Experimental & Analysis of Connecting Rod Optimization for Weight Reduction

IJSTE - International Journal of Science Technology & Engineering | Volume 4 | Issue 4 | October 2017 ISSN (online): 2349-784X

Experimental & Analysis of Connecting Rod Optimization for Weight Reduction Prof. N. D. Patil Assistant Professor PVPIT Budhgaon

Prof. P. P. Awate Assistant Professor PVPIT Budhgaon Prof. S. P. Shinde Assistant Professor PVPIT Budhgaon

Abstract Connecting rods are widely used in a variety of engines such as in-line engines, V-engines, opposed cylinder engines, radial engines, and oppose-piston engines and in compressors. The connecting rod is an integral component of internal combustion engine and compressor. It acts as a linkage between piston and crankshaft. The connecting rod has some numbers of zones, namely, the small end (also called piston pin end), the central shank (I-cross-section) and the big end (also called as crank pin end). The connecting rod is a pin is jointed in which more weight is concentrated towards the big end. To study this property, the location of the center of gravity point of connecting rod lies more towards the big end. The connecting rod can be make either by casting, powder metallurgy or forging. The connecting rods are widely manufactured of forged steel, but can be made of aluminum 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 of engines, or of cast iron. Keywords: Analysis of Connecting Rod Optimization, Connecting Rod Optimization for Weight Reduction ________________________________________________________________________________________________________ I.

INTRODUCTION

Objectives           

Modeling current connecting rod. Analyzing for stresses and deformation. Topological optimization for the model. Results from topological optimization will be implemented on existing model. Analyzing for stresses and deformation on optimized model. Machining the existing connecting rod as per optimization result. Finding high strain portion from CAE software. Mounting strain gauge on same portion. Preparing fixtures to hold connecting rod for experimental testing. To conduct test on Universal Testing Machine to find stress and deflection of existing connecting rod. Correlating results of both CAE and experimental. Connecting Rod

Forces existing on the connecting rod, the various forces acting on the connecting rod are as follows:  Force on the piston due to gas pressure and inertia of the reciprocating parts.  Force due to inertia of the connecting rod or inertia bending forces.  Force due to friction of the piston rings and of the piston.  Force due to friction of the piston pin bearing and the crankpin bearing. In designing a connecting rod, the following Dimensions are required to be determined.  Dimensions of cross-section of the connecting rod.  Dimensions of the crankpin at the big end and the piston pin at the small end.  Size of bolts for securing the big end cap.  Thickness of the big end cap.

4

Experimental & Analysis of Connecting Rod Optimization for Weight Reduction (IJSTE/ Volume 4 / Issue 4 / 002)

Fig. 1: 2D Drafting of Connecting Rod

Force Calculations We know, Crank throw (t’) = 64mm Dia. of Bore (d) calculate as follows, cc d=√ 3π × t′

5883 =√ 3π × 6.4

d = 9.876cm

Pressure (pb) exerted due to combustion on piston head, BHP × 746 × 60 pb = pb = L×A×N×K×n

135 × 746 × 60 π 4

1 2

0.128 × × 98.76 × 10−3 ×2400 × × 6

Pressure (pb) = 855947.1 N/m2 Therefore, Force (F) = Pressure x C/S Area = 855947.1xπ/4 x (98.76x10-3)2 = 6556.64 ~ 6560N II. FINITE ELEMENT ANALYSIS OF CONNECTING ROD

Yield Strength 250 MPa

 

Table – 1 Finite Element analysis Density Poisons Ratio 7850 kg/m3 0.3

Young’s Modulus 200GPa

Component: Connecting Rod Material: Mild Steel Mechanical Properties of Mild Steel

By using design parameters of existing connecting model create 3D CAD model of connecting rod using CATIA software and then model is imported in ANSYS software for further finite element analysis of connecting rod.

Fig. 2: 3D CAD model of connecting rod

5

Experimental & Analysis of Connecting Rod Optimization for Weight Reduction (IJSTE/ Volume 4 / Issue 4 / 002)

CAD Geometry of a exiting model in CATIYA

Fig. 3: CAD Model of Connecting Rod

CAD Geometry of an exiting model in ANSYS

Fig. 4: CAD Geometry of an existing model Table - 2 Properties of Mild Steel Material Mild Steel Youngâ&#x20AC;&#x2122;s Modulus 200 GPa Poisons Ratio 0.3 Density 7850 kg/m^3 Yield Strength 250 MPa

Meshing for exiting model in ANSYS

Fig. 5: Meshing Exiting Model

6

Experimental & Analysis of Connecting Rod Optimization for Weight Reduction (IJSTE/ Volume 4 / Issue 4 / 002)

Table – 3 Meshing Exiting Model Element & Nodes Element type Wedge No. of Elements 82105 No. of Nodes 52748

III. CONCLUSION The modeling of connecting rod and FE Analysis has been presented. Topology optimization were analyzed to the connecting rod and according to the results, it can be concluded that the weight of optimized design is 11% lighter The results clearly indicate that the new design much lighter .Material optimization approach will be considered for future research. REFERENCES [1] [2] [3] [4] [5] [6] [7] [8] [9]

Kuldeep B, Arun L.R, Mohammed Faheem “Analysis and optimization of connecting rod using alfasic composites”, International Journal of Innovative Research in Science, Engineering and Technology, Vol-2, Issue-6, June 2013. AbhinavGautam, K Priya Ajit “Static Stress Analysis of Connecting Rod Using Finite Element Approach” IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE) e-ISSN: 2278-1684, p-ISSN: 2320-334X, Volume 10, Issue 1 (Nov. - Dec. 2013), PP 47-51 Vivek.c.pathade, Bhumeshwar Patle, Ajay N. Ingale ”Stress Analysis of I.C. Engine Connecting Rod by FEM”, International Journal of Engineering and Innovative Technology, Vol-1, Issue-3, pp-12-15, March2012. J.D.Ramani, Sunil Shukla, Pushpendra Kumar Sharma, “FE-Analysis of Connecting Rod of I.C.Engine by Using Ansys for Material Optimization” Int. Journal of Engineering Research and Applications www.ijera.com ISSN : 2248-9622, Vol. 4, Issue 3( Version 1), March 2014, pp.216-220 K. Sudershan Kumar, Dr. k. Tirupathi Reddy, Syed Altaf Hussan “Modeling and analysis of two Wheeler connecting rod”, International Journal of Modern Engineering Research, Vol -2, Issue- 5, pp-3367-3371, Sep-Oct-2012. Pravardhan S. Shenoy “Dynamic Load Analysis and Optimization of Connecting Rod” The University of Toledo May 2014. Leela Krishna Vegi, Venu Gopal Vegi, “Design And Analysis of Connecting Rod Using Forged steel,” International Journal of Scientific & Engineering Research, Volume 4, Issue 6, June-2013 ISSN 2229-5518. Hypermesh Help Desk for Topology Optimization. Dassault Systems user manual.

7

Turn static files into dynamic content formats.

Create a flipbook

Experimental & Analysis of Connecting Rod Optimization for Weight Reduction

Published on Feb 6, 2018

IJSTE

Connecting rods are widely used in a variety of engines such as in-line engines, V-engines, opposed cylinder engines, radial engines, and oppose-piston engines and in compressors. The connecting rod is an integral component of internal combustion engine and compressor. It acts as a linkage between piston and crankshaft. The connecting rod has some numbers of zones, namely, the small end (also called piston pin end), the central shank (I-cross-section) and the big end (also called as crank pin end). The connecting rod is a pin is jointed in which more weight is concentrated towards the big end. To study this property, the location of the center of gravity point of connecting rod lies more towards the big end. The connecting rod can be make either by casting, powder metallurgy or forging.