Connecting Rod B.E.

Bolts

Prepared by

P. Mukherjee
Connecting Rod B.E. Bolts
Learning Objectives

♦ Function

♦ Forces and stresses on bottom end bolts

♦ Design features

♦ Problems

♦ Maintenance Procedure
Con-rod Bottom End Bolts
Subjected to….

Steady load
- comprised of static tensile force due to pretensioning

Dynamic working load
– due to varying gas force
– Inertia forces of reciprocating parts
– centrifugal forces at cranks

Dynamic working load is heavy, cyclic and fluctuating in

nature and superimposed on steady load.
 Stresses in B.E. Bolts

Tensile Stress
– fluctuating nature
– more pronounced in 4-stroke engine due to load reversal

Shear Stress
– in way of two halves

Bending Stress
– fluctuating nature

Resulting in Fatigue
Load Reversal

In trunk type 4-stroke
engine load reversal takes
place at the end of exhaust
stroke

Causes change of load on
bearing haves

As a result B.E. bolts
subjected to additional
tensile stress
Fatigue Failure of B.E. Bolt

Bolt is initially subjected to steady load due to pretensioning

During operation bolt is subjected to varying dynamic load
which superimposes on steady load

Causes fluctuating load on the bolt at every operating cycle

Under such operating condition any material will fail at well
below the yield point, even at much lower load, known as fatigue failure

Fatigue life of bolt depends on fluctuating stress range
 No Corrosion
Fluctuating Stress

Endurance Limit

No of Cycles for failure

 No Corrosion
Fluctuating Stress

Endurance Limit

Corros
ion

No of Cycles for failure

Design Feature

Shank dia is 10% less than core dia

Fillet is provided between shank and bolt head to prevent stress

concentration

3 to 4 threads remain free below contact face of the nut

High degree of surface finish to prevent stress concentration

Cold rolling of threads to improve fatigue strength

Bolt stiffness to be less than bearing housing – less dynamic load on bolt

High UTS alloy steel with long thin elastic bolts for higher fatigue strength

Fitted portion to keep as short as possible to prevent stress

concentration and to obtain greatest resilience
Bolt Development
Causes to Aggravate Bolt Failure

Stress concentration
– in way of change of section
– damaged fillet
– damaged surface finish

Over stretching / tightening

– causing permanent damage due to plastic deformation

Uneven tightening
– causing overloading of some bolt

Inadequate pretension
– causing high fluctuation of stress in bolts and consequently fatigue failure

Improper seating of bolt head and nut

– resulting in bending stress in bolts

Corrosive attack
– due to contaminated lube oil
Inspection & Maintenance

Sound testing to detect internal flaws and cracks

Bolt threads

Surface finish of bolts

Fillet area

Measuring elongation of bolts

Checking pretension of bolts

Checking locking device, if any

Never change one bolt in a set, change the whole set

Bolt Tightening Method

Hydraulic device
– tightening must be done in stages
– correct pressure to be applied
– pressure gauge calibration is required

Torque spanner
– frictional effect should be considered
– proper lubricant to be applied

Hand tightening
– angular accuracy is essential