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Materials Today: Proceedings 2 (2015) 2291 – 2299

4th International Conference on Materials Processing and Characterization

Design and Optimization of Four Wheeler Connecting Rod Using

Finite Element Analysis

D.Gopinatha,Ch.V.Sushmab*
a
Assistant Professor,Chaitanya Bharathi Institute of Technology,Hyderabad,India.
b
Assistant Professor,Chaitanya Bharathi Institute of Technology,Hyderabad,India

Abstract
Every vehicle that uses an internal combustion engine requires at least one connecting rod depending upon the
number of cylinders in the engine. It undergoes high cyclic loads of the order of 10 8 to109cycles, which range from high
compressive loads due to combustion, to high tensile loads due to inertia. Therefore durability of the component is of critical
importance. Due to these factors the connecting rod has been the topic of research for different aspects such as production,
materials, performance simulation, etc.
The main objective of research was to explore weight reduction opportunities for the production of forged steel,
aluminium and titanium connecting rods. This has entailed performing a detailed load analysis. Therefore, this study has dealt
with two subjects, first, static load stress analysis of the connecting rod for three materials, and second, optimization for weight
of forged steel connecting rod.
In this research, firstly a proper geometrical model was developed using CATIA. Then the model is imported to the
HYPERMESHwhich is a finite element pre-processor that provides a highly interactive and visual environment to analyse
product design performance and the Finite Element model was developed. The stresses were found in the existing connecting rod
for the given loading conditions using Finite Element Analysis software ANSYS 11.0.The topology optimization technique is
used to achieve the objectives of optimization which is to reduce the weight of the connecting rod.
© 2014 The Authors. Elsevier Ltd. All rights reserved.
© 2015 Elsevier
Selection Ltd. All rights
and peer-review reserved.
under responsibility of the conference committee members of the 4th International conference on
Selection and peer-review under responsibility of the conference committee members of the 4th International conference on Materials
Materials Processing and Characterization.
Processing and Characterization.

Keywords:connecting rod;weight optimization;stress analysis;

* Corresponding author. Tel.: +0-000-000-0000 ; fax: +0-000-000-0000 .

E-mail address: gopinath.yatna@gmail.com

2214-7853 © 2015 Elsevier Ltd. All rights reserved.

Selection and peer-review under responsibility of the conference committee members of the 4th International conference on Materials Processing
and Characterization.
doi:10.1016/j.matpr.2015.07.267
2292 D. Gopinath and Ch. V. Sushma / Materials Today: Proceedings 2 (2015) 2291 – 2299

1. Introduction

Connecting rod is one of the most critical components internal combustion engines bearing the statically and
dynamically fluctuating loads. The optimization of connecting rod had already started as early years. However,
everyday consumers are looking for the best from the best. That’s why the optimization is really important for
automotive industry especially. Optimization of the component is to make the less time to produce the product that
is stronger, lighter and less total cost productions. The design and weight of the connecting rod influence on car
performance. Hence, it effects on the car manufacture credibility. The structural factors considered for weight
reduction during the optimization include the buckling load factor, stresses under the loads, bending stiffness, and
axial stiffness. Thus, the component can give the higher strength, efficient design and lighter that would create a
major success in the automotive and manufacturing industry. The benefits of connecting rod optimization are
eventually go back to consumer itself. Among the main objectives are to improves the engine performance and also
to strengthen the product that is ensure the safety of human being. Connecting rod failed due to insufficient strength
to hold the load. By maximize the strength, automatically it will longer the life cycles of the connecting rod. Lots of
knowledge will be apply and produced during the process.

Nomenclature

t thickness of the web and flange

dc diameter of the crank pin
dp diameter of the piston pin

2. Literature review

K. Sudershan Kumar [1] et al, described modeling and analysis of Connecting rod. In his project carbon steel
connecting rod is replaced by aluminum boron carbide connecting rod. Aluminum boron carbide is found to have
working factory of safety is nearer to theoretical factory of safety, to increase the stiffness by 48.55% and to reduce
stress by 10.35%. Vivek. C. Pathade [2] et al, he dealt with the stress analysis of connecting rod by finite element
method using pro-e wild fire 4.0 and ANSYS work bench 11.0 software and concluded that the stress induced in the
small end of the connecting rod are greater than the stresses induced at the bigger end, therefore the chances of
failure of the connecting rod may be at the fillet section of both end. Pushpendra Kumar Sharma [3] et al, performed
the static FEA of the connecting rod using the software and said optimization was performed to reduce weight.
Weight can be reduced by changing the material of the forged steel connecting rod to crackable forged steel (C70).
And the software gives a view of stress distribution in the whole connecting rod which gives the information that
which parts are to be hardened or given attention during manufacturing stage. Ram bansal [4] et al, in his paper a
dynamic simulation was conducted on a connecting rod made of aluminum alloy using FEA. In this analysis of
connecting rod were performed under static load for stress analysis and optimization. Static load analysis was
performed to determine the in von-mises stresses of the connecting rod.

3. Design of ConnectingRod

The connecting rod does this important task of converting reciprocating motion of the piston into rotary motion
of the crankshaft. It consists of an upper forked section which fits on the crosshead bearings while the lower part fits
 D. Gopinath and Ch. V. Sushma / Materials Today: Proceedings 2 (2015) 2291 – 2299 2293

on the crankpin bearing. For the analysis of I.C. Engine connecting rod the most critical area is considered and
accordingly the model of connecting rod is formed. The different dimensions of the engine and connecting rod are
given below.

3.1 Configurations of the Engine

Connecting rod length = 140mm Maximum gas pressure = 3.6MPa

Piston diameter = 88mm Bearing pressure at big end = 7MPa
Crank radius = 48.5mm Bearing pressure at small end = 14MPa
Stroke length = 97mm Allowable stresses in the bolts = 60MPa
Speed of the engine = 1800r.p.m. Allowable stresses in the cap = 80MPa

3.2 Standard Proportions of the I-Section

Width of the section, B = 4t
Depth of the section, H = 5t
Area of the section, A = 11t2
Depth of the section near the big end = 1.1H to 1.25H
Depth of the section near the small end = 0.75H to 0.9H
Moment of inertia about x axis Ixx = 34.91t4
4
Moment of inertia about y axis Iyy = 10.91t
Therefore Ixx/Iyy = 3.2
Radius of gyration of the section about X-axis = 1.78t
Length of the crank pin = 1.25dc to 1.5dc
Length of the piston pin = 1.5d p to 2dp
3.3 Dimensions of the I –Section
గ‫כ‬஽మ ‫כ‬௣
The maximum force acting on the piston due to gas pressure, F = = 21895.64N
ସ
Since factor of safety is considered F= 131373.864 N
Radius of gyration of the section about X-axis,Kxx = √ (419t4*(1/12)×11t2))= 1.78t
Radius of crank = 97/2= 48.5mm
From Rankine’s formula,(σc×A)/[1+(L/ Kxx)2] =131373.864 = 11t2 / [1+(6.076/t)2] =>t = 6.52mm
Width of the section, B = 4t= 4 × 7 = 28 mm
Height of the section, H = 5t = 5 × 7 = 35 mm
dc = 49.05 say 49 mm
lc = 1.3 dc = 1.3 × 49 = 63.7 say 64 mm
Therefore, equating the load on the piston pin or the small end bearing to the maximum gas force,
30 (dp)2= 21895.644 N
dp = 27.96 say 28 mm
lp = 2 dp = 2 × 29 = 58 mm
3.4 Maximum Tensile Force
Mass of the connecting rod, m = volume× length×density= 0.435kg
Maximum Bending moment = m× ω2×r× (l/9√3)= 6732.216 N-mm
Section modulus = Ixx/(5t/2) = 419×64×2/ (12×5×7) = 2585.8mm3
Maximum bending stress due to inertia bending forces = Mmax/Zxx= 2.6N/mm2
2294 D. Gopinath and Ch. V. Sushma / Materials Today: Proceedings 2 (2015) 2291 – 2299

Maximum tensile force = mR× ω2×R× (1+r/l) = 2177.85N

4. Finite Element Analysis
The objective of FEA was to investigate stresses and problem area experienced by the connecting rod. From
Stress contours, the state of stress as well as stress concentration factors can be obtained and consequently used
for life predications. Forged steel connecting rod was selected for the FEA, since this connecting rod was also used
at optimization. Linear elastic analysis was used to connecting rod is designed for long life where stresses are
mainly elastic. Therefore material properties are show in table 1 below:

Table1: Properties of materials

Value
S No Material property Forged Aluminium Titanium
steel alloy alloy
1.
Young’s modulus (E) 200GPa 70GPa 116GPa

2. Density (U) 7850 Kg/m3 2700 Kg/m3 4506 Kg/m3

3. Poisson’s ratio (P) 0.3 0.33 0.34

The model of connecting rod is created in CATIA as shown in fig1 as per the dimensions of connecting rod.

Fig1: Model of connecting rod by CATIA

4.1 Meshed Model Using Hyper mesh

Fig2 shows meshed model of connecting rod in HYPERMESH.A tetrahedral element was used for the solid mesh.
Total number of elements 43367 and Total number of nodes 67038were generated.
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Fig2: Meshed Model of connecting rod in HYPERMESH

4.2 Analysis of Connecting Rod Using ANSYS

Static analysis is used to determine the displacement stresses, strains and forces in structures or components due to
loads that do not include significance inertia and damping effects. Steady loading in response conditions are
assumed. The kinds of loading that can be applied in a static analysis include externally applied forces and
pressures, steady state inertial forces such as gravity or rational velocity imposed (nonzero) displacements.
A static analysis can be linear or non-linear. In our present work, we consider linear static analysis.

Fig3: Loading conditions for connecting rod

Fig3 shows loads applied to model of connecting rod Pressure of 14MPa is applied at small end and 7MPa is applied
at big end. The tensile force of 2177.8N was applied at small end of the connecting rod.

4.3. ANSYS Results for Forged Steel

The fig4 indicates the von-mises stress distribution in the forged steel connecting rod for the given loading
conditions. The maximum value is 63.55 MPa and minimum value is 0.016456 MPa.
2296 D. Gopinath and Ch. V. Sushma / Materials Today: Proceedings 2 (2015) 2291 – 2299

Fig4: von-mises stress for forged steel

The fig5 indicates the maximum shear stress distribution in the forged steel connecting rod for the given loading
conditions. The maximum value is 36.378 MPa and minimum value is 0.009479 MPa.

Fig5: shear stress for forged steel

5. Structural Analysis Results for Forged Steel

The maximum and minimum values of the structural analysis results for the given loading conditions to the forged
steel connecting rod are mentioned in the following table2.

Table2: Structural analysis results for forged steel connecting rod

S.NO. Parameter Maximum Minimum

1 Von-Mises Stress (MPa) 63.55 0.016456

2 Maximum Principal Stress (MPa) 80.755 -5.7004

3 Maximum Shear Stress (MPa) 36.378 0.009479

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5.1. StructuralAnalysis Results for Aluminium

The maximum and minimum values of the structural analysis results for the given loading conditions to the
aluminium connecting rod are mentioned in the following table3.

Table3: Structural analysis results for aluminium connecting rod

S.NO. Parameter Maximum Minimum

1 Von-Mises Stress (MPa) 64.393 0.016354

2 Maximum Principal Stress (MPa) 83.753 -6.6041

3 Maximum Shear Stress (MPa) 36.963 0.0090943

5.2. Structural Analysis Results for Titanium

The maximum and minimum values of the structural analysis results for the given loading conditions to the titanium
connecting rod are mentioned in the following table4.

Table4: Structural analysis results titanium connecting rod

S.NO. Parameter Maximum Minimum

1 Von-Mises Stress (MPa) 64.701 0.03184

2 Maximum Principal Stress (MPa) 84.821 -6.9241

3 Maximum Shear Stress (MPa) 37.17 0.017834

6.Comparison of Different Materials

The structural analysis results for the given loading conditions to the connecting rod made with different materials
are compared as follows. The Fig6 shows Von-Mises stress behaviour under given loading conditions for steel,
aluminium and titanium was compared and it is observed that the von-mises stresses is less in steel ,moderate in
aluminium and high in titanium.

Fig6: Von-mises stresses variation vs.material

2298 D. Gopinath and Ch. V. Sushma / Materials Today: Proceedings 2 (2015) 2291 – 2299

7. FE Model Optimization

The Objective of optimization task was to minimize mass of connecting rod under the effect of a load range
comprising the two extreme loads, the peak compressive gas load, such that the maximum, minimum, and
equivalent stress amplitude are within the limits of allowable stresses. The buckling load factor under the peak gas
load has to be permissible. Mathematically stated, the optimization statement would appear as follows:
Objective: - Minimize Mass and Cost
x Compressive load = peak compressive gas load.
x Maximum Stress < Allowable Stress.
x Side constraints (component dimension).

From fig7, it is observed that initial mass of structured steel connecting rod is 539 grams is reduced to 482 grams by
optimization technique as shown in fig8.

Fig7.FEA model after optimization

Fig8.FEA model after optimization

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8. Results of Optimization

Maximum von-mises stresses and deformation was found out in finite element analysis. Maximum stress
occurred in the transition area between crank end and shank region for compressive loading at pin end. The mass of
the initial model is 539 grams and the material is removed in three iterations. After analysing the three iterations, the
iteration3 is showing the best results of optimization. The mass of the connecting rod after optimization is482grams.

Table 5.

S.NO. Parameter Optimization

1 2 3
1 Von-Mises Stress (MPa) 63.594 79.342 63.676

2 Total Deformation (m) 5.5293e-6 5.6319e-6 5.5349e-6

3 Mass (Kg) 0.506 0.463 0.483
4 % Weight reduction 6.12% 14.02% 10.38%
9. Conclusions

From the static structural analysis it is observed that Von-Mises stresses, shear stresses for steel, aluminium and
titanium was compared and it is observed that the stresses are less in steel ,moderate in aluminium and high in
titanium for a given loading conditions.

After carrying out static structural analysis the stresses in each loading conditions were studied and then area where
excess material can be removed were decided. Optimization was performed to reduce weight of a forged steel
connecting rod subjected to the peak compressive gas load and the peak tensile load. The shank region of the
connecting rod offered the greatest potential for weight reduction. The rib and the web thicknesses were reduced,
while maintaining forgeability.

¾ Mass of the optimized connecting rod is 483 grams and the optimized geometry is 10.38% lighter than the
current connecting rod for the same strength.
¾ The peak stresses mostly occurred in the transition area between pin end, crank end and shank region in
forged steel connecting rod. The value of stress at the middle of shank region is well below allowable limit
of 250MPa.

10. References

[1] K. Sudershan Kumar, Dr. k. Tirupathi Reddy, Syed Altaf Hussan “Modeling and analysis of two Wheeler
connecting rod”, International Journalof Modern Engineering Research, Vol -2, Issue- 5, pp-3367-3371, Sept 2012.

[2] Vivek.c.pathade, Bhumeshwar Patle, Ajay N. Ingale ”Stress Analysis of I.C. Engine Connecting Rod by FEM”,
International Journal of Engineering and Innovative Technology, Vol-1, Issue-3, pp-12-15, March2012.

[3] Pushpendra Kumar Sharma1, Borse Rajendra R, “fatigue analysis and optimisation of connecting rod using finite
element analysis”, International Journal Of advance research in Science and Engineering, Vol. No.1, Issue No. I, pp-
3367-3371, September 2012.

[4] Ram Bansal, “Dynamic simulation of connecting rod made of aluminium alloy using finite element analysis
approach”, IOSR Journal of Mechanical and Civil Engineering, Volume 5, Issue 2, PP 01-05, Jan. - Feb. 2013