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PAPER PRESENTATION

ON
OPTIMUM DESIGN ON CONNECTING ROD
Submitted by.,
A.ARULJOTHI
P.SHREEKANTH
FINAL YEAR MECHANICAL ENGINEERING
V.R.S. COLLEGE OF ENGINEERING
TECHNOLOGY,ARASUR,VILLUPURAM Dt.,

INTRODUCTION
connecting
rods
-Steel,Aluminium,titanium
magnitude of loads
bending stress caused by the inertia
loads

BASIC DESIGN RULES


Connecting rod length: Connecting
rod
length 3 crank radius
3 14.3
42.3mm
Minimum wall thickness: 5mm

CONSTRUCTION OF WEB SECTION

According to Rankines formula,


ca A
Wcr
2
1 a L Kxx
=
Ixx2 = 4 Iyy2
Kxx ^ 2 Kyy^2

Fc = Fp = 2795N

Ixx
Iyy

=3.2

DESIGN CRITERIA

Assume both end hinged,


Factor of safety for Buckling load = 6
Buckling load Wcr = Fc 6 2795 6 16770 N
Area of cross section, A = 11t2 mm4

Moment of inertia about X-axis, Ixx =


Radius of gyration, Kxx =

419t 4
12

Ixx = 1.78t
A

Equivalent of rod for both end hinged, L=l = 61mm


For
= =220 N/mm
Aluminium
, formula,
From
Rankines
ca A
W =
2
1 a L Kxx
c

cr

16700

220 11t 2
=
1
61 1.78t 2
1
3200

By solving
t , 3.3mm

VALIDATION OF FEAMODEL:
Material property-Scalar Value
Material Name -Aluminium
Youngs modulus- 0.71e5 N/mm2
Poisson ratio-0.34
Mass density-7850 kg/m3
Tensile Strength-280 Mpa
Yield Strength -220 Mpa
Fatigue Strength-140 Mpa

AIR LOAD CALCULATION


Piston Diameter, D = 66.7 mm
Delivery Pressure = 8 bar
Net force acting on the piston (FL):
FL = Pressure acing on the piston Area
= P (/4) D2
= 0.8 (/4) 66.72
= 2795 N

Net force acting on the connecting rod (F c):


Mass of piston assembly = 0.250 kg
Mass of connecting rod = 0.065 kg
Total weight of reciprocating masses = 0.315 kg
Rated speed of compressor, N = 3000 rpm
Crank throw, r = 14.3 mm
cos 2

2
cos

Inertia force of the connecting rod: F L = M r

0.0143

cos 60
cos 30

4
.
26
2

=3.79 314
=535 N

Weight of reciprocating parts (WR):

r
Ma

Mb 1
Weight of Reciprocating parts WR =
l


=0.044 0.272 1 14.3
61

= 0.380

Net Force acting on the connecting rod:(Fc)


F c = F L F I + WR
= 2795 535 + 3.79
= 2264 N

Model and boundary condition of the


connecting rod
Model of connecting rod
Loads and Boundary conditions

Load of 2264N acting on the piston pin

Stress comparison of connecting rod


Crank web thickness: 3.5 mm

Crank web thickness: 5mm

Maximum stress = 33 Mpa


Maximum stress= 15.6
Mpa

Crank web thickness: 3.5 mm

Crank web thickness: 5mm

Maxmimum deformation = 10 Microns


Maxmimum deformation = 6 Microns

Discussion
It is found that Stress induced 15.6 Mpa is very low as compared to the allowable
pressureof 140Mpai.e., Factor of safety is 7. Since it over designed, it is redesigned
to reduce the material.
In manufacturing point of view, minimum 5mm is necessary for
Gravity Die Casting (GDC), so
casting of connecting rod is
changed to Pressure Die casting(PDC) to achieve the target

Modal analysis of connecting rod:


Mode 1: Along the axis of crank
Mode
pin 2: Perpendicular to the axis of

Frequency: 2391 Hz

Frequency: 5214 Hz

FATIGUE ANALYSIS OF CONNECTING


ROD:

Life: 1000000 cycles

Factor of safety: 1 to 5

Result and discussions:


The following conclusions can be drawn from the
results of this analysis and calculation:
Stresses and displacements were observed to be
significantly lower under the given conditions.
The buckling load factor for the designed connecting
rod is 83, which is more than adequate.
Fatigue strength was the most significant (i.e., design
driving factor) in the design and optimization of the
connecting rod.
The section modulus of the connecting rod should be
high enough to prevent high bending stress due to
inertia forces and gas load.
The optimized geometry is 30% lighter than the
current connecting rod for the same fatigue strength.