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LP-8 Connecting Rod Problems Done

This lesson plan covers connecting rod problems in internal combustion engines. The class will be 70 minutes and taught by Engr. Kashif Usman to 2nd year mechanical department students. The objectives are for students to understand bend, twist, and alignment of connecting rods. The class will begin with an introduction on piston pins and then cover topics like identifying connecting rod problems, bending, twisting, and alignment of connecting rods, and problems related to connecting rods. Common connecting rod issues include fatigue, hydrolock, over-revving, and pin failure. The class will include a discussion activity and students are expected to maintain a practical notebook.

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Kashif Usman
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40 views

LP-8 Connecting Rod Problems Done

This lesson plan covers connecting rod problems in internal combustion engines. The class will be 70 minutes and taught by Engr. Kashif Usman to 2nd year mechanical department students. The objectives are for students to understand bend, twist, and alignment of connecting rods. The class will begin with an introduction on piston pins and then cover topics like identifying connecting rod problems, bending, twisting, and alignment of connecting rods, and problems related to connecting rods. Common connecting rod issues include fatigue, hydrolock, over-revving, and pin failure. The class will include a discussion activity and students are expected to maintain a practical notebook.

Uploaded by

Kashif Usman
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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LESSON PLAN

Week: 08 Taught By: Engr. Kashif Usman

Subject: Problem in Internal Combustion Engine Class: 2nd Year


Mechanical Department Time: 70 minutes
Topic: Connecting rod problems
Objective(s): Students will be able to:
 Understand Bend, twist and allignment
Skill focused on: Connecting rod
Resources:
White Board, Marker, PowerPoint Presentations
Methodology:
At the beginning of the class, I will give a brief introduction on engine piston pin. After that, the
following topics will be taught using piston pin:

Introduction:
Every connecting rod springs out twists under the constant pounding of the explosive pressures
developed in the combustion area.
Quick wearing of rings takes place due to the non-alignment condition of the connecting rod.
Rings do not scrap enough oil from the cylinder walls, and the result is increased oil consumption.
Misaligned connecting rods lead not only in the connecting rod bearings but also on the piston
skirt and cylinder walls. They cause engine knock, oil pumping, and blow by. Twisted connecting
rods cause the piston to turn slight by within the alignment bore each time the rod reverses
direction at both top and bottom of stroke. This constant movement tends to wear both the
cylinder wall and the piston excessively. Where the cylinder ridge is found to be deepest along
the length o the block, a twisted rod is quite frequently the connecting cause.

Problems Related To Connecting Rod:


Connecting rods are subjected to tons of force during engine operational. The old piston and the
bearing inserts will indicate the condition of the connecting rod. If any piston or bearing wear
abnormalities are found, there may be a problem with the connecting rod.
For example, if one of the bearings is worn, the connecting rod may be bent, if the back of the
bearing insert has marks on it, the rod big end may be distorted, allowing the insert to shift inside
the rod.

Bending, Twisting and Alignment of Connecting Rod:


After any rectification or reconditioning has been carried out on connecting rod, they should be
checked for correct alignment before they are re-erected in the engine. It will be fairly obvious
that the axis of the gudgeon pin must be in true parallelism with the axis of the big end if
satisfactory results are to be obtained. If this is not the case, the piston will be subjected to
detrimental stress and strain resulting in uneven wear. This will lead to blow by of the charge
from the explosion in the cylinder. There are several alignment jigs especially designed for testing
and rectifying connecting rods and piston in this respect.

Identification of Connecting Rod Problems:


Connecting rods give rise to many engine faults. Small end rap is caused by or worn bush, or pin,
or stripped or loose clamp bolt. Big end knock may be due to worn bearing, white metal, which
has fatigued and broken up, a blocked oil passage or shells “fretting”, i.e. loosening and wearing
against the rod. A ‘seized’ big end bearing can cause a bent connecting rod; the bent rod may hit
the bottom of the bore or may touch the camshaft in its maximum sideway position. It can be
bent by the offset big end being fitted the wrong way round. It can be twisted during the
tightening of the clamping bolt. This usually results in the piston being tilted or given too much
thrust to one side. A rod may cause imbalance by not matching the others fitted.
Bending, twisting and braking are the inherent problems of the connecting rod.
I-beam shape has a very high strength-to weight ratio which takes care of the problems of the
connecting rod.

Problems of Connecting Rod


Connecting rod can experience problems while working. This is because it experiences various stresses
during in the combustion chamber. Some of these issues can be fixed while some required complete
changing of the connecting rod. During the operation, the rod is stretched and compressed, which can cause
the con rod to break. The broken rod can completely damage the engine. Below is the failure that occurs on a
connecting rod:

Fatigue:
This is the main reason why connecting rod break. It often occurs in older engines. Compression and the
stretching of the rod during process takes place thousands of time in a minute. This eventually causes wears
to the part until it ends up breaking. Lack of oil and present of dirty in the engine can speed this issue.

New engines can also experience fatigue in the connecting if the engine is rebuilt. Well, it happens when
cheap parts or the wrong ones are used.

Hydrolock:
Hydrolock is caused when water penetrates into the piston chamber lead to deformation of the connecting
rod. This usually occurs when the vehicle drives through a flooded street.

Little water in the cylinder can cause knocking or tapping sound which can be easily repaired. However, if
there is a lot of water in the cylinder, all the space for spark time has been taken which may cause the
cylinder rod to bend or snap.

Over Revving:
Over revving is a failure that occurs in new and high-performance engines. If the tachometer shows red, it
indicates the condition of the connecting rod is in danger. This is because the forces acting on the con rod
increase dramatically at high revolutions.

Pin Failure:
The piston pin that connects the connecting rod to the piston get wear and cause failure. In some engine, it
results in catastrophic engine failure. This is when the connecting rod goes the engine block or when the
crankshaft is bent.

Activity– 1:Discussion on topic by Group-1


Success Criteria:

C.W: Nil
H.W:Maintain Practical Notebook
HoD Sign: ______________ Date: __________________

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