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Mehancis of Materials 2

Project Report

Submitted By:
Faizan Akbar 705-BSME-FET-F17B

Hassan Ali 722-BSME-FET-F17B

Submitted To:

Engr Sajjad Ahmed

Date of Submission:

22nd May, 2019


To study the failure of Connecting Rod
Abstract: In the present work, a failed connecting rod from a automobile
engine was investigated for the root cause of and possible mechanisms
leading to its premature failure. It is most likely that the connecting rod
failed on the end of exhaust stroke due to the tensile force being at the
highest TDC. Observation of the fracture surface reveals fatigue fracture
morphology, as observed in similarly connecting rods. Upon dismantling the
engine, a connecting rod was found to have failed along with its neck and
its slip bearings. Connecting rods undergo cyclical tensile and compressive
loading during the combustion cycle, suggesting fatigue could be the cause
of a failure.

Introduction:
A connecting rod made up of 2024-T6 Aluminum alloy. It may be fractured
due to cyclic tensile and compressive loading. We will find the forces which
causes the fatigue.

If failure is due to fatigue we have to find number of cycles which is the life of
connecting rod.

The connecting rod has bent. We will see its cross section to discover what
actually happened and what the real cause of failure is.

Objectives:
 To find the cause of failure
 To study the properties of connecting rod material.
 To estimate the number of cycles.

Theory:
A connecting rod is a rigid member which connects a piston to a crank or
crankshaft in a reciprocating engine. Together with the crank, it forms a simple
mechanism that converts reciprocating motion into rotating motion. A
connecting rod may also convert rotating motion into reciprocating motion, its
original use.

Fatigue Failure:
In materials science, fatigue is the weakening of a material caused by
repeatedly applied loads. It is the progressive and localized structural damage
that occurs when a material is subjected to cyclic loading. The nominal
maximum stress values that cause such damage may be much less than the
strength of the material typically quoted as the ultimate tensile stress limit, or
the yield stress limit.

Fatigue occurs when a material is subjected to repeated loading and unloading.

Types of Failure
There are two types of failure
 Ductile failure
 Brittle failure

Ductile Failure
Ductile fracture is a type of fracture characterized by extensive deformation of
plastic or "necking." This usually occurs prior to the actual fracture. The term
"ductile rupture" refers to the failure of highly ductile materials. In such
cases, materials pull apart instead of cracking.

The failure of connecting rod is also ductile it does not break into pieces it is
deformed due to stress concentration which is due to fatigue repeated tensile
and compressive stress.
Brittle Failure
Brittle Fracture is the sudden, very rapid cracking of equipment under stress where the
material exhibited little or no evidence of ductility or plastic degradation before
the fracture occurs.

Mechanism

The free body diagram of connecting rod is as follow:


 Connecting rod could not be failed under normal operating
conditions. However it could be failed due to overwork or
increased friction between rings and walls due to engine
overheating or poor lubrication.
 This increase load on piston leads to engine failure.
Therefore in our case it is failure of connecting rod.
 Now we have to see that the connecting rod has finite or
infinite life in overload condition. If infinite than after how
much cycles part will be fail.
Connecting Rod Mechanical Properties
The material of connecting rod is 2024-T6 Aluminum alloy.
The Table shows its mechanical properties which are as follow:

The connecting rod failure is due to fatigue so we will calculate after how
many cycles the material fail.
Calculations

Data

Sut = 427 MPa


Sy = 345 MPa
Surface finish is As- forged
Axial Load is applied
b = 16mm
t = 6mm
Stress concentration dimensions
w = 1.7cm
d = 1cm
r = 0.2cm

Find

To Check life is finite or not if finite then estimate Number of Cycles

Solution
Sut= 427 MPA Or 61.9 Kpsi

Se Prime= 0.5Sut = 30.9Kpsi

As forged So a= 39.9 b= -0.995


Ka = aSutb = 0.6580

Kd = 1
Se = KaKbKcKdSePrime =17.28 Kpsi
For Compressive Stress = KfF/A

Using Table A-15-3

W/d =1.7 r/d = 0.2 So Kt = 2

Radius = 2mm Sut = 61 Kpsi Aluminum Alloy


So q = 0.82

Kf = 1.82
Force Calculation
We will calculate force using pressure and area of the piston on which pressure
is exerting.
P = 1000Kpsi/ 6.89MPa
Diameter of Piston = 60mm
F=PA
A=3.14D2/4= 2.82*10-3
F= 19.4 KN
Stress Calculation
Stress = Kf F/A
Here area of cross section where the rod is bent which is equal to
Area = 0.016*0.006 = 9.6*10-5
Kf=1.82
So Stress = 368 MPA /53.4 Kpsi
Life Calculation
nf = Sy/Stress
Sy = 345MPa
Stress=368MPA
nf = 0.9375
So Life is not finite We will estimate number of cycles
Number of Cycles

So using values
a = 179.61
b = -0.17

N = 1252 Cycles Answer


References
http://asm.matweb.com/search/SpecificMaterial.asp?bassnum=MA2024T6
Shigley Mechanical Engineering Design 9th Edition
Mechanics of Material 6th Edition Beer Johnson
Wikipedia.com www.google.com

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