Guide

Prof. HARSHAL AHIRE

 CONTENTS
1. Abstract
2. Introduction
3. Literature Review
4. Specification of problem
5. Aims and objectives
6. Methodology
7. Comparison of Results
8. Conclusions
• References
 INTRODUCTION
• Topology optimization is a mathematical method that optimizes material layout within a given design space ,
for a given set of loads , boundary conditions and constraints with the goal of maximizing the performance of
a the system.
• Topology optimization is very efficient method to check the performance of modified version of the main
component without manufacturing the actual model of the component which saves the cost of manufacturing.
• These method is widely used in industries who makes modification in their product to maintain their position
in competitive market.
• The intermediate component between crank and piston is known as connecting rod. Today, connecting rods
are best known through their use in internal combustion piston engines, such as automotive engines.
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 trans-fer linear,
reciprocating motion of the piston into rotary motion of the crankshaft.
 LITERATURE REVIEW
Authors Methodology Conclusion

Mohd Nizam Sudin • Brake pedal was designed in SOLIDWORKS software • Reduction in weight of brake pedal without the
• Analyzed in ANSYS software substitution of material was done with the application
• Weight reduction was done by application of topology optimization and analysed in of topology optimization.
ANSYS software for checking stress distribution

A. Merulla • Designing and analysis of base model of chassis. • Best model from finite number of modified models
• Designing of new models of chassis for optimal distribution of material and to was selected which satisfies requirements and
become more efficient than base model. demand.
• Analyzing finite number of modified models and selecting best model which
satisfies demands.

Dipalee S. Bedse • Connecting rod of HERO HONDA Motor cycle was designed in CATIA and All • In this case present Hero Honda Motor Cycle
parameters related to it are check in HYPERMESH software . connecting rod fatigue life is 8.9*107 no. of cycles.
• Also tested experimentally on UTM. • In order to improve fatigue life of connecting rod we
(2017)
• Modifications were made in neck radius at crank and pin end. make small changes in geometry of connecting rod ie.
• Material – Carbon Steel 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.
 LITERATURE REVIEW
Authors Methodology Conclusion

Dr.K.Tirupathi • Connecting rod of SUZUKI GS150R Motorbike was designed on PRO-E 4.0 software • The working factor of safety is nearer to theoretical
Reddy and checked on ANSYS software by applying boundary conditions. factor of safety in aluminum boron carbide.
• Changes were made in thickness, width and height of connecting rod. • Percentage of reduction in weight is same in
• Present material – Carbon Steel Aluminum 360 and aluminum boron carbide.
(2012) • Replaced with materials – 1. Al reinforced with boron carbide Percentage of increase in stiffness in aluminum
2. Al 360 boron carbide is more.
3. Titanium • Percentage of reducing in stress ALUMINIUM
BORON CARBIDE and ALUMNUM is same than
CARBON STEEL.
Pramod bhingole • Connecting rod of BAJAJ PULSAR 150cc was designed on CATIA software and • 42CrMo steel alloy which required less material and
checked on ANSYS 14.0 software by applying boundary conditions. less dimensions to sustain required pressure
• Present material was carbon steel and it was replaced with three materials ( 20CrMo, generated inside the cylinder compared with 20CrMo
(2014)
30CrMo and 42CrMo ). Performance of three materials was tested on ANSYS software and 30crMo materials connecting rod.
and best material was selected. • For the same amount of forces acting on the
connecting rod, the steel alloy 42crMo is 11.67 %
less in weight with respect to 20CrMo whereas
30CrMo alloy is only 6.42 % less compared with the
20CrMo conceding rod.
A.Jafari • Connecting rod of universal tractor (U650) was designed in CATIA and its fatigue • The fatigue analysis of connecting rod was done and
analysis was done in ANSYS software. results of it were compare with requirements to
• Connecting rod was made from material Cast Iron. make connecting rod with proper material to
(2017) withstand the conditions and requirements.
 LITERATURE REVIEW
Authors Methodology Conclusion

B.Anusha • Connecting rod of HERO HONDA SPLENDOR • The stress induced in the structural steel is less
which is market available is selected for the than the cast iron therefore structural steel is used
present investigation. The dimensions are found for connecting rod.
(2017) using vernier caliper and screw gauge.
• The software results of two materials are
compared and utilized for designing the
connecting rod.

Akshaydata vinayakrao • Connecting rod of two wheeler was designed in • Aluminium is selected as material for connecting
CATIA V5 R21 software and checked in ANSYS rod as it has less weight compare to other
18.1 software. materials and significant strength
(2016)
• Present material was carbon steel and compared
its performance with three other materials ( SAE
4340, 42CrMo4 and Al7075-T651)
• Aim is to select material with less weight and
sufficient strength.
 Specification of 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 SOLIDWORKS and it’ll be analyzed in ANSYS 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 (ANSYS). 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.
 AIMS AND OBJECTIVES
• The aim of the of the project is to design modified version of current model of connecting rod which will have
the more strength, long life and less material requirement than current one.
• objectives :
a) Find out the problem areas by studying the existing system of linkages in which identify the different para-
meters 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 SOLIDWORKS and it’ll be analyzed in ANSYS 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 ANSYS software.
e) To recommend the best alternative design for the connecting rod through experimentation and validation.
 Methodology
1. Accurate measurement of dimensions of connecting rod
2. Modelling of connecting rod in SOLIDWORKS software
3. Analyzing in ANSYS software by applying boundary conditions
4. Modifications in dimensions or material
5. Analysis of modified model in ANSYS software
6. Finding fatigue life of basic and modified model using FEMCAT
software
7. Comparison of various parameters between modified and basic
model
8. Numerical analysis of both models
9. Validation of modified model
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.
REFERENCES

[1] Ashley, S. (2010) Shedding pounds on a magnesium diet. Automotive Engineering International, pp. 34-36.
[2].Bendsøe, M.P. & Kikuchi, N. 1988. Generating optimal topologies in structural design using homogenization method.
Computer Methods in Applied Mechanics and Engineering 71: 197-224.
[3]. Afzal, “Fatigue Behavior and Life prediction of Forged Steel and PM Connecting Rods”, Master’s Thesis, University of
Toledo, 2004
[4]. Ahad Ridzun Bin Ibrahim, “Analysis of Connecting Rod Fracture Using Finite Element Analy-sis”,pp.110-112.
[5]. 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.
[6]. 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.
[7]. 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
[8]. Swapnil B. Ikhar, “Modeling and Analysis of Connecting Rod of Two Wheeler (Hero Honda Splendor)” Discovery, Volume
24, Number 83, October 4, 2014
[9]. 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.
[10]. Pravardhan S. Shenoy, “Dynamic load analysis and optimization of connecting rod”, 2004,pp. 30-42.
[11]. 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.
[12]. Schreier, L, “Tension and compression in connecting rods”, 1999.
[13]. V.B.Bhandari Design Data book