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Stress Analysis of Connecting Rod using FEA

Conference Paper · February 2015

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Gurunath Shinde Vahid Jamadar

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Ganesh S. Jadhav Vinayak D. Yadav

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 Stress Analysis of Connecting Rod using FEA
Prof.Gurunath V Shinde1, Prof.Vinayak D Yadav2, ME CAD/CAM Engineering
Prof.V.M.Jamadar3, Prof.G S Jadhav4, Asst.Professor1234, DACOE, Karad
Dr S M Sawant5, Professor, RIT, Islampur

Abstract— IC engine is heart of any vehicle, while in running
conditions different components of engine undergoes static and
dynamic loadings. The main aim of paper is to analyze static
stresses developed in connecting rod. Dimensions are measured
from connecting rod and CAD model is developed in Pro-E 2.0
and ANSYS software is used for static analysis of connecting rod.
This method is known as Finite Element Analysis by Simulation
in which Pro E and ANSYS Software packages are used for
simulation. The main advantage of using simulation is to save
time and cost involved in analysis. The input conditions like time
and money. Material Properties, static load, boundary conditions
etc. are given. The loads on the connecting rod were
obtained as a function of crank angle.
Keywords—Static Analysis, FEA, Simulation
1. INTRODUCTION
Since early atmospheric engines the transfer of energy from
expansion chamber of an engine to develop a device that
supplied the work has done with a series of linkages. These
linkages were crucial to harness the power being produced by
engines. As the engines developed in the 20th century and the
modern day internal combustion engine started to be mass
produced, the importance of the connecting rod as well as the
crank shaft was essential. to the operation of a reliable engine.
Time and effort were necessary to create the best design for a
connecting rod to allow it to handle high stresses while
minimizing weight. The reduction of weight of connecting
rods is important to ensure that the engine can operate safely
in higher RPM’s due to the decreased inertia held within the
lighter rods. The goal has become to remove as much material
from these rods while still maintaining their strength and
integrity so as to safely perform under the conditions of each
engine.
Throughout the production of these internal combustion
engines the power produced has steadily been increasing,
leading to increased forces being developed in modern day
engines. For example: in 2001 General Motors released a new
and improved Diesel truck with a Duramax Diesel engine. The
rated horsepower was 300 and the torque of this engine was
500 if-ft. General Motors has revised the engine five times
since its release; however, its internals have only seen minor
changes. Its current 2011 version is producing 400 horsepower
and 765 b-ft of torque.
These increases of 125% in horsepower and 153% in torque
while utilizing the same block illustrate the need for a good
understanding of the forces generated in the engine as well as
the way each of the components deal with this force. The
connecting rod directly sees the force applied to the crank and
drive train as it translates the linear motion of the stroke of the
piston to the rotational movement of the crank. If the
connecting rod was to fail, catastrophic damage would occur
to the engine requiring costly repairs.
Therefore, it is important for engineers to properly
determine the stresses present within the rod to ensure that
even under its worst conditions it will still perform without
yielding or failing altogether. By being able to model the
connecting rod and determining the forces present on it under
all conditions it is possible to use programs such as ANSYS to
determine the stresses developed within the connecting rod.
Material Selected Carbon Steel
Young's Modulus 2 x 105MPa
Poisson’s Ratio 0.3
Tensile Yield strength 415 MPa
Density 7850kg/m3
Behavior Isotropic
Table.1. Material properties of connecting rod
2. LITERATURE REVIEW
H.B.Ramani has do Analysis of Connecting Rod under
Different Loading Condition Using ANSYS Software [1].
Finite element codes are less complicated than many of the
word processing and spreadsheet packages found on modern
microcomputers. Nevertheless, they are complex enough that
most users do not find it effective to program their own code.
Asadi, et al (2010) [2] developed detailed load analysis under
service loading conditions was performed for connecting rod
and The conclusions can be drawn from this study as follows
the maximum pressure stress was obtained between pin end
and rod linkage and the maximum tensile stress was obtained
in lower half of pin end. The crank and piston pin ends are
assumed to have a sinusoidal distributed loading over the
contact surface area, under tensile loading. This is based on
experimental results. [3]
3. FEA MODELING OF CONNECTING ROD
a) Defining geometry of the Connecting Rod:
 The model of connecting rod was generated in pro/E
wildfire 2.0. The model of connecting rod is shown in
figure.1.

Figure 3.Meshing of CAD Model

Figure 1.CAD model of Connecting rod in Pro E 2.0
c) Boundary Conditions:
Analysis done with load applied at the piston end and
restrained at the crank end or other load applied at the crank
end and restrained at the piston end. Here The load applied at
the piston end and cylindrical support was given at the crank
end. The analysis carried out under axial load. Here the tensile
or compressive load was equal to 4319N.

Fig.2.Connecting Rod Dimensions (All Dimensions are in

mm)
The initial solid model imported as a .igs file into ANSYS.
This first model serves to give a general idea of the areas of
high stress concentration and is, therefore, a simplification of
the actual connecting rod. Some minor features such as fillets
and bolts were neglected. These simplifications made
modeling quick and easy.. The less complex the model, the
shorter the import time and the more likely it is that the import
will be successful.The element type used for the initial model
is SOLID187. It was used with the tetrahedral option, making Figure 4.Loads applied on connected rod
it a 10-node element with 3 degrees of freedom at each node.
This element type is well-suited to the complex geometry d) Static Analysis:
presented by the connecting rod and is capable of illustrating
tensile, compressive and bending stresses. For the preliminary ANSYS simulation, it was assumed
that the maximum force in the connecting rod is applied at top
b) Mesh Generation: dead center of the power stroke. Making this assumption, the
Tetrahedral meshing is done. The numbers of elements are force and constraints are applied as shown in Fig.3, below.
18921 and the numbers of nodes are 31237.This initial The red arrows indicate the applied force and the blue arrows
simulation relied on a simple automesh. It may be necessary to indicate the constrained points.
mesh manually in subsequent simulations where the model is
more detailed and the geometry is more complex. For this first
analysis, however, an automesh gives a reasonable estimate of
stresses and the areas on which to concentrate for more
detailed analyses.
 Figure 5 Von Mises Stress Figure. 7 Shear Stress

Load= 4319N

Name Min. Max.

0.327 x 10-1 74.64
Von Mises Stress
N/mm2 N/mm2
42.34
Shear Stress 11.32 N/mm2
N/mm2
0.58 x 10-6
Elastic Strain 0.12 x 10-6 mm
mm
Table 2

Figure 8 Elastic Deformation

Figure 6 Von Mises Stress

4. CONCLUSIONS:
Material Properties
Tensile Yield strength 415 MPa
Factor of Safety 4
Allowable Stress 103.75Mpa
Ansys Results 74.64Mpa
Working Factor of Safety 5.6

Table.3
Using ANSYS it is possible to found out stresses in
connecting rod, in static analysis. For the future scope and for
optimization purpose we need to find buckling load and
dynamic analysis of connecting rod.

References
[1] H.B.RAMANI, Mr. Neeraj Kumar, Mr. P. M. Kasundra“Analysis of
Connecting Rod under Different Loading Condition Using ANSYS Software”
International Journal of Engineering Research and Technology (IJERT) ISSN:
2278- 0181Volume 1 Issue 9 Published in November 2012

[2] Webster,W., D.Coffell R., and Alfaro D.,(1983),“A Three Dimensional

Finite Element Analysis of a High Speed Diesel Engine Connecting Rod,”
SAE Technical Paper Series, Paper No. 831322

[3] Asadi, et al (2010), “Paper of Optimization of connecting rod of MF-285

tractor”

[4] Anil kumar, Kamaldeep Grover , Balvinder Budania (GJUS&T, Hisar),

“Optimization of Connecting Rod Parameters using CAE Tools”, 2012,
International Journal of Latest Trends in Engineering and Technology
(IJLTET) Volume2,Issue4,Pages 361-365.

[5]K. Sudershn Kumar, Dr. K. Tirupathi Reddy, Syed Altaf Hussain ( RGM
College of Engg. & Technology, Nandyal-518501, India), “ Modeling and
Analysis of Two Wheeler Connecting Rod”, 2010, International Journal of
Modern Engineering Research (IJMER). Vol. 22, No. 2, pages 63-74

[6]Ansys Structural Lab Manuals

[7] Nitin Ghokhale, “Practical Finite Element Analysis”, Finite to Infinite

Publications,Jan.2008

[8]Bhandari V.B. “Design of Machine Elements” TATA McGraw Hill

Publications, Jan.2008

[9] Sham Tickoo, “Pro/E Wildfire2.0” Dreamtech Publications, Jan.2006

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