Computer Aided Engineering/FEM Lab

Problem Based Learning (PBL)

Milestone 1:

Group members:
Raja Shayan Amjad 190598
Muhammad Bilal Shakeel 200554
Junaid Ansar 200530

Submitted to
Engineer Saqlain Mushtaq

DEPARTMENT OF MECHANICAL AND AEROSPACE

ENGINEERING
AIR UNIVERSITY ISLAMABAD (2023)
 Table of Contents
Problem Statement .................................................................................................................... 2
Abstract for project .................................................................................................................... 4
Summary of Reference Research work with referencing .......................................................... 4
Relevant Design Calculations ..................................................................................................... 5
References ................................................................................................................................. 8
Distribution of Work among Members...................................................................................... 9

Problem statement:
FATIGUE ANALYSIS OF CONNECTING ROD
OF INTERNAL COMBUSTION ENGINE
MADE FROM ALUMINUM ALLOY-A
COMPARISON WITH STEEL AND TITANIUM
ALLOY MATERIALS
Problem Statement
A connecting rod is a component of an internal combustion engine that connects the piston
to the crankshaft. It plays a crucial role in the engine's operation by transferring the force
generated by the combustion of fuel and air mixture in the cylinder to the rotation of the
crankshaft. The connecting rod is typically made of high-strength steel and is designed to
withstand the high stresses and loads that occur during engine operation but it also can be
made of aluminium (for lightness and the ability to absorb high impact at the expense of
durability) or titanium (for a combination of strength and lightness at the expense of
affordability) for high performance engines. It is a critical component that requires careful
design and manufacturing to ensure optimal engine performance and reliability. You have
been tasked with designing a connecting rod for a specific engine, taking into account the
factors mentioned above. This involves determining the appropriate section thickness of the
connecting rod based on the engine's power, speed, and operating conditions. Additionally,
you must create a geometric model of the connecting rod that accurately represents its size
and features, such as oil passages or bearing surfaces. You will also need to analyse the
buckling load and stresses that the connecting rod will experience during engine operation
using an appropriate ANSYS module. By considering these factors and applying appropriate
design principles, you should ensure that the connecting rod will perform reliably under
real-world conditions.
 Abstract for project
The internal combustion engine consists of three main components, the Piston, the
Connecting Rod, and the Crankshaft. Connecting rods can be manufactured from many
different materials and with many design shapes, each type of connecting rod is designed
according to the type of engine fuel ( diesel or petrol ).p During manufacturing an engine it
is important to choose the correct connecting rod. Information about fatigue analysis was
needed for connecting rod to properly decide which one is optimum for there engine
according to safety and life, by using numerical technique of Finite Element method ( ANSYS
) Package. Higher safety factor is achieved by using aluminium alloy rather than titanium
alloy and steel materials with about 32.1 % and 35.6 % percentage increment respectively.
Aluminium connecting rod has life reached higher than both mention materials about 99 %.

Summary of Reference Research work with

referencing
A connecting rod is an important component in automobile engines that transfers linear
motion of the piston to the rotational motion of the crankshaft [1]. The fatigue
characteristics of different materials, such as SMA40, copper, and PF materials, have been
investigated for use in connecting rods [1][2]. Steel is the most widely used material for
connecting rods, but they can also be made of aluminum or titanium for specific purposes
[1]. The failure of connecting rods is usually caused by over-revving the engine, which places
a tremendous amount of stress on the rod bolts [3]. The stress on the connecting rod is
mainly produced at the joint of the connecting rod shell and the bottom end or the top end,
and it can be calculated using the durability module [5]. Finite element analysis and fracture
mechanics approaches have been used to evaluate the relation between tightening force
and fatigue crack propagation in connecting rod bolts [4][6]. Fatigue analysis and longevity
after a 1000000-cycle load have been assessed through using ANSYS software, which allows
the rod to be optimized for durability without the need for expensive and time-consuming
testing of series of prototypes [7]. Innovative pre-stressing elements, such as stress pins,
have been taken into consideration for large and non-axisymmetric precision forming
tooling [8]. The design of the connecting rod is crucial, and the I-beam profile of the stem
can sustain the loads well enough in the longitudinal direction [12].
 Relevant Design Calculations

Mathematical modelling :
The head and lumen endure the alternating hydraulic pressure can be determine by
equation [9] :

To estimate the mean and alternating stresses, maximum and minimum forces must be
firstly determined as follows:

Therefore, mean and alternating stresses are determined as follows :

According to Soderberg fatigue failure criteria, the safety factor can be estimated from
following formula [10]

For carrying out the fatigue analysis, it is necessary to determine the maximum load. As a
piston reciprocates between top dead center (TDC) and bottom dead center (BDC), the rod
was applied to experiences power loads and inertia loads. Power loads result from the
expansion of burning gases during combustion that push down on the head of the piston
and cause the crank to turn. Thus, power loads are always compressive in nature. This
compressive force is equal to the area of the bore multiplied by the chamber pressure. In
this study, for calculating the maximum load, the mean effective pressure of the cylinder
and mechanical yield of the engine were assumed to be 0.8 and 0.7 MPa respectively. The
maximum total load was thus found to be 9500 N [7], then, only half of this force is apply on
one half of upper connecting rod ring ( 4750 N ). The dimensions of the present connecting
rod under study is shown in figure:
The mechanical properties for Aluminum alloy, Titanium alloy and forged steel are available
in ANSYS libratory. The volume is estimated from following basic formula :

Table1: Mechanical properties for considering materials [11].

Table2: Mass weight of connecting rods [11].

Table (3): Experimental results for duration and safety

 References
[1]. Tae-Gyu Kim, Hyun-Soo Kim, In-Duck Park and Hye Sung Kim," A Study on Fatigue
Characteristics of Connecting Rod Materials for Automobile", Key Engineering Materials,
Vol. 345-346, PP. 279-282, Trans. Tech. Publications, Switzerland, 2007.
[2]. James R. Dale, " Connecting Rod Evaluation ", Metal Powder Industries Federation, 105
College Road East, Princeton, NJ 08540-6692, January, 2005.
[3]. Columbus and Nebraska, " Connecting rods 101 Design, Material, Modifications, and
Machining ", Tech. Article Archives, July, 2007.
[4]. S. Griza, F. Bertoni, G. Zanon, . Reguly, and T.R. Strohaecker, "Fatigue in engine
connecting rod bolt due to forming laps", Engineering Failure Analysis,Vol.16, Issue 5, Pages
1542 1548, July, 2009.
[5]. Gunjal N.U. Analysis of Connecting rod using Reverse Engineering method and modify
the design using polynomial curve / N.U.Gunjal, V.B. Shinde // International Journal of
Advance Research and Innovative Ideas in Education, 2016. - No.2 (4). - p.467-474.
[6]. Reddy G.K. Design and Analysis of Connecting Rod / G.K. Reddy, B.N.Vadithe //
International Journal of Research, In Advanced Engineering Technologies, 2017. - No.6 (1). -
p. 240-251.
[7]. M. Omid, S.S. Mohtasebi, S.A. Mireei, and E. Mahmoodi, " Fatigue Analysis of
Connecting Rod of U650 Tractor in the Finite Element Code ANSYS", Journal of Applied
Sciences ISSN: 18125654, Vol. 8, Issue: 23, PP. 4338-4345, Pakistan, 2008.
[8]. M. Koc and M.A. Aslanm, " Design and Finite Element Analysis of Innovative Tooling
Element (Stress Pins) to Prolong Die Life and Improve Dimensional Tolerances in Precision
Forming Processes ", Journal of Materials Processing Technology, ISSN: 09240136, Vol. 142,
Issue: 3, PP. 773-785, 2003.
[9]. Liu Yongqi, Wang Yanxia, Men Xiuhua, and Lin Fenghua, " An Investigation on Piston Pin
Seat Fatigue Life on the Mechanical Fatigue Experiments ", Trans. Tech. Publications, Key
Engineering Materials, Vol. 324 325, PP. 527 530, 2006.
[10]. Robert L. Norton, " Machine Design ", Prentice Hall Publisher, USA, 1998.
[11]. J. L. Meriam, " Statics ", Second Edition, John Wiley & Sons, Inc., USA, 1975
[12]. Rodríguez Sánchez A.E. Determination of the Side and Front-rear Buckling Loads for a
Connecting-rod / A.E. Rodríguez Sánchez // DOI: 10.15680/ijirset.2017. 0602003.
International Journal of Innovative Research in Science, Engineering and Technology, 2017. -
No. 6 (2). - p.1442-1448.

Distribution of Work among Members

Raja Shayan Amjad : research and compilation. Presentation.
Junaid Ansar: Design and Solidworks.
Bilal Shakeel: ansys Analysis
( Although All aspects of the work will be shared among the members)