International Journal of Modern Engineering Research (IJMER)

www.ijmer.com Vol.2, Issue.5, Sep-Oct. 2012 pp-3367-3371 ISSN: 2249-6645

Modeling and Analysis of Two Wheeler Connecting Rod

K. Sudershn Kumar1, Dr. K. Tirupathi Reddy2, Syed Altaf Hussain3
*(PG student, School of Mechanical Engineering RGM College of Engg. & Technology, Nandyal-518501, India)
** (School of Mechanical Engineering, RGM College of Engineering & Technology, Nandyal-518501, India)
*** (School of Mechanical Engineering, RGM College of Engineering & Technology, Nandyal-518501, India)

ABSTRACT: The connecting rod is the intermediate fixed at either end , so that the angle between the
member between the piston and the Crankshaft. Its primary connecting rod and piston can change as the rod moves up
function is to transmit the push and pull from the piston pin and down and rotates around the crank shaft .T he big end
to the crank pin, thus converting the reciprocating motion connects to the bearings journal on the throw connecting
of the piston into rotary motion of the crank. rod is under tremendous stress from the reciprocating load
Existing connecting rod is manufactured by using represented by the piston ,actually stretching and being
Carbon steel. This paper describes modeling and analysis compressed with every rotation, and the load increases to
of connecting rod. In this project connecting rod is replaced the third power with increasing engine speed .Connecting
by Aluminum reinforced with Boron carbide for Suzuki rod for automotive applications are typically manufactured
GS150R motorbike. A 2D drawing is drafted from the by forging from either wrought steel or powder metal.
calculations. A parametric model of connecting rod is Schematic diagram for connecting rod as shown in figure 1
modelled using PRO-E 4.0 software. Analysis is carried out
by using ANSYS software.
Finite element analysis of connecting rod is done
by considering two materials ,viz.. Aluminum Reinforced
with Boron Carbide and Aluminum 360. The best
combination of parameters like Von misses stress and
strain, Deformation, Factor of safety and weight reduction
for two wheeler piston were done in ANSYS software.
Compared to carbon steel, aluminum boron carbide and
aluminum 360, Aluminum boron carbide is found to have Fig:1 Schematic diagram of connecting rod.
working factor of safety is nearer to theoretical factor of
safety, 33.17% to reduce the weight, to increase the II. SPECIFICATION OF THE PROBLEM
stiffness by 48.55% and to reduce the stress by10.35% and The objective of the present work is to design and
most stiffer. analyses of connecting rod made of Aluminum Reinforced
with Boron carbide. Steel and aluminum materials are used
Keywords: Connecting rod, Static analysis, Carbon steel, to design the connecting rod. In this project the material
Aluminum, Aluminum reinforced with Boron carbide, (carbon steel) of connecting rod replaced with Aluminum
Aluminum 360. Reinforced with Boron carbide. Connecting rod was created
in Pro-E. Model is imported in ANSYS 12.0 for analysis.
I. INTRODUCTION After analyis a comparison is made between exisisting steel
Connecting rods are widely used variety of and aluminum connecting rod viz., Aluminum Reinforced
engine. The function of connecting rod is to transmit the with Boron carbide in terms of weight, factor of safety,
thrust of the piston to the crank shaft, and as the result the stiffnes, deformation and stresse.
reciprocating motion of the piston is translated into
rotational motion of the crank shaft. It consist of a pin –end. III. THEORETICAL CALCULATIONS OF
A shank section, and crank an end .Pin end and crank end CONNECTING ROD
pin holes are machined to permit accurate fitting of 1. A connecting rod is a machine member which is subjected
bearings. One end of the connecting rod is connected to the to alternating direct compressive and tensile forces. Since
piston by the piston pin. Connecting rods are subjected to the compressive forces are much higher than the tensile
forces generated by mass and fuel combustion .Theses two force, therefore the cross-section of the connecting rod is
forces results in axial load and bending stresses. A designed as a strut and the Rankin formula is used.
connecting rod must be capable of transmitting axial 2. A connecting rod subjected to an axial load W may buckle
tension, axial compression, and bending stress caused by with x-axis as neutral axis in the plane of motion of the
the thrust and full of the piston and by centrifugal force. connecting rod, {or} y-axis is a neutral axis. The
Finite element (FEM) Modal is a modern way for fatigue connecting rod is considered like both ends hinged for
analysis and estimation of the component .The influential buckling about x-axis and both ends fixed for buckling
component factors are able to change such as material about y-axis. A connecting rod should be equally strong in
.cross section conditions etc. buckling about either axis.
In modern automotive internal combustion Let
engine, the connecting rods are most usually made of steel A = cross sectional area of the connecting rod.
for production engine. But can be made of aluminum or L = length of the connecting rod.
titanium for high performance of engines of cast iron for 𝜎c =compressive yield stress.
application such as motor scooters. They are not rigidly Wcr =crippling or buckling load.
www.ijmer.com 3367 | Page
 International Journal of Modern Engineering Research (IJMER)
www.ijmer.com Vol.2, Issue.5, Sep-Oct. 2012 pp-3367-3371 ISSN: 2249-6645
Ixx and Iyy =moment of inertia of the section about x-axis t2 =10.03
and y-axis respectively. t=3.167mm
Kxx and Kyy =radius of gyration of the section about x-axis t=3.2mm
and y- axis respectively. Width of section B = 4t =12.8mm
Rankin formula = (Ixx=4Iyy). Height of section H = 5t = 16mm
Area A = 11t2 = 112.64mm2
3.1 PRESSURE CALCULATION FOR 150CC Height at the big end (crank end) = H2 = 1.1H to 1.25H
ENGINE H2 =17.6mm
Suzuki GS 150 R Specifications Height at the small end (piston end) = 0.9H -0,75H
Engine type air cooled 4-stroke H1 =12mm
Bore × Stroke (mm) = 57×58.6
Displacement = 149.5CC 3.3 DESIGN CALCULATION FOR ALUMINUM 360.
Maximum Power = 13.8bhp@8500rpm Buckling load w B = maximum gas force × F.O.S
Maximum Torque = 13.4Nm@6000rpm WB = σC×A = 31386 N
Compression Ratio = 9.35/1 1+ a(L\KXX)2
Density of Petrol C8H18 = 737.22kg/m3 σC = compressive yield stress = 172 MPa
= 737.22E-9kg/mm3 Kxx = IXX\A
Temperature = 60F = 288.855K Kxx = 1.78t
Mass = Density × Volume a= σc \π2E
= 737.22E-9×149.5E3 a = 0.002
= 0.11Kg By substituting σC, A, a, L, KXX on WB then
Molecular Weight of Petrol 114.228 g/mole 4565t4-37663t2-81639.46=0
From Gas Equation, t2 =16.64
PV=Mrt t =4.08mm
R = R*/Mw = 8.3143/.114228 t =4.1mm
= 72.76 Width of section B = 4t =16.4mm
P = (0.11x72.786x288.85) / 149.5E3 Height of section H = 5t = 20.5mm
P = 15.469 Mpa. Area A = 11t2 = 184.91mm2
Height at the big end (crank end) = H2 = 1.1H to 1.25H
3.2 DESIGN CALCULATION FOR CARBON STEEL H2 =25.625mm
Thickness of flange & web of the section = t Height at the small end (piston end) = 0.9H -0,75H
Width of section B= 4t H1 =18.45mm
The standard dimension of I SECTION.

Figure2: Standard dimension of I - Section. Figure3: 2D drawing for connecting rod.

Height of section H=5t IV. SPECIFICATION OF EXISTING

Area of section A= 2(4t×t) +3t×t CONNECTING ROD
A=11t² Table 1 shows the specifications of the connecting
MI of section about x axis: rod for carbon steel (Suzuki GS). The typical chemical
Ixx=1\12 (4t (5t) 3-3t (3t) 3) = 419\12t4 composition of the material is 0.61%C, 0.095% Al,
MI of section about y axis: 0.82%Mn, 0.00097%Br, 0.145% C, 7.8Co, 75.56Fe and
IYY = (2+1\12t(4t)3+1\12(3t) t3) = 131\12 t4 3.25 Mo.
IXX\ IYY= 3.2
Length of connecting rod (L) = 2 times the stroke Table: 1 Specifications of connecting rod:
L = 117.2 mm S.No Parameters Value
Buckling load w B = maximum gas force × F.O.S 1 Bore × Stroke 57×58.6
WB = σC×A = 37663 N (mm)
1+ a(L\KXX)2 2 Length of 112 mm
σC = compressive yield stress = 415MPa connecting rod
Kxx = IXX\A 3 Thickness of For C.S = 3.2mm
Kxx = 1.78t connecting rod For AL 360 = 4.1
a= σc \π2E mm
a = 0.0002 4 Width of For C.S = 12.8mm
By substituting σC, A, a, L, KXX on WB then connecting rod For AL 360 = 16.4
4565t4-37663t2-81639.46=0 mm
www.ijmer.com 3368 | Page
 International Journal of Modern Engineering Research (IJMER)
www.ijmer.com Vol.2, Issue.5, Sep-Oct. 2012 pp-3367-3371 ISSN: 2249-6645
5 Height of For C.S
connecting rod H1 =12mm
H2 =17.6mm
For AL 360
H1 =18.45mm
H2 =25.625mm

V. STRUCTURAL ANALYSIS OF
CONNECTING ROD
Dimensions of Width and height of the conecting
rod is For C.S = 12.8mm and For AL 360 = 16.4 mm. A 3- Figure7: von misses Stress for carbon steel.
D model of connecting is used for analysis in ANSYS 12.0.
The loading conditions are assumed to be static. Analysis
done with pressure 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. The element choosen is
SOLID 187, it was used with the tetrahedral option, making
it a 10-node element with 3 degrees of freedom at each
node. The finite element analysis is carried out on carbon
steel connecting rod as well as on three different materials
of carbon steel, aluminum boron carbide and aluminum
360. From the analysis the equivalent stress (Von-mises Figure8: Displacement of carbon steel.
stress), strain, displacements were determined and are
shown in figure 4-15. Table 2 shows the comparative of 6.2 ALUMINUM 360:
factor of safety for three different materials.

VI. STRUCTURAL ANALYSIS OF

CONNECTING ROD

Figure9: modeling of aluminum 360.

Figure4: loads and boundary conditions.

6.1 CARBON STEEL:

Figure10: von misses strain of aluminum 360.

Figure5: Mesh of carbon steel.

Figure11: von misses stress of aluminum 360.

Figure6: von misses strain of carbon steel.
www.ijmer.com 3369 | Page
 International Journal of Modern Engineering Research (IJMER)
www.ijmer.com Vol.2, Issue.5, Sep-Oct. 2012 pp-3367-3371 ISSN: 2249-6645
( Mpa )
Tensile 540 317 485
strength
(Mpa)
Theoretical 6 6 6
Factor of
safety
(N)
Allow stress 69.16 28.47 50
( Mpa )
Ansys result 49 43.925 43.925
Figure12: Displacement of aluminum 360. ( Mpa)
Working 8.47 4 6.95
6.3 ALUMINUM BORAN CARBIDE: Factor of
safety
(N)

7.1. RESULT FOR WEIGHT OF CONNECTING ROD

Density of Carbon steel = 7.87e-6 Kg/mm3
Volume of connecting rod = 92419.78mm3
Weight of connecting rod = Density × Volume
=7.87e-6×92419.78
= 0.727 kg
= 7.131 N
1. Density of Al 360 =2.685e-6 kg/mm3
Volume of connecting rod =180935.21mm3
Figure13: von misses train of aluminum boron carbide. Weight of connecting rod =Density × Volume
= 0.48581 kg
= 4.765 N
Percentage of reduction in weight = W of Carbon steel-W
of Al 360 / W of Carbon steel
=0.727-0.48581/0.727
=0.3317
Aluminum boron carbide = W of Carbon steel-W of
Aluminum boron carbide/W of Carbon steel
=0.727-0.48581/0.727
=0.3317

7.2. RESULT FOR STIFFNESS OF CONNECTING

Figure14: von misses stress aluminum boron carbide. ROD:
Carbon steel
Weight of connecting rod =0.727Kg
Deformation =0.00941mm
Stiffness =Weight/Deformation
=0.727/0.0094
=77.34 kg/mm
Aluminum360
Weight of connecting rod =0.48581Kg
Deformation =0.0033166mm
Stiffness =Weight/Deformation
=0.48581/0.00331
=146.77 kg/mm
Figure15: Displacement aluminum boron carbide. Aluminum boron carbide
Weight of connecting rod =0.48581Kg
VII. RESULTS Deformation =0.012219mm
Stiffness = Weight/Deformation
Table 2. Comparison of factor of safety. = 0.48581/0.012219
Material Carbon Aluminum Aluminum = 39.7585 kg/m
properties steel 360 boron
carbide
Yield strength 415 172 300

www.ijmer.com 3370 | Page

 International Journal of Modern Engineering Research (IJMER)
www.ijmer.com Vol.2, Issue.5, Sep-Oct. 2012 pp-3367-3371 ISSN: 2249-6645
7.3. RESULT FOR PERCENTAGE OF INCREASE IN IX. CONCLUSIONS
STIFFNESS: By checking and comparing the
Aluminum 360 =77.34-146.77/77.34 results of materials in above tables and finalizing the results
= -0.8977 are shown in below.
Aluminum boron carbide = 77.34-39.7585/77.34
= 0.4855 For considering the parameters,
The working factor of safety is nearer to theoretical factor
7.4. RESULT FOR PERCENTAGE OF STRESS of safety in aluminum boron carbide.
REDUCTION: Percentage of reduction in weight is same in Aluminum 360
Aluminum 360 =49.625-43.925/49.625 and aluminum boron carbide.
=0.1035 Percentage of increase in stiffness in aluminum boron
Aluminum boron carbide =49-43.925/49 carbide is more.
=0.1035 Percentage of reducing in stress ALUMINIUM BORON
CARBIDE and ALUMNUM is same than CARBON
VIII. GRAPHS STEEL.

REFERENCES
1. Afzal, A. and A. Fatemi, 2004. "A comparative study of
fatigue behaviour and life predictions of forged steel
and PM connecting rods". SAE Technical Paper, 1:
1529.
2. Anonymous, 2008. "Nissan Z24engine Maintenance
and Repayments catalogue". Megamotor Co.
3. Chen, N., L. Han, W. Zhang and X. Hao, 2006.
"Enhancing Mechanical Properties and Avoiding
Fig 16: Von-Misses Stress for three materials. Cracks by Simulation of Quenching Connecting Rod".
Material Letters, 61: 3021-3024.
4. El-Sayed, M.E.M. and E.H. Lund, 1990. “Structural
optimization with fatigue life constraints,” Engineering
Fracture Mechanics, 37(6): 1149-1156.
5. Jahed Motlagh, H., M. Nouban and M.H. Ashraghi,
2003. "Finite Element ANSYS". University of Tehran
Publication, PP: 990.
6. Khanali, M., 2006. "Stress analysis of frontal axle of
JD 955 combines". M.Sc. thesis. Thran University, 124.
7. Kolchin, A. and V. Demidov, 1984. "Design of
Fig 17: Von-Misses Strain for three materials. Automotive Engines". MIR Publication.
8. Meriam, J.L. and L.G. Kraige., 1998. Engineering
Mechanics, 5th Edition, New York, john willey, 712.

9. Repgen, B., 1998. “Optimized Connecting Rods to

Enable Higher Engine Performance and Cost
Reduction,” SAE Technical Paper Series, Paper No.
980882.
10. Shigley, J.E. and C.R. Mischke, 2001. "Mechanical
Engineering Design", McGraw-Hill, New York, 776.
Webster, W.D., R. Coffell and D. Alfaro, 1983.
Fig 18: Displacement for three materials. 11. “A Three Dimensional Finite Element Analysis of a
High Speed Diesel Engine Connecting Rod,” SAE
Technical Paper Series, Paper No. 831322.

BOOKS:
1. Machine design by R.S. KHURMI, J.K GUPTA.
2. Design data by PSG.
3. A text book of Machine Design by S.Md.
JALALUDEEN.

Fig 19: working factor of safety for three materials.

www.ijmer.com 3371 | Page