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P. G. Student- ABMSPs Anantarao Pawar College of Engineering & Research, Parvati. (Pune University)
Assistant Professor- ABMSPs Anantarao Pawar College of Engineering & Research, Parvati. (Pune University)
ABSTRACT
The paper deals with the static and fatigue analysis of optimized design of automotive connecting rod. Optimized design is
nothing but modification of existing design having initial weight 11.46kg. After modifying I-Section, there is about 17.37%
weight reduction achieved. Fatigue analysis of modified design having weight of 9.47kg, shows fatigue life of 1.5E006.
Experimental validation is done on optimized Connecting Rod design by testing the same on servo hydraulic testing machine
which shows same fatigue life as given by FEA analysis. Then failure analysis has been carried out to check whether any other
factor is responsible for this failure except design parameters or not. These checked parameters are chemical composition,
surface finish at failure region and grain flow. These parameters are as per specifications. So we can say that failure is due to
design only. But since fatigue life is sufficient, the modified design is optimized on.
Keywords: Connecting rod, Mass Optimization, Static Analysis, Fatigue Analysis, Fatigue Factor of safety,
Experimental Validation, Failure Analysis.
1. INTRODUCTION
1.1 Existing Design Analysis Summary
We have carried out static and fatigue analysis of existing design which is having geometrical detail is as follows. Its
mass is 11.46kg.
Compression at Piston
End
3rd Principal Stress
350 MPa
(at cross oil hole)
Fatigue Life
2.3
1.393E7
Note: Since loading at piston end condition is worse than loading at crank end, we will consider loading at piston end
condition for simulating most worst condition, so that design will be on safer side.
1.2 Topology Optimization
Here topology optimization is carried out in order to optimize the original connecting rod. HYPERMESH OptiStruct is
used for optimization analysis. Here blue color shows scope for material removal.
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Stress constraint
Optimization Response
Boundary conditions.
Accordingly, we modify existing design and analyzed the under same loading and boundary conditions as discussed
below.
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142 MPa
439 MPa
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1. FE Input Window: - This window is starting point of fatigue analysis through which we taking the FE input data.
This data is nothing but the .rst file that we have prepared during above static analysis. This file contains two load
cases i.e. tension loading and compression loading. This FE input data is used for fatigue life calculations.
2. SN-Analysis: - This window is main part of this software, where actual fatigue life calculations are carried out. Here,
we goes through different steps related to defining material and loading conditions and accordingly this will calculate
fatigue life for each and every node.
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The rods are used to test under constant amplitude axial loading at a frequency of between 1 to 3.5Hz.
Load conditions used: Rated speed: 5270 kgf (i.e. equivalent to inertia force = 15699.555N.) to -27020 kgf (i.e.
equivalent to Gas force = -265071.8801N.) Total 10 connecting rods are tested and their results are as follow.
4.2Fatigue Life Results by Experimental Fatigue Test
No. of Cycles
Passed
1,482,326
Failure location
T2
1,43,598
T3
1,254,383
T4
1,358,339
T5
1,409,634
T6
T7
5,94,612be
1,432,242
T8
1,329,924
T9
1,426,954
T10
1,379,258
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From experimental results, it is clear that out of 10 tests, 8 connecting rod is failed at oil way cross drilling which is the
same location shown by FEA Analysis and Life also matching with that of calculated by the N-Code software which in
the range of 1E006 to 1.51E006 cycles.
C
0.38
0.44
0.43
Ni
Mn
0.70
1.00
0.84
Mo
Si
0.10
0.40
0.32
Al
P
0.020
0.016
Cu
S
0.025
0.040
0.030
V
Cr
0.90
1.20
1.07
B
Min. %
0.15
0.010
Max. %
0.10
0.25
0.040
0.08
Actual
0.09
0.20
0.036
0.08
0.007
0.0002
Remark: Chemical Compositions meets the specifications and confirms to 708M40T as per BS970
5.2Microstructure
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Remark: Crack is initiated from machined surface and no inclusion observed at Fracture initiation point.
5.5 Grain Flow
6.CONCLUSIONS
Existing design of connecting rod is having mass of 11.46kg and having fatigue factor of safety 2.38. Fatigue life
of this design is 1.393E007 cycles, which somewhat more than the requirement criteria of E006 cycles.
In Modified design, we have removed material from existing design so as to get 17.35% weight reduction. This
design is having fatigue factor of safety 1.81 and having fatigue life of 1.581E006 cycles, which is satisfying the
criteria of range of E006 cycles.
So, removing the material from different sections, stress level increases and fatigue factor of safety along with
fatigue life reduced. But if removal of material in such fashion that fatigue factor of safety is in between 1.5 to 2.0
then component will get sufficient fatigue life in the range of E006 cycles.
From experimental results, it is clear that out of 10 tests, 8 connecting rod is failed at oil way cross drilling which
is the same location shown by FEA Analysis and Life also matching with that of calculated by the N-Code software
which in the range of 1E006 to 1.51E006 cycles.
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Since all other factors contributing to fatigue life are as per specifications, connecting rod fatigue failure is due to
Design aspect only. So if that component is having sufficient fatigue life (i.e. in the range if 106Cycles) then our
Design is Optimum one.
References
[1] P. C. Sharma and Aggarwal, A text book of Machine Design, fourth edition 1993, S. S. Kataria and sons
publication.
[2] R K. Jain, A text book Machine Design, Seventh edition 1995, Khanna publications.
[3] Priyanka D. Toliya, Ravi C. Trivedi, Prof. Nikhil J. Chotai, Design and Finite Element Analysis Of Aluminium6351 Connecting Rod, International Journal of Engineering Research & Technology (IJERT) ISSN: 2278-0181,
Vol. 2 Issue 5, May - 2013.
[4] M.M. Noor, M.N. Shuhaizal, K. Kadirgama, Julie J. Mohamed, M. R. M. Rejab, A. N. M. Rose, Analysis Of
Connecting Rod Based On Finite Element Approach , Malaysian Technical Universities Conference on
Engineering and Technology March 8-10, 2008, ISBN 978-983-42358-4-0.
[5] Manish P Vekariya, Marmik M Dave, Static Structure Analysis of Diesel Truck Engine Connecting Rod volume
2, issue 6, June 2013 ISSN No. 2277-8179.
[6] Abhinav Gautam, 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.
AUTHOR
Vikram Appa Shedge received the Bachelor of Engineering degree with distinction in
Mechanical Engineering from Rajarambapu Institute of Technology, Sakharale in 2012 and
currently working as a student of M. E.- Design in Pune University (ABMSPs Anantarao
Pawar College of Engineering & Research, Parvati- Pune). During 2012-2013, he worked as an
Assistant Professor at PESs, College of Engineering, Phaltan.
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