DEPARTMENT OF MECHANICAL ENGINEERING

POLITEKNIK KOTA KINABALU

SESSION: 1 2023/2024

DJJ40173
CASE STUDY MARKS
ENGINEERING DESIGN
NAME : IZZATUL NADWA TAIDIN & SYLZIA RABECCA
RADIN
MATRIC NO. : 07DKM21F2043 & 07DKM21F2025
CLASS : DKM 4A
LECTURER : EN SAHRIZAN

CHAPTER 1 : Introduction to Engineering Design

PLO 3 : Design solution
: Implement engineering design process on project design taking into design
CLO 2
consideration, ergonomic factors and material selection
C1 : Remember DK5 : Engineering Design DP1 : Depth of Knowledge
C2 : Understand DP4 : Familiarity of issues
C3 : Apply DP5 : Extent of Applicable Code

Instructions:
1. This assignment contains only ONE (1) task that is set in the English language.
2. Your assignment should be typed using 12 pt Times New Roman font and 1.5 line spacing.
3. Group of maximum 2 members preparation is needed for your assignment. Do not plagiarize from
others.
4. The report should be submitted Individually

Evaluation
This case study accounts for 20% of the total marks for the course and shall be assessed based on the
rubrics attached.

Plagiarism: Marks Deduction

Warning: The submitted assignment will automatically undergo a similarity check. If plagiarism is
detected, marks would be deducted as follows:
Assignments with 10 - 30 % overlap with others: 20% deduction from the total marks scored.
Assignments with 31 - 50 % overlap with others: 40% deduction from the total marks scored.
Assignments with more than 50% overlap with others: Zero mark would be given.

INTRODUCTION

The CRF450R is a legendary and highly acclaimed off-road motorcycle that has earned its place as a
dominant force in the world of motocross and dirt biking high- performance that is manufactured by
Honda. It is a flagship model in Honda's CRF series, which stands for “Competition Race Four-Stroke”.
This is a true embodiment of engineering excellence and a testament to the brand's commitment to pushing
the boundaries of off-road motorcycling. CRF450R is introduced in the early 2000s and continually refined
and upgraded over the years. The CRF450R is a true masterpiece of engineering and innovation.

At the heart of the CRF450R lies a powerful and meticulously crafted 450cc four- stroke engine, which is
renowned for its exceptional power, torque, and overall performance. Honda's engineers have finely tuned
this engine to deliver an optimal balance between raw power and precise control. This engine producing an
awe inspiring amount of power and torque that propels riders to victory on the toughest tracks. Whether
it's navigating tight corners, powering through sand dunes, or launching off massive jumps, the CRF450R's
engine delivers relentless power and performance.

Connecting rods play a crucial role in the engine of a CRF450R, a high-performance motocross
motorcycle. These components are a vital link between the piston and the crankshaft, facilitating the
conversion of reciprocating motion into rotational motion. At the heart of this engine, the connecting rods
are integral components that connect the pistons to the crankshaft. These slender yet robust components are
meticulously engineered to withstand the extreme stresses and forces generated during the combustion
cycle. The design and construction of connecting rods in a CRF450R are engineered to withstand extreme
stresses and high RPM (revolutions per minute) commonly encountered in motocross racing. These rods
are typically made from high-strength materials such as forged steel or lightweight titanium to ensure
durability and reliability under these demanding conditions.

DESIGN PROCESS
Designing a connecting rod for a specific engine, like the CRF450R, follows a structured process that
combines engineering principles with practical considerations. Here's an overview of the design process for
a connecting rod in the context of the CRF450R:
1. Requirements Analysis:

Determine the engine's specifications, including power, RPM, and cylinder pressure, to establish the
connecting rod's load requirements.To understand the intended use of the motorcycle, such as motocross
racing or trail riding.

2. Material Selection:

Choose appropriate materials like steel or aluminium alloy based on strength, weight, and cost
considerations.Typically, high-strength steel alloys are used for connecting rods in high-performance
engines.

3. Geometry Design:

Determine the connecting rod's length, width, dimensions , and thickness to meet strength and weight
requirements, considering factors like the rod's shape (I-beam or H-beam).

4. Load Analysis:

Perform stress analysis to calculate the forces and fatigue analysis to ensure the connecting rod can
withstand the cyclic loads during engine operation.Consider factors like the reciprocating and rotating
masses, combustion forces, and inertial loads.

5. Modelling and Simulation:

Use computer-aided design (CAD) software to create 3D models and simulate how the rod will perform
under different conditions.Use finite element analysis (FEA) software to simulate the rod's behaviour
under various loading conditions.

6. Prototyping:

Create physical prototypes of the connecting rod for testing and validation, which may involve 3D
printing, forging or machining.
7. Testing:

Perform various tests, including tensile testing, fatigue testing, and dynamic analysis, to validate the
connecting rod's performance and durability.Ensure that the rod can withstand the stresses it will encounter
in the engine.

8. Iterative Design:

Based on test results, refine the design as necessary to enchance performance ,strength ,reliability.

9. Manufacturing:

Once the design is finalized, produce the connecting rods at scale through processes like forging, CNC
machining, or casting.

10. Quality Control:

Implement rigorous quality control procedures measures to ensure each rod meets the specified tolerances
and material properties.

11. Assembly:

Integrate the connecting rods into the engine assembly, ensuring proper fit, alignment and torque
specifications.

12. Performance Testing:

Test the CRF450R engine with the new connecting rods to verify performance, durability, and reliability
under real-world conditions.

13. Documentation:

Maintain detailed records of the design and manufacturing processes for future reference and quality
assurance. Throughout this process, collaboration between mechanical engineers, materials scientists, and
manufacturing experts is crucial to ensure a successful connecting rod design that meets the engine's
requirements and safety standards.

ERGONOMICS FACTOR

Designing an ergonomic connecting rod for a CRF450R involves considering various factors to ensure
optimal performance and rider comfort. While the primary function of a connecting rod is to transmit
power from the piston to the crankshaft. This indirectly affects the bike's ergonomics.

1. Weight Distribution:

The weight of the connecting rod should be carefully balanced to minimize vibrations and reduce rider
fatigue. Proper weight distribution helps to maintain the stability and control, especially during high-speed
and off-road riding.

2. Length and Geometry:

The length and shape of the connecting rod should be optimized to provide efficient power transmission
while maintaining a comfortable riding position. The connecting rod's geometry affects the engine's overall
dimensions and how it fits within the frame.

3. Vibration Dampening:

Design features like counterweights or vibration-dampening materials can be incorporated into the
connecting rod to reduce vibrations transmitted to the rider's hands and feet. Minimizing vibrations
improves rider comfort and control.

4. Material Selection:

Choosing the right materials for the connecting rod will impact its strength-to-weight ratio, which is crucial
for performance. Lightweight, durable materials like forged steel or titanium can be used to reduce the
overall weight of the engine components while maintaining strength.

5. Maintenance Accessibility:
Ease of maintenance is an important ergonomic consideration. The design should allow for straightforward
access to the connecting rod for servicing or replacement. Quick and hassle-free maintenance reduces
downtime for riders.

6. Heat Management:

Proper heat dissipation is essential to prevent excessive heat transfer to the rider's legs and feet. Heat-
resistant coatings or heat shields can be used to minimize the transfer of heat from the engine to the rider.

7. Compatibility with Other Components:

The connecting rod design should be compatible with other engine components, such as the piston,
crankshaft, and cylinder. Ensuring proper alignment and fitment reduces wear and tear, enhancing overall
performance and rider comfort.

8. Ergonomic Handlebar and Footpeg Placement:

While the connecting rod itself doesn't directly control handlebar and footpeg placement, its design should
allow for flexibility in adjusting these components to achieve the desired rider ergonomics.

Proper alignment of handlebars and footpegs contributes to rider comfort and control. It's important to note
that the design and manufacturing of connecting rods are highly specialized tasks that require a deep
understanding of mechanical engineering and metallurgy. Manufacturers like Honda invest significant
resources in research and development to ensure that all components, including connecting rods, meet the
highest standards of performance and rider comfort.
DESIGN
Designing connecting rods for a high-performance motorcycle engine like the Honda CRF450R requires
careful consideration of various factors to ensure durability, strength, and optimal engine performance.
Connecting rods play a critical role in transferring power from the piston to the crankshaft. Here's an
explanation of the key design considerations for CRF450R connecting rods:

1. Material Selection:

Material choice is crucial for connecting rod design. Typically, connecting rods are made from high-
strength steel, aluminum alloy, or titanium. Steel rods offer excellent durability and are commonly used in
high-performance engines like the CRF450R. Aluminum and titanium rods are lightweight but less
common due to their higher cost.

2. Design Geometry:

The connecting rod's length, width, and thickness are carefully designed to ensure optimal strength-to-
weight ratio. The rod's length affects the engine's stroke and overall performance, so it must be precisely
calculated for the desired power characteristics.

3. Big End and Small End:

The big end of the connecting rod connects to the crankshaft, while the small end connects to the piston
pin. The big end usually has a split design to allow for easy assembly onto the crankshaft. The small end is
designed to accommodate the piston pin and may include a bushing or bearing for reduced friction and
wear.

4. Rod Bolts:

Connecting rods are secured to the crankshaft and piston using rod bolts. These bolts must be high-strength
to withstand the forces generated by the engine. Bolt size and material are selected to ensure sufficient
clamping force and resistance to fatigue.

5. Weight Reduction:
Weight is a critical factor in high-performance engines, as it affects the engine's responsiveness and
overall performance. Connecting rods are often designed with weight-saving features such as scalloped
sides, lightening holes, and thinner sections in non-critical areas.

6. Heat Treatment:

Heat treatment processes, such as quenching and tempering, are employed to enhance the strength and
durability of the connecting rods. Proper heat treatment ensures the rods can withstand high loads and
temperature variations.

7. Precision Machining:

Connecting rods undergo precise machining to achieve the desired dimensions and surface finish. The
bearing surfaces are carefully machined to ensure a proper fit with the crankshaft and piston pin.

8. Balancing:

To minimize engine vibration and ensure smooth operation, connecting rods are balanced to precise
tolerances. Balancing involves removing material from specific areas to achieve uniform weight
distribution.

9. Lubrication:

Lubrication channels and oil holes are designed into the connecting rod to ensure proper oil flow to critical
areas, such as the piston pin and bearings. Lubrication is crucial for reducing friction and preventing
overheating.

10. Finite Element Analysis (FEA):

FEA is often used in the design process to simulate the structural behavior of connecting rods under
various loads and conditions. FEA helps engineers optimize the rod's design for strength and durability
while minimizing weight.
11. Testing and Validation:

Connecting rod designs are subjected to rigorous testing, including load testing and durability testing, to
ensure they can withstand the demands of high-performance engines. In the case of the CRF450R, the
connecting rods are designed to withstand the high RPMs and power output of the engine, making material
selection, geometry, and precision manufacturing critical factors in their design. These rods must strike a
balance between strength, weight, and durability to deliver the desired level of
performance and reliability.
MATERIAL SELECTION

Selecting the appropriate material for connecting rods in an engine, such as the CRF450R, is crucial for
ensuring durability and performance. Several factors should be considered when choosing the material for
connecting rods, including strength, weight, thermal conductivity, and cost. Typically, connecting rods are
made from one of the following materials:

1. Steel:

Steel connecting rods are strong, durable, and commonly used in many high- performance engines. They
can handle high levels of stress , the relatively cost- effective and less likely to fail under extreme
conditions.Steel connecting rods can be made from various alloys, such as 4340 or 4140 which are heat-
treated for increased strength.However, they tend to be heavier than some other materials, which can affect
engine balance and performance.

2. Forged Steel:

Forged steel connecting rods are even stronger and more durable than regular steel rods. They are often
used in high-performance and racing engines where the extra strength is required. While they are heavier
than some other materials, their superior strength can make them a good choice for demanding
applications.

3. Aluminum:

Aluminum connecting rods are very lightweight but are generally not as strong as steel or titanium
rods.This can improve engine responsiveness and performance.They are often used in applications where
reducing weight is critical.However, they may not be suitable for extremely high-stress applications like
CRF450R engines performance which experience with high loads.

4. Titanium:

Titanium connecting rods are both strong and lightweight , making it ideal for used in high-performance
and racing engines where weight reduction is critical. Titanium rods offer a good balance between strength
and weight, but they can be expensive to manufacture.It has excellent fatigue resistance , ultra-high-
perfomance engines where weight reduction is a top priority.

5. Composite Materials:

Some modern engines use composite materials like carbon fiber or fiberglass reinforced with epoxy resin
for connecting rods, which can offer a combination of strength and weight reduction but it can be
expensive to manufacture and may require careful engineering to ensure reliability.

6. Manufacturability:

Some materials are more challenging to machine and work with than others. Consider the ease of
manufacturing when selecting a material.

7. Billet Steel:

These are solid steel rods machined from a single piece of steel. They are strong and durable, making them
suitable for high-performance applications.

When selecting connecting rod material for a CRF450R or any other high- performance engine, it's
essential to consider the specific requirements of the application, the budget, and the trade-offs between
strength, weight, and cost. It's also important to ensure that the chosen material is compatible with the
engine's operating conditions, such as temperature and stress levels.

Additionally, it’s important to keep in mind that the design and manufacturing processes used for
connecting rods can also influence their performance. High-quality manufacturing techniques, such as
precision machining and heat treatment, can enhance the performance and durability of connecting rods
regardless of the material chosen. It's often a good idea to consult with experienced engine builders or
engineers to make the best material selection for your specific application.
MANUFACTURING PROCESS
The manufacturing process of connecting rods for a CRF450R involves several precise steps to ensure the
quality and reliability of the component. Connecting rods are critical engine parts that link the piston to the
crankshaft, transmitting the power generated in the combustion chamber to the crankshaft :

1. Material Selection:

The connecting rods are often made from high-strength materials like forged steel, aluminum, or titanium,
depending on the application. The choice of material depends on factors such as weight, strength, and cost.

2. Forging:

Forged steel connecting rods are created through a hot forging process. A billet of steel is heated to a high
temperature and then shaped using dies under extreme pressure. This process ensures the material's
strength and integrity.

3. Machining:

After forging, the connecting rod blank is machined to precise dimensions. This involves cutting, milling,
and drilling operations to create the rod's final shape, including the small and big end bearing bores.

4. Heat Treatment:

Heat treatment is a critical step to improve the mechanical properties of the connecting rod. It involves
heating the rod to a specific temperature and then rapidly cooling it to achieve the desired hardness and
toughness.

5. Shot Peening:

Shot peening is a surface treatment process that involves bombarding the connecting rod with small metal
beads or shots. This process induces compressive stresses on the surface, enhancing fatigue resistance.

6. Balancing:
It may undergo balancing process, which is to ensure that the connecting rods is properly balanced. This
also involves removing material from specific areas to achieve the desired balance.

7. Bearing Installation:

The connecting rod is equipped with bearings at both ends. The small end typically uses a bushing or
needle roller bearing, while the big end connects to the crankshaft using a larger bearing. Proper
installation of these bearings is crucial for long-term performance.

8. Quality Control:

To verify dimensional accuracy, quality control checks are performed at various stages of manufacturing.
material quality, and structural integrity. Any non- conforming parts are rejected.

9. Surface Finishing:

The connecting rod may undergo additional surface finishing processes, such as shot blasting or polishing,
to improve its appearance and remove any surface imperfections.

10. Assembly:

Once the connecting rod is complete and passes quality control checks, it is ready for assembly into the
engine. This involves attaching the piston to the small end and connecting the big end to the crankshaft.

11. Testing:

Connecting rods may undergo various tests, including stress tests. This is to ensure that they meet the
required performance standards and can withstand the engine's demands. The specific details of the
manufacturing process may vary depending on the manufacturer's techniques and the type of materials
used.

Additionally, precision and quality control are paramount in producing connecting rods for high-
performance engines like the CRF450R to ensure safety and reliability under extreme operating conditions.
ESTIMATED COST

The estimated cost of the design process for connecting rods in a CRF450R engine can vary significantly
depending on various factors. To estimate the cost, you'll need to consider several key components of the
design process:

1. Design Requirements:

The specific requirements for the connecting rods must be define, such as material type (typically forged
steel or aluminum), dimensions, weight constraints, and performance specifications.

2. Engineering Expertise:

A team of experienced engineers is needed, including mechanical and structural engineers. This is to
design and analyze the connecting rods. The cost of their salaries or consulting fees will be a significant
part of the project cost.

3. CAD Software and Tools:

Invest in computer-aided design (CAD) software licenses and other design tools necessary for the
modeling and simulation of connecting rod designs. The cost can vary based on the software's complexity
and licensing model.

4. Materials and Testing:

The cost of materials that required for prototype development and testing must be estimate. This includes
the cost of the raw materials, machining, heat treatment, and any additional surface treatments or coatings.

5. Prototyping:

The estimated cost of the design process for connecting rods in a CRF450R engine can vary significantly
depending on various factors, including the complexity of the design, materials used, labor costs, and the
specific design requirements.
6. Design Requirements:

The specific requirements for the connecting rods must be defined. Such as material type (typically forged
steel or aluminum), dimensions, weight constraints, and performance specifications.

7. Engineering Expertise:

You will need a team of experienced engineers, including mechanical and structural engineers. This is to
design and analyze the connecting rods. The cost of their salaries or consulting fees will be a significant
part of the project cost.

8. CAD Software and Tools:

Invest in computer-aided design (CAD) software licenses and other design tools necessary for the
modeling and simulation of connecting rod designs. The cost can vary based on the software's complexity
and licensing model.

9. Materials and Testing:

Estimate the cost of materials required for prototype development and testing. This includes the cost of the
raw materials, machining, heat treatment, and any additional surface treatments or coatings.

10. Prototyping:

Create prototypes of the connecting rods for testing and validation. The cost will depend on the chosen
prototyping method (e.g., 3D printing, CNC machining, or traditional casting/forging).

11. Testing and Validation: Conduct various tests to ensure the connecting rods meet performance and
safety standards. This may include stress analysis, fatigue testing, and dynamic testing. The cost will
depend on the complexity of the tests and the need for specialized equipment.
CONCLUSION

The development of new high-performance connecting rods for the CRF450R is a significant advancement
in the field of motocross and off-road motorcycle engineering. These innovative connecting rods offer
several key benefits that enhance the overall performance of the CRF450R, ultimately delivering a better
riding experience for enthusiasts and professional riders alike.

1. Improved Durability:

The new connecting rods are likely constructed from advanced materials, such as high-strength alloys or
composite materials, which are designed to withstand the high- stress conditions experienced during
motocross and off-road riding. This improved durability ensures that the connecting rods can endure the
rigors of intense riding without failure.

2. Enhanced Strength-to-Weight Ratio:

High-performance connecting rods are designed to be both lightweight and exceptionally strong. This
design optimization contributes to the motorcycle's overall performance by reducing the reciprocating mass
in the engine, resulting in quicker acceleration and improved handling.

3. Increased Engine Efficiency:

Upgraded connecting rods can lead to better engine efficiency, as they help maintain the alignment and
synchronization of the engine components. This improved coordination leads to more consistent power
delivery, reduced vibrations, and smoother operation, all of which contribute to enhanced performance.

4. Higher RPM Capability:

High-performance connecting rods are often designed to handle higher RPM (Revolutions Per Minute)
ranges. This allows the engine to produce more power at higher speeds, which is crucial for motocross
racing and other high-performance applications.

5. Customization Options:
Manufacturers may offer different configurations and materials for these connecting rods, allowing riders
to tailor their motorcycle's performance to their specific needs and preferences. This level of customization
can be particularly beneficial for professional riders and racing teams.

6. Increased Reliability:

By using advanced materials and manufacturing techniques, these connecting rods are less prone to wear
and fatigue, leading to increased reliability and longer service intervals. This is especially valuable for
riders who demand consistent performance without frequent maintenance.

7. Competitive Advantage:

For competitive riders and racing teams, the introduction of high-performance connecting rods can provide
a significant advantage on the track, potentially leading to improved lap times and better race results.

In conclusion, the development of new high-performance connecting rods for the CRF450R represents a
commendable step forward in motorcycle engineering. These components contribute to improved
durability, engine efficiency, and overall performance, providing riders with a more competitive and
enjoyable riding experience. Whether you're a professional racer or a passionate enthusiast, these high-
performance connecting rods can take your CRF450R to the next level of performance and reliability.

REFERENCES
https://www.con-rods.com/for-honda-2002-2008-crf-450r-cn506m.html
https://jsdmachineworks.com/02-08-honda-crf450r-carrillo-connecting-rod/
https://radical-rpm.com/en/connecting-rods-honda/2512-biela-wossner-honda-crf- 150.html