Career Episode 3

ANSYS Investigation of Connecting Rod

3.1 Introduction
Project Title: Ansys Investigation of Connecting Rod
Chronology: Insert
Organization: The Maharaja Sayajirao University of Baroda
Location: India
Position: Team Leader
Under guidance of: Insert
3.2 Background
3.2.1
The pressure exerted by the expansion of the gas inside the automobile engine is conveyed to
the crankshaft, from the piston by the means of a connecting rod. The pressure generated by
the consumption of fuel is considerably large, so a strong material that can bear the pressure
should be selected. The piston is under cyclic load which causes stress concentration and
fatigue in the piston. As a result of the continuous periodic load, frequent failure of the
connecting rod occurs if the material is not selected properly. Cast iron and steel have been
widely used in the manufacturing of connecting rods. Aluminum alloys and composite materials
are also used to reduce the weight of the engine. However, steel is the most commonly used
material in connecting rods because they have a very high strength and are suitable for engines
with a high compression ratio. Likewise, in modern days the use of finite element techniques is
increasing rapidly to evaluate the designed prototype. In engine parts, FEA is generally used to
examine the stress and temperature distribution.

This project was carried out to design and evaluate a connecting rod. C 70 steel was chosen as
the connecting rod’s material due to its very high yield strength. The rod’s dimensions were
calculated theoretically and the bending stress level on the rod was also checked analytically.
SolidWorks software was utilized to develop a virtual 3D model of the connecting rod. The
induced stress levels and the resulting deflection in the rod was examined in ANSYS. The stress
from both numerical simulation and analytical calculation was observed to be under the
acceptable bounds.

3.2.2 Objectives
The main aim of this study was to carry ANSYS investigation of the connecting rod. Some
additional aims were:
  To increase the connecting rod’s strength so that it could sustain high cyclic loads.
 To increase the overall working performance of the connecting rod by selecting stiff,
hard and strong material.

3.2.3 Organizational Structure

The Maharaja
Sayajirao University
of Baroda

Department of
Mechanical
Engineering

Project Supervisor

Project Leader
( Shyamal
Sushyanbhai Team Members
Chudasama)

Figure 1: Organizational Structure

3.2.4 Responsibilities
 To obtain project relevant information by reviewing past papers, books and manuals.
 To select the material and software for the project.
 To determine the dimensions by conducting the design calculations.
 To compose a virtual 3D geometry of the rod in SolidWorks software.
  To assess stress levels and deflection on the connecting rod by using ANSYS software.
3.3 PEA

3.3.1
In order to assess past research on this subject, I started my study by compiling various
technical research articles and papers. Then, I looked at fundamental functions and core
components for rod connection in motors. For example, I reviewed the various connecting rod
components such as the I-beam, crank pin, cap, bushings, rod nut, and bearing inserts. After
that, I started to examine the design process of a connecting rod from different books. I read
the theory of machines book and machine element design book in order to learn the structural
design of the rod. Then, I learned researched the challenges in the connecting rod design. I also
read the different failure mechanisms of the connecting rods and their root causes. I also
investigated the high strength materials that were used to make the rod. I also discovered
about SolidWorks' basic features and tools and common modelling methods. Lastly, by looking
at online resources, tutorial and reading ANSYS guidelines, I learned to use ANSYS.

3.3.2
After that, I began the selection of material for the connecting rod. I reviewed the various
materials used by manufacturers to produce the connecting rod. Following my research, I
discovered that the most preferred materials in the commercial sectors aluminum alloys and
steel. In this analysis, I opted to use C70 steel because it had very high yield strength and
stiffness as compared to aluminum. Then, I explored the metallurgical properties of C 70 steel
in online resources. I discovered that it had a very high ultimate strength of 800 N/mm 2 and
yield strength 600 N/mm2. Likewise, its young's modulus was 210 N/mm 2 and density was 7850
kg/m3. Additionally, for modelling the rod I decided to use SolidWorks. Lastly, I selected ANSYS
to simulate the structural domain of the connecting rod.

3.3.3
I began to calculate the dimensions and bending stress levels of the connecting rod. Initially, I
assumed the 147.5 CC engine for starting the design. I then accumulated the parameters
needed to calculate the measurements of the rod. I also procured the specs of the motor, such
as its RPM, rated power, bore diameter, and stroke length. I first calculated the piston
displacement value. Then, I computed the pressures on the piston by using the compression
ratio. Then, I determined the force acting on the connecting rod. I considered the standard I-I
section as the rod’s main body. I also used the moment of inertia equation of I-section to find
the value of web thickness of the beam. Next, I determined the dimensions of other parameters
of the I-section after acquiring its web thickness. I used a high factor of safety of 5 to obtain the
allowable bending stress of C70 steel. Then, I calculated the actual bending stress developed in
the I-beam. I realized that the actual stress was under the allowable value. I also computed the
dimensions of the small end and the larger end of the rod. Lastly, I calculated the cyclic force
acting on the connecting rod which would be used in ANSYS to determine the stress from
numerical simulations.

3.3.4
In order to build up the connecting rod, I used SolidWorks. I first changed the sketch unit into
millimeters. Then, I picked the front plane for drawing the rod’s 2D sketch. In the selected
plane, I first drew the I-channel’s outline. After that, I properly gave its dimensions by using the
smart dimension tool. I made its dimensions equal to the calculated values obtained from
previous calculations. Next, I created two circles by using the circle tool. I sketched one circle at
the larger end of the connecting rod and the next at the opposite end. I removed the undesired
entities after joining the beam's profile with the circle. And, I used the extrude function to
create the 3D geometry from the 2D sketch. Similarly, I used the cut-extrude feature to make
slots in the both ends of the rod. In addition, I used the fillet tool to create the smooth ends in
the rod body. Finally, I double-checked the dimensions and transformed the file to IGES file
type.

Design required

3.3.5
I initially updated the material in the ANSYS library. I assigned all the values of C70 steel. Then,
in the model, I switched the material from structural steel to the newly defined C70 steel. Then,
I accessed the prototype in ANSYS mesh where I started meshing the structure. I used
finer mesh elements as the overall size of the connecting rod was small. I also inserted the
value of target mesh which allowed me to obtain a mesh with specified number of elements.
Then, I moved on to the boundary constraints. At the rod bearing inserts, I assigned fixed
support to suppress the motion. I applied the calculated force value at the rod busing which lied
at the smaller end. Then, I evaluated the geometry and the acquired the results of structural
analysis. After reviewing the obtained results, I discovered that the stress levels were within
C70 steel’s permissible stress range. I also saw that the deformations were considerably lower.

Analysis required

3.4 Technical Problems and Solutions

3.4.1
While mesh the connecting rod’s geometry in ANSYS, I faced an issue. To begin, I initially
developed the mesh under the default settings. I obtained distorted mesh. I consulted about
this with the supervisor and found that this might lead to inaccurate results. So, I looked up in
the internet and got an idea of performing the mesh manually. Therefore, I performed mesh
manually by defining the more node numbers. Further, I took large area and generated mesh. I
obtained fine mesh and then run the simulation. I obtained accurate results from the analysis
and was thus able to solve the meshing problem.

3.5 Creative Work

I obtained accurate structural results from numerical simulation by decreasing the stress
concentration in the model by removing sharp edges and by using finer mesh of better quality.

3.6 Team Management and Codes

I applied several management approaches while working as a team leader. During project
initiation, I along with my team mates arranged a meeting with the supervisor regarding the
project planning and scheduling. I slightly modified the project plan by considering the advice of
the supervisor. I took serious decisions while selecting materials and component for the
project. I regularly encouraged each member during hard times and motivated them for
common goal. I consulted seniors and supervisor for solving technical difficulties obtained in
the project. I prepared project presentation and listened to the advice of each group members
for any changes. I submitted the project report to the university after preparing it.

I followed ICS 35.240.10 for the designing guidelines using computer aided design. Similarly, I
also followed the guidelines specified by the university.

3.7 Project Summary

Hence the ANSYS investigation of the connecting rod was completed. After comparative
analysis, C 70 material was selected due to its high yield strength. The theoretical calculation
was conducted, where the dimensions of the rod were calculated. The 3D model of the
connecting rod was prepared in the SolidWorks software. Static structural of the rod was done
in ANSYS software and the parameters like deformation and strain were obtained. The values of
all the parameters was found within the limit permitted and design was considered safe. Since,
proper material was selected and design was prepared having less deformation and stress
value, the effectiveness of the rod was improved.
I improved leadership skill by taking many serious decisions. I also improvised management skill
in the project. Besides, I improved designing skills too.