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Fatigue Numerical Analysis and Life Prediction of Connecting

Rod used in Commercial Light Vehicle(CLV)

Thesis Proposal Submitted to Faculty of Mechanical and Industrial Engineering in

Partial Fulfillment of the Degree of Masters of Science in Mechanical Design
By: Tibebu Meride Zelelew
Advisor: Dr. Alem Bazezew

Out Line:Introduction
Problem statement
Objective
Literature Review
Methodology
Cost brake down
Schedule

Introduction
Automobile internal combustion engine connecting rod is a high
volume production critical component. It connects reciprocating piston
to rotating crank shaft, transmitting the thrust of piston to crankshaft,
and is subjected to complex loading. It undergoes high cyclic loads of
the order of 108-109 cycles, which range from high tensile loads
because of inertia.
the tensile and compressive forces are applied on the connecting rod
during the engine cycle.
The tensile force is applied during the exhaust stroke.
the compression occurs at the power stroke

Cont.
Fatigue life prediction was also carried out for design with increased thickness in the
highest stress region.
. The thickness was increased to improve the fatigue life.
The stress analysis was done using finite element method by employing commercial
software package ANSYS/ABAQUS.
The most common types of connecting rods are: steel
aluminum.

The most common types of manufacturing processes are

casting,
forging
powered metallurgy.

Cont.
Connecting rods are widely used in variety of engines such as,
in-line engines,
opposed-piston engines.

A connecting rod consists of

a pin-end
a shank section
a crank-end.

Pin-end and crank-end pinholes at the upper and lower ends are
machined to permit accurate fitting of bearings.

Cont..
As the lower end of the connecting rod revolves with the crank shaft, the upper
end is forced to turn back and forth on the piston pin. Although this movement
is slight hence the bushing is necessary because of the high pressure and
temperatures.

functionality, connecting rods must have the highest possible rigidity at the lowest
weight.
The function of connecting rod is to transmit the thrust of the piston to the
crankshaft. The role of connecting rod in the conversion of reciprocating motion
into rotary motion. A four strokes are intake, compression, power, and exhaust.
Each stroke requires approximately 180 degrees of crankshaft rotation, so the
complete cycle would take 720 degrees

Problem statement
. In particular, the new analysis will examine the fatigue numerical
analysis and life prediction of connecting rod made of Aluminum
LM25 alloy Reinforced with Boron Silicide. Steel and aluminum
materials are used to fatigue life prediction the connecting rod. In this
project, the material (carbon steel) of connecting rod replaced with
Aluminum Reinforced with Boron carbide. The connecting rod was
created in SOLIDWORKS/CATIA. Model is imported in ANSYS
Workbench /ABAQUS for analysis.

Objectives
General objective
Fatigue numerical analysis and life prediction of connecting rod made
of Aluminum LM25 alloy Reinforced with Boron Silicide.
Specific Objectives:
To determine the lifespan of connecting rod due to cyclic loading. The
results were carried out under fully reversed loading.
To reduce weight of the existing connecting rod with desired strength.

Cont.
To determine the Von Misses stresses, Shear stresses, Equivalent
Alternating stress, Total Deformation and Fatigue Analysis of
connecting rod by FEM.
To calculate stresses in critical areas and to identify the spots in
connecting rod where there are more chances of failure.
Document the challenges to be addressed for uniformity in load
distribution for connecting rod.

Literature Review
Prof. Vivek C. Pathade [1,] proposed the major stress induced in the
connecting rod was a combination of axial and bending stresses in operation.
Kul deep B et. AL proposed the material of connecting rod was replaced by
aluminum based composite material reinforced with silicon carbide and fly
ash.
Zheng Bin Liu Yongqi et.al analyzed stress distribution, safety factor and
fatigue life cycle of connecting rod by using 3D finite element method.
Om Prakashet.al found the existing design performs by modelling and
evaluates critical regions in the connecting rod under fatigue loading.

Cont.
Zhou Qinghai et.al they obtain the vibration characteristics and vibration frequency
distributions, structural characteristics of the connecting rod mechanism using modal
analysis.
Dr. K. B. Roy analyzed various designs of connecting rod and finally he selects an
optimal design for Finite Element Analysis.
M.N. Mohammedl M.Z. et al in this paper author had focused on analysis of
connecting rod failure.
Vivek.C. Pathade, et al from the experimental results and analysis done using finite
element method author concluded, that the stresses on the both end of connecting
rods are different and stresses at the small end of the connecting rod are higher than
the stresses on the larger end.

Cont..
SB Chikalthankar, et al the paper has been written to demonstrate the analysis
of connecting rod used in combustion engines using finite element
analysis(FEA). The modified Goodman diagram is used to carry out fatigue
study based on stress life(SxN) theory.
Zheng, et al has written this paper after carrying out extensive study for stress
distribution and fatigue life of connecting rod in combustion engines in light
vehicle engine were analyzed using the commercial 3D finite analysis
software and ANSYSTM.
Privank D. et al this sole objective of this technical paper, is to investigate the
failure analysis of the connecting rod of the automotive combustion engine

Methodology
Analytical
Static load analysis
Dynamic load analysis

Finite Element Method

Cost brake down

Stationary Cost

3165 birr

Total Transportation Cost

4500 birr

Miscellaneous Expenses

4800 birr

Total Project Cost

13761.5

Time schedule
No.

Activities

Data collection

Literature review

Methodology

3.1

Analytical

3.2

FEM

Results and discussion

Conclusion

Summited date

Month 1

Month 2

Month

Month

Month

Month

Month 6

Month 7

Generally

redesign

Project start

Phase 1

Phase 2

Engine data sheet

Geometry Baseline

Loads Calculation

Phase 3

Structural FEA

Is The Safety Factor

Acceptable?

Phase 4

Output

Fatigue safety factor

Final Technical Repot

Project end

Detailed Drawing

Thanks!!!