibrations).

6) Buckling Analysis:

Used to calculate the buckling loads and determine the buckling mode shape. Both
linear (Eigen value) buckling and nonlinear buckling analyses are possible.

5.5 PROCEDURE FOR PERFORMING STATIC STRUCTURAL

ANALYSIS

STEP 1: Selection of analysis feature

Open Ansys workbench and then select static structural analysis from left side tool bar

Fig 5.2: Structural analysis interface

STEP 2: Engineering Data

The data to be calculated is to be submitted in the module properties such as

yield strength, young’s modulus, Poissons’s ratio, F.O.S are to be provided.
 30

Fig 5.3: Engineering data interface

STEP 3: INSERTION OF GEOMETRY

Right click on the geometry and then click on import geometry. Then close the
present tab and again right click on the geometry then click on the modify designer
tool.

Fig 5.4: Import of Geometry

STEP 4: MODEL

Right click on the model. To load the model in to work bench.

STEP 5: MESHING

Click on mesh option and insert patch confirming method and select meshing
method as Tetrahedrons.
 31

Fig 5.5: Meshing interface

Select sizing and set span angle center of mesh as fine.

Fig 5.6: Mesh Details

Fig 5.7: Connecting rod meshing model

 32

STEP 6: INSERTION OF SUPPORTS AND FORCES AND STATIC

STRUCTURE INTERFACE

Fig 5.8 Static Structural interface adding fixed supports and loads

5.9 Supports and loading

Again, right click on Static structural icon. Click on INSERT. Then select force and
click on apply. Then the force is defined by the component i.e., in which direction the
force is to be applied.

STEP 7: ANALYSIS

Right click on Solution icon. Click on INSERT. Then select Equivalent stress, Max.
Shear stress, Safety factor, Fatigue life and click on apply. Now right click on Solution
icon and click on Solve.
 33

Fig 5.10 Solutions

STEP 8: STATIC ANALYSIS RESULTS

5.5(a) MATERIALS : STRUCTURAL STEEL

Fig 5.11 Steel properties

Fig 5.12: Equivalent stress Fig 5.13: Max shear stress

 34

Fig 5.14: Safety factor Fig 5.15: Total deformation

Table 5.1 Results of structural analysis of Structural Steel

Mechanical value Maximum Minimum

Equivalent stress 275.56MPa 0.0054414MPa
Max shear stress 143.89MPa 0.0031369MPa
Factor of safety 15 0.90905
Total deformation 0.00011441m 0m

5.4(b) MATERIAL: ALLUMINIUM ALLOY

Fig 5.16 properties of aluminium alloy

 35

Fig 5.17 Equivalent stress Fig 5.18 Max shear stress

Fig 5.19 Safety factor Fig 5.20 Total deformation

 36

Table 5.2 Results of Structural Analysis of Aluminium alloy

Mechanical value Maximum Minimum
Equivalent stress 275.01MPa 0.0059090MPa
Max shear stress 142.35MPa 0.003412MPa
Factor of safety 15 1.0161
Total deformation 0.00032219m 0m

5.6(c) MATERIALS: TITANIUM ALLOY

Fig 5.21 Titanium alloy properties

Fig 5.22 Equivalent stress Fig 5.23 Max shear stress

 37

Fig 5.24 Safety factor Fig 5.25 Total deformation

Table 5.3 Results of Structural Analysis of Titanium Alloy

Mechanical value Maximum Minimum

Equivalent stress 275.68MPa 0.006449MPa
Max shear stress 141.17MPa 0.003716MPa
Factor of safety 15 3.375
Total deformation 0.00023721m 0m

Table 5.4 Results of structural Analysis

MATERIALS STRUCTURAL ALLUMINIUM TITANIUM

VALUES STEEL ALLOY ALLOY
Equivalent stress 275.56MPa 275.01MPa 275.68MPa
Max. Shear stress 143.89 142.35MPa 141.17MPa
Factor of safety 0.90905 1.0161 3.375
Mass 0.79897Kg 0.28193Kg 0.47022Kg
 38

Mass

Aluminum alloy 0.28193

Material

Titanium alloy 0.47022

Structural steel 0.79897

0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9

Structural steel Titanium alloy Aluminum alloy
Mass 0.79897 0.47022 0.28193

Kg

Fig 5.1 Mass vs Materials

Max.Shear Stress

Aluminium alloy 142.35

Materials

Titaniun alloy 145.17

Structural steel 143.89

140.5 141 141.5 142 142.5 143 143.5 144 144.5 145 145.5
Structural steel Titaniun alloy Aluminium alloy
Max. shear 143.89 145.17 142.35

MPa

Fig 5.2 Max. shear stress vs material

 39

Max. Equivalent stress

Aluminium alloy 275.01

Material

Titanium alloy 275.68

Structural steel 275.56

274.6 274.8 275 275.2 275.4 275.6 275.8

Structural steel Titanium alloy Aluminium alloy
Equivalent stress 275.56 275.68 275.01

Mpa

Fig 5.3 Equivalent stress vs Materials

Factor of safety

Titanium alloy 3.375

Materials

Aluminium alloy 1.0161

Structural steel 0.90905

0 0.5 1 1.5 2 2.5 3 3.5 4

Structural steel Aluminium alloy Titanium alloy
Factor of safety 0.90905 1.0161 3.375

Factor of safety

Fig 5.4 Factor of safety vs Materials

 40

5.6 PROCEDURE FOR PERFORMING MODAL ANALYSIS:

STEP 1: Selection of Analysis feature

Open Ansys 2020 R1 workbench and then select modal analysis from left side tool
bar.

Fig 5.26 Modal analysis Interface

STEP 2: Engineering Data

The data to be calculated is to be submitted in the module properties such as yield

strength, young’s modulus, Poissons’s ratio, F.O.S are to be provided.

Fig 5.27 Engineering data interface

 41

STEP 3: INSERTION OF GEOMETRY

Right click on the geometry and then click on Import Geometry. Then close the
present tab and again right click on the geometry then click on the modify designer
tool.

Fig 5.28 Import of geometry

STEP 4: MODEL

Right click on the model to get the connecting rod model.

STEP 5: MESHING

Click on mesh option and insert patch confirming method and select meshing
method as Tetrahedrons.

Fig 5.29 Meshing interface

 42

Select sizing and set span angle center of mesh as fine.

Fig 5.30 Mesh Details

STEP 6: INSERTION OF SUPPORTS AND FORCES AND MODAL

INTERFACE

Fig 5.31 Modal interface adding fixed supports and loads

Again, right click on Modal icon. Click on INSERT. Then select force and click on
apply. Then the force is defined by the component i.e., in which direction the force is
to be applied.

STEP 7: ANALYSIS

Right click on Solution icon. Click on INSERT. Then select Equivalent stress, Max.
Shear stress, Safety factor, Fatigue life and click on apply. Now right click on
Solution icon and click on Solve.
 43

5.6(a) MODAL ANALYSIS OF STEEL

Fig 5.32 Total Deformation 1 Fig 5.33 Total Deformation 2

Fig 5.34 Total Deformation 3 Fig 5.35 Total Deformation 4

 44

Fig 5.36 Total Deformation 5 Fig 5.37 Total Deformation 6

TABLE 5.5 Results of modal analysis of Structural steel

S.NO MODE FREQUENCY

1 1 1083.1
2 2 1647.6
3 3 2362.7
4 4 5533.8
5 5 5549.1
6 6 7184.7

Structual steel
8000 7184.7
7000
5533.8 5549.1
Frequency ()Hz

6000
5000
4000
3000 2362.7
1647.6
2000 1083.1
1000
0
NODE 1 NODE2 NODE 3 NODE 4 NODE 5 NODE 6
Modes

Graph 5.5 Frequency vs modes analysis of Structural steel

 45

5.6(b)MODAL ANALYSIS ON ALLUMINIUM ALLOY

Fig 5.38 Total Deformation 1 Fig 5.39 Total Deformation 2

Fig 5.40 Total Deformation 3 Fig 5.41 Total Deformation 4

 46

Fig 5.42 Total Deformation 5 Fig 5.43 Total Deformation 6

Table 5.6 Result of modal analysis of Aluminium alloy

s.no Mode Frequency(Hz)

1 1 1086.7
2 2 1653.7
3 3 2355.8
4 4 5544.2
5 5 5555.0
6 6 7221.9
Table 5.6 Result of modal analysis of Aluminium alloy

Aluminium alloy
8000 7221.9
7000
6000 5544.2 5555
Frequency ()Hz

5000
4000
3000 2355.8
1653.7
2000 1086.7
1000
0
1 2 3 4 5 6
Modes

Fig 5.6 Mode vs frequency analysis of Aluminium alloy

 47

5.6(c)Modal analysis on titanium alloy

Fig 5.44 Total Deformation 1 Fig 5.45 Total Deformation 2

Fig 5.46 Total Deformation 3 Fig 5.47 Total Deformation 4

 48

Fig 5.48 Total Deformation 5 Fig 5.49 Total Deformation 6

Table 5.7 Result of modal analysis of titanium alloy

s.no Mode Frequency (Hz)

1 1 978.9
2 2 1490.3
3 3 2109.0
4 4 4987.2
5 5 4992.7
6 6 6518.0

Titanium alloy
7000 6518
6000 4987.2 4992.7
Frequency()Hz

5000
4000
3000 2109
2000 1490.3
978.9
1000
0
1 2 3 4 5 6
Modes

Fig 5.7 Frequency vs Modes for Titanium alloy

 49

5.6(d) INTERPRETATION OF RESULUTS

1. The Connecting rod model was safe for only for titanium alloy and aluminium
alloy during the Static structural analysis and factor of safety is more than one for
both aluminium and titanium alloy and also having low density

2. Aluminium alloy has reduction in weight with respect to titanium alloy and
structural steel

3. Max shear stresses for all materials are in range but structural steel has max shear
stress

4. Von misses stresses for all materials are in range but structural steel has max shear
stress.

5. Aluminium alloy has high natural frequency with respect to the other structural
steel and titanium alloy.

6.Titanium has low natural frequency with respect to other aluminium alloy and
structural steel.
 50

CHAPTER 6

CONCLUSIONS

CONCLUSIONS

1. From the analysis it is clear that titanium alloy is best material for manufacturing of
connecting rod althrough it has more weight than the aluminium alloy it having more
factor of safety and high natural frequency which optimizes the design of connecting
rod

2. Aluminium alloy is second choice for production of manufacturing of connecting

rod

3. Structural steel is not effective with regarding to mass and it increases the weight
of connecting rod.

FUTURE SCOPE

The analysis is focused on static structural and modelling analysis. So, further study
may include dynamic loading and working conditions of the connecting rod. The
thermal analysis can also be performed , by using Ansys. Buckling load can also be
performed.

Further one can investigate the behaviour of connecting rod for the evaluation of
performance of existing model by carrying out Experimental Stress Analysis(ESA)

The above analysis can be performed assigning latest material composition to the
connecting rod for the further optimisation of design.
 51

REFERENCES

[1] KULDEEP BASAVARAJAPPA, MOHAMMED FAHEEM, “Analysis and

optimization of connecting rod using ALFASIC composites” International Journal of
Innovative Research in Science Engineering and Technology 2(6):2480-2487, June
2013

[2] D. SOORYA PRABAKARAN AND P. RAMACHANDRAN, “Design and

thermal analysis of Composite Connecting Rod ” International Journal of Engineering
and Robot Technology. 4(1), 2017, 28-36.

[3] KUMBHA SAMBAIAH, DR. A RAMA RAO AND DR. M MAHESH

“Optimization for thermal analysis connecting rod of internal combustion engine by
using two different materials” , International Journal of Applied Research 2017; 3(12):
278-282

[4] ASHISH KUMAR, Er. SHUBHAM PARMAR “Analytical Study and Design
Analysis of Connecting Rod of Mahindra Pijo by Finite Element Analysis”,
International Journal of Scientific Development and Research (IJSDR) www.ijsdr.org

[5] AISHA MUHAMMAD AND IBRAHIM HARUNA SHANONO “Finite

Element Analysis of a connecting rod in ANSYS”, March 2020IOP Conference
Series Materials Science and Engineering 736(2):022119

[6] DR. B.K.ROY “Design Analysis and Optimization of Various Parameters of

Connecting Rod using CAE Softwares” International Journal of New Innovations in
Engineering and Technology (IJNIET)
[7] MULUKUNTLA VIDYA SAGAR AND KANJARLA SHYAM KUMAR “Static
analysis of Connecting Rod.” International Journal of Modern Trends in Engineering
and Research (IJMTER)
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