Career Episode 2

2.1 Introduction
 Project Title: Design, modeling and evaluation of connecting rod
 Chronology: Insert date
 Institution: Gujarat Technological University
 Name of college: Shankersinh Vaghela Bapu Institute of Technology
 Location: Gandhinagar, India
 Under the guidance of: Insert Supervisor
 Project Position: Team Head
2.2 Background
2.2.1
The connecting rod in an automobile engine is a high-volume production integral part that links
the piston's reciprocating motion to the rotating crankshaft, delivering the piston's thrust to the
crankshaft. Mainly, cast iron material is generally used in manufacturing the connecting rod due
to its high stress-bearing capability. Besides this, its high density and weight have resulted in the
heavyweight of the engine. Therefore the use of aluminum material is rising in the modern
manufacturing of the connecting rod for the IC engine. The replacement of traditional material
with the aluminum alloy has significantly increased the strength of this material and has made it
suitable for the design of the connecting rod. The rod is designed considering that it should
withstand high load and the impact that gets subjected during the engine's power stroke.
This project focused on the design of connecting rods using aluminum and aluminum alloy
(ALFASIC). Detailed studies of the conventional material for manufacturing were done. The
exploration of the aluminum alloy for the new model of the connecting rod was made in this
project. The design and the fine element analysis were carried in this project. The engine
specification was considered to determine the dimensions of the connection rod, followed by
creating the 3D geometry of the proposed connecting rod using SolidWorks. Furthermore, the
ANSYS software was used to analyze the connecting rod made up of the aluminum alloy. The
study of the stress concentration was done to make sure the safe design of the rod.
2.2.2 Goals
The principal objective of this project was to design the connecting rod with aluminum alloy
material. Moreover, additional aims were:

 To design the lighter model of the connecting rod along with high mechanical strength.
 To make the economical design and improve the power production from the IC engine.
Institutional Structure

Gujarat
Technological
University

Shankersinh
Vaghela Bapu
Institute of
Technology

Department of
Mechanical
Engineering

Project
Supervisor

Panchal Akash
Project members
(Team Leader)

Figure 1: Institutional Chart

2.2.3 Duties
 To study different kinds of literature and gain deeper understandings of the design of
connecting rods.
 To explore and make the material selection for the lightweight model of the rod.
 To conduct the theoretical calculations and determine all the specifications of the rod.
 To prepare the 3D structure of the connecting rod using the CAD tool.
 To import the model in ANSYS and perform the analysis.
2.3 PEA
2.3.1
I performed numerous research and studies relating to the design and analysis of the connecting
rod utilizing aluminum alloy material throughout the early phase of performing tasks. I learned
about the rod's working principle through investigation.  I looked into the performance and
toughness of an aluminum alloy and inspected its suitability for the design of the connecting
rod. I read the research article on the different design factors and considerations that had to be
made throughout the connecting rod design process. I also investigated the different components
of four-stroke engines and the significance of the connecting rod in the combustion engine. I
investigated the piston and the crankshaft, their working principle, and assembly design with the
connecting rod. Furthermore, I did the training to model the 3D structure of the connecting rod
and also researched the methodologies to perform the Finite element analysis.
2.3.2
I began to find out different components that made the connecting rod's design and explored the
suitable materials for its modeling. Firstly, I considered commercial aluminum and new
aluminum alloy (ALFASIC) material due to its low density and high strength to bear impact and
immense stress. I chose the I-beam, smaller and bigger end model to be designed from the
calculation. I chose a reference four-stroke engine to consider its engine specification to calculate
the force or impact load on the connecting rod. Likewise, I selected SolidWorks software to
generate the 3D structure of the proposed connecting rod with the dimension calculated from the
theoretical means. Moreover, I nominated the ANSYS software to conduct the finite element
analysis on the designed model of the connecting rod.
2.3.3
I began the design and the calculation phase, where I made various considerations of the engine
specifications such as displacement, bore, torque, power, speed, etc. Firstly, I calculated the
dimension of the rod, which included the thickness, section height, width, diameter of small and
big-end, and its heights. I determined the ratio of the moment of inertia about the X and Y-axis. I
calculated the pressure on the connecting rod and then determined the force. I used the Racking-
Gordon formula to determine the thickness, height, width, and area of the I-section of the
connecting rod. Likewise, I considered the allowable bearing pressure and calculated the
diameter of the pins for the big end and small end. Following the standard ranges given by the
data book, I calculated the root diameter of the bolt and the length of the crank pin.
Calculations
Consider the connecting rod design for an engine of 180cc
Max rated power = 16 BHP at 8500 rpm
Highest available torque = 13.8 Nm at 6500 rpm
Diameter of bore = 62 mm
Stroke length = 55 mm
Consider the connecting rod body is made from standard I section
If 't' is the thickness of the I flange then assume the width and height of the I section to be 5t and
6t, respectively.
Area of the I flange = 5t2 + 5t2 + 4t2 = 14t2
Radius of gyration about x-axis = Kxx = 2.215t
Connecting rod’s length = 2 x stroke length = 110 mm
Pressure on the connecting rod exerted by the engine = mRT/V
Where m = fuel mass = mass of petrol = density x volume of cylinder = 737.2 x 10 -9 x 178.6 =
0.131 kg
R = specific mass = 8.3/0.131 = 63.36
T = temperature = 274K
So, P = 0.131 x 63.36 x 274 / 178.6 = 12.73 MPa
Force on the piston due to the pressure (F p) = P x area of cylinder = 12.73 x π x 622 / 4 =
38431.63N
Now we know from the Racking-Gordon equation of I section
F = (Fc x A) / (1+a (1/Kxx) ^2)
Where, F = buckling load, Fc = compressive stress of material = 170 MPa , A = 14t2, a =
buckling constant = 1/500, l = connecting rod’s length and Kxx = radius of gyration of I section
about x-axis.
Solving the Racking-Gordon equation we get,
t = 4.87 mm = 5mm
So, thickness (t) = 5mm
Height of I section = 5t = 25mm
Width of I section = 6t = 30mm
Area (A) = 350 mm2
Height at the end of the piston = 0.64 H = 0.64 x 25 =16mm
Height at the end of the crank = 1.25 H = 1.25 x 25 =31.25mm
Calculation of small end pin diameter
Force on the piston due to the pressure (Fp) = 38431.63 N
Fp= Bearing pressure x Projected area
Usually, the permissible bearing pressure is taken from 12.5 to 16 MPa and (l/d) ratio for the
bush is assumed as 1.5 to 2.
Fp= pb x dp x lp
Where,
pb is the permissible bearing pressure piston pin, MPa
dp is the diameter of piston pin, mm
Fp is the force on piston N
38431.63 = dp x 1.5dp x 15
dp = 41.33 mm
lp = 1.5 dp = 62 mm
Outer diameter of pin = dpo= dp + 2tb + 2tm = 42+ 4+ 10 = 56 mm
Calculation of large end pin diameter
Fp= pb x dp’ x lp
38431.63 = dp’ x 1.5dp x 10
dp = 50.6 mm
lp = 1.5 dp’ = 51mm
Outer diameter of pin = dpo= dp + 2tb + 2tm + 2tmb = 51+ 4+ 10 + 6 = 71 mm
2.3.4
I executed the CAD modeling of the connecting rod using all the rod dimensions that were
calculated from the theoretical studies. Firstly, I drew a preliminary schematic of all the
connecting rod components to comprehend the subsequent design better. I used SolidWorks to
model the 2D design of the rod with the help of this rough sketch. I used the feature extrude boss
base to generate the solid rod model up to the desired thickness. I also used the extrude cut tool
to make the slight deep groove on the I-section of the connecting rod. Moreover, I used the fillet
tool to remove all the sharp edges on the body of connecting rod. Finally, I saved this model in
the .IGES format, which would be further ready for the analysis in the ANSYS.
2.3.5
I uploaded the connecting rod model into ANSYS Workbench and began the Finite element
analysis procedure. I defined the characteristics of the material that I chose for the rod's design.
Then, I utilized the correct meshing type and finer mesh specifications to produce an acceptable
mesh quality with plenty of mesh elements and nodes to provide satisfying results. I finished the
structural modeling of the proposed connecting rod by using boundary constraints such as fixed
support and force on the rod structure. Finally, after simulating the rod structural model, I
obtained the findings. I examined the stress distribution and deformation on the connecting rod
model's surface. I discovered that all values were less than the material's permitted limit; thus, I
decided that the proposed model of the connecting rod for the considered engine was safe.
Moreover, I found that the stress, deformation and strain were considerably lower in the
aluminum alloy connecting rod than the aluminum connecting rod.
2.4 Technical issues and their solutions
2.4.1
In the analysis of the connecting rod model, I discovered significant distortion on the I-section. I
understood that such a large deformation might harm the engine, which would not be feasible for
repairing. So, I immediately discussed the problem with my project supervisor, and we
brainstormed various solutions. He advised me to make minor changes to the rod's dimensions.
He instructed me to increase the thickness of the I-section beam before analyzing the new model.
I referred to his suggestion and increased the thickness of the connecting rod while modeling a
new 3D structure. I examined this revised model and saw that the deformation had been
substantially reduced.  Finally, the proposed connecting rod design was determined to be safe for
use in the given engine.
2.4.2
I discovered an issue in the mesh while meshing the 3D model of the connecting rod, which
resulted in the simulation being interrupted and I being unable to give a solution after the
simulation. This issue halted the evaluation process and made it hard to attain the project's goal.
So I looked for a similar sort of topic in an internet discussion group. I took the help of several
skilled designers to investigate the issue. Later, I discovered that an inadequate amount of mesh
elements and nodes and poor mesh quality may cause similar meshing errors. As a result, I
investigated the meshing procedure and made some changes. I decreased the size of the mesh
element and also adjusted the meshing option to fine mesh. I also used advanced mesh in the
proximity and curvature of the rod's geometry. Finally, I was able to resolve this issue and
produce high-quality mesh. I ran this model simulation and got good results as well.
2.5 Creative works
I redesigned the I-section beam of the connecting rod by increasing its thickness so that the
deformation would not harm the engine. I also produced the fine mesh and generated a
satisfactory solution from the analysis.
2.6 Team Management
I was assigned as the project leader by my group for this academic project. So, I fulfilled my
duties by arranging weekly group meetings to exchange our opinions and findings. Likewise, I
divided the entire tasks of the project into several stages, such as preparation, planning,
execution, and analysis, in order to produce a good workflow. I divided the tasks that needed to
be completed in each stage. I also split the work into smaller portions and completed them on
schedule. Making regular reports and reporting our progress to our supervisor was how I kept
track of our development. After each month, I also revised our project goals. In addition, I
supported and encouraged my team to execute the project successfully.
2.7 Summary
In this project, a connecting rod was designed and evaluated by using two materials. The static
structural behavior of aluminum rod and aluminum alloy rod were compared. I-section beam was
used in the main body of the connecting rod. The dimensions of the connecting rod were
computed for a reference piston. The rod's structural domain was composed in SolidWorks, and
it was then examined in ANSYS to find the critical stress and deformation and their position.
Based on the findings, compared to ALFASIC alloy connecting rods, commercial aluminum
connecting rods were heavier. They had a lower rigidity as they experienced higher stress and
deformation than the proposed alloy.
I improved my 3D modeling skills and learned how to use ANSYS for performing structural
analysis. I learned how to optimize a mechanical component and enhanced my theoretical
understanding of engineering principles. I also learned how to lead a team. In addition, I
increased my communication and public speaking abilities.