Published by : International Journal of Engineering Research & Technology (IJERT)

http://www.ijert.org ISSN: 2278-0181

Vol. 5 Issue 10, October-2016

Design and Analysis of a Connecting Rod

Sebastian Antony, Arjun A., Shinos T. K Anoop P.
B.Tech. Mechanical Dept. Assistant Professor, Mechanical Dept.
Muthoot Institute of Technology and Science Muthoot Institute of Technology and Science
Ernakulam, India Ernakulam, India

Abstract— The main function of a connecting rod is to convert II. FINITE ELEMENT ANALYSIS
linear motion of piston to rotary motion of crank. It is the main A. Design
component of an internal combustion (IC) engine and is the most The connecting rod is designed using CATIA V5 6R 2014
heavily stressed part in the engine. During its operation various according to the specifications given below.
stresses are acting on connecting rod. The influence of
Parameter Value
compressive stress is more in connecting rod due to gas pressure
and whipping stress. Length of connecting rod 150
The objective of this study is to carry out a FEA analysis of a Outer diameter of big end 56
connecting rod and obtain its stress distribution on application Inner diameter of big end 48
of the force.
Geometry of connecting rod used for FEA, its generation, Outer diameter of small end 32
simplifications and accuracy is done by using Catia. Mesh Inner diameter of small end 24
generation, the load application, particularly the distribution at
Table 1: Dimensions of Connecting Rod
the contact area, factors that decide application of the restraints
and validation of the FEA model are also discussed. FEM was
used to determine structural behavior under static load
condition (static FEA).

Keywords—Connecting Rod, Catia, Ansys, FEA

I. INTRODUCTION
In modern automotive internal combustion engines, the
connecting rods are most usually made of steel for production
engines, but can be made of aluminium (for lightness and the
ability to absorb high impact at the expense of durability) or
titanium (for a combination of strength and lightness at the
expense of affordability) for high performance engines. They Fig 1: Catia Model of Connecting Rod
are not rigidly fixed at either end, hence the angle between B. Meshing
the connecting rod and the piston changes as the rod moves The connecting rod model is imported to the ANSYS
up and down and rotates around the crankshaft. Connecting (mechanical APDL 14.5) by converting the Catia file into .anf
rods are manufactured by means of forging. extension file format. The element type selected is solid185.
After successful import of model material property is defined.
Being one of the most integral parts in an engine’s design, the The materials and their properties used and necessary for the
connecting rod must be able to withstand tremendous loads analysis is given in table 2.
and transmit a great deal of power. In a reciprocating piston
engines, connecting rod connects the piston to the crank or Material Young’s modulus Poisson’s Density
crankshaft. Together with the crank, they form a simple (GPa) ratio (Kg/mm3)
mechanism that converts reciprocating motion into rotating Steel 200 .303 8050
motion. Aluminium 69 .334 2700
As the connecting rod is rigid, it may transmit either a push or
Table 2: Material Properties
a pull and so the rod may rotate the crank through both halves
of a revolution, i.e. piston pushing and piston pulling. After defining the element type and material property,
meshing is done. Meshing is probably the most important part
The small end is attatched to the piston pin and the big end in analysis. Meshing means to create a mesh of some grid-
connects to the bearing journal on the crank. Typically there points called 'nodes'. It's done with a variety of tools &
is a pinhole bored through the bearing and the big end of the options available in the software. The results are calculated
connecting rod so that pressurized lubricating motor oil by solving the relevant governing equations numerically at
squirts out onto the thrust side of the cylinder wall to lubricate each of the nodes of the mesh. For the design under
the travel of the pistons and piston rings. consideration, finite element mesh is generated using
tetrahedral mesh type taking fine size to 1mm and minimum
edge length as 0.1mm with 50730 nodes.

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Vol. 5 Issue 10, October-2016

Fig 2: Meshed Model Of Connecting Rod

Fig.4: Total Deformation of Aluminium
C. Load Analysis
1. Compressive Loading:
Crank End: p = 37.66 MPa
Piston pin End: p = 69.98 MPa

2. Tensile Loading:
Crank End: p = 41.5 MPa
Piston pin End: p = 77.17 MPa

Since the analysis is linear and elastic, for static analysis the
stress, displacement and strain are proportional to the
magnitude of the load. Therefore, the result obtained from
FEA is applied to several elastic load carries in a proportional
manner.

a) Compression at Bigger end

For the analysis of connecting rod, a compressive force
of magnitude 37.66MPa is applied on the bigger end, keeping
the smaller end fixed. Fig.5: Von-Mises Stress of Steel

Fig.3: Total Deformation of Steel Fig.6: Von Mises Stress of Aluminium

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Vol. 5 Issue 10, October-2016

b) Tension at bigger end

A tensile force of magnitude 41.15 MPa is applied at the
bigger end while keeping the smaller end remain fixed.

Fig.10: Von Mises Stress of Aluminium

c) Compression in Smaller End

A compressive load of magnitude 69.98 MPa is
Fig.7: Total Deformation of Steel applied at the smaller end keeping the bigger end fixed.

Fig.11: Total Deformation of Steel

Fig.8: Total Deformation of Aluminium

Fig.12: Total Deformation of Aluminium

Fig.9: Von-Mises Stress of Steel

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Vol. 5 Issue 10, October-2016

Fig.13: Von-Mises Stress of Steel

Fig.16: Total Deformation of Aluminium

Fig.14: Von Mises Stress of Aluminium Fig.17: Von-Mises Stress of Steel

d) Tension in Smaller End

A tensile force of 77.17 MPa is applied at the
smaller end while keeping the bigger end remains fixed.

Fig.18: Von Mises Stress of Aluminium

Fig.15: Total Deformation of Steel

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Vol. 5 Issue 10, October-2016

III. RESULTS AND DISCUSSIONS Buckling and bending stresses, non – symmetric shape of
Material: Steel connecting rod, Flash and bolt holes was eliminated while
Method of Load applied Maximum Maximum stress analysis. We could conclude that the influence of
loading (MPa) displacement (N/mm2) compressive stress is more in connecting rod due to gas
(mm) pressure and whipping stress as shown. The piston region
Compressive at 41.15 0.012 2490.87 suffers tensile stress due to inertia loads. The more stressed
bigger end
part of the rod is being shown using von misses stress plot.
Tensile at bigger 37.66 0.007 1605.51
end IV.CONCLUSION
Compressive at 77.17 0.005 2044.90
small end
It was observed that connecting Rod made up of
Tensile at 69.98 0.003 1267.33 Aluminium has higher intensity of stress induced as
smaller end compared to connecting Rod made up of Steel. Also there is a
great opportunity to improve the design. Hence steel is a
Material: Aluminium better choice for connecting rods.
Method of Load applied Maximum Maximum stress
loading (MPa ) displacement (N/mm2) REFERENCE
(mm) [1] Hippoliti, R., 1993, “FEM method for design and
Compressive at 41.15 0.055 3611.37 optimization of connecting rods for small two-stroke engines,” Small
bigger end Engine Technology Conference, pp. 217-231.
Tensile at bigger 37.66 0.034 2655.57 [2] Serag, S., Sevien, L., Sheha, G., and El-Beshtawi, I., 1989, “Optimal
end design of the connecting-rod”, Modelling, Simulation and Control, B,
Compressive at 77.17 0.016 1999.21 AMSE Press, Vol. 24, No. 3, pp.49-63.
small end [3] Mukesh Kumar, Veerendra Kumar” Finite Element Analysis of I.C
Tensile at 69.98 0.008 1177.86 Engine Connecting Rod: A Review”,International Journal Of
smaller end Engineering Sciences & Research Technology July, 2014
[4] Kuldeep B, Arun L.R, Mohammed Faheem “Analysis and optimization
of Connecting rod using Alfasic Composites”,International Journal of
Comparison of von mises stress variation for the two Innovative Research in Science, Engineering and Technology;Vol. 2,
materials are as shown below, Issue 6, June 2013
[5] Abhinavgautam, K Priya Ajit “Static Stress Analysis of Connecting
Rod Using FEA Approach”, Journal of Mechanical and Civil
Engineering (IOSR-JMCE) Volume 10, Issue 1 (Nov. - Dec. 2013)
4000
3500
3000
maximum 2500
stress in 2000
N/mm2 1500
1000
500
0
steel compressive

aluminium load type

Graph 1: Load applied at The Bigger End

2500

2000
maximum 1500
stress in
N/mm2 1000
500
steel 0
aluminium compressive tensile
load type

Graph 2: Load applied at smaller End

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