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Project Report
Submitted By:
Faizan Akbar 705-BSME-FET-F17B
Submitted To:
Date of Submission:
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.
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 connecting rod failure is due to fatigue so we will calculate after how
many cycles the material fail.
Calculations
Data
Find
Solution
Sut= 427 MPA Or 61.9 Kpsi
Kd = 1
Se = KaKbKcKdSePrime =17.28 Kpsi
For Compressive Stress = KfF/A
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