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Savitribai Phule Pune University, Pune 2015 Course

A Project Report on
Design ,Analysis and Manufacturing of
Connecting Rod
By
Mr. Prasad Fulpagar Exam. Seat No 71614022F
Mr. Vishal Gaikwad Exam. Seat No 71614039L
Mr. Ronak Satone Exam. Seat No 71712746L
Mr. Saurabh Khodade Exam. Seat No 71414428C

Guide
Prof.V.H.Bansode

Department of Mechanical Engineering

Sinhgad Technical Education Society’s
Smt. Kashibai Navale College of Engineering
[2019-20]

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Sinhgad Technical Education Society’s

Smt. Kashibai Navale College of Engineering

CERTIFICATE

This is to certify that Mr. Prasad Fulpagare Exam. Seat No.71614022F

Mr.Vishal Gaikwad Exam. Seat No.71614039L
Mr.Ronak Satone Exam. Seat No.71712746L
Mr.Saurabh Khodade Exam. Seat No.71414428C
have successfully completed the Project Stage – I entitled Design ,Analysis and
Manufacturing of Connecting Rod.

under my supervision, in the partial fulfillment of Bachelor of Engineering-Mechanical

Engineering of Savitribai Phule Pune University.

Date: -
Place: - Pune Seal

Prof.V.H.Bansode Prof…………….
Guide External Examiner

Dr. N.P. Sherje Dr. A.V. Deshpande

Head of Department Principal

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ACKNOWLEDGEMENT

I take this opportunity to thank all those who have contributed in successful completion of
this Project Stage -1 work. I would like to express my sincere thanks to my guide
Prof.V.H.Bansode. who have encouraged me to work on this topic and provided valuable
guidance wherever required. I also extend my gratitude to Dr. N. P. Sherje (H.O.D
Mechanical Department) who has provided facilities to explore the subject with more
enthusiasm.

I express my immense pleasure and thankfulness to all the teachers and staff of the
Department of Mechanical Engineering of Smt. Kashibai Navale College of
Engineering for their co-operation and support.

Mr..Prasad Fulpagar Sign.……………….

Mr. Vishal Gaikwad Sign.……………….
Mr. Ronak Satone Sign.……………….
Mr. Saurabh Khodade Sign.……………….

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Contents
Topic No. Name of Topic Page No.

1 Introduction 1
2
1.1 Problem statement

1.2 Objectives 3

1.3 Scope 4

1.4 Methodology 5

1.5 Organization of Dissertation 6

2 7
Literature Review

2.1
2.2
3 Design of proposed work 15

3.1 Element 1
3.2 Element 2
3.3 Element 3
4 Conclusion 20
5 Future Scope 21
References 22

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Abstract

To obtain weight optimized connecting rod of an compressor which can withstand the load acting
on it due to compressed gases. The connecting rod is used to translate the rotating motion of electric
motor to the oscillatory motion of the piston. The rod is subjected to the high cyclic loads of
compression and tension. The optimized connecting rod with reduced weight results in the reduced
inertial forces in the system. The objective is to design and analysis the structural stress distribution
of connecting rod at the real time condition during process. Once the designing of the connecting
rod is done FE analysis is done depending on the loading condition of the connecting rod. Loading
of connecting rod is calculated based upon the gas pressure and compressor specification. The
modeling of the connecting rod is done on Catia V5 and analysis work is done on ANSYS 19.2.
The parameters like Von mises stress, Von mises strain and displacement was obtained from
ANSYS software which shows reduction in weight and improvement in strength the overall results
of the analysis are also validated by the analytical method and UTM machine. Thus the process
results in the optimized and effective connecting rod.

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1. INTRODUCTION

The reciprocating compressor uses a piston, which moves inside a cylinder, to compress the air.
When the piston moves down, air is drawn in. When the piston moves up, the air is compressed.
Two sets of valves take care of the air intake and exhaust. One-way valves (usually inside the
cylinder head) make sure that the sucked-in air cannot escape and that the compressed air cannot
flow back when the piston moves down again.

Fig. 1 Reciprocating Compressor

The function of connecting rod in compressors is to transmit the power from crankshaft to the
piston to compress the air. The role of connecting rod in the conversion of rotary motion into
reciprocating motion. The lighter connecting rod and the piston, greater resulting compression and
less the vibration because of the reciprocating weight is less.

Fig.2 Air Compressor

There are different types of materials and production methods used in the creation of connecting
rods. The most common types of Connecting rods material are steel and aluminum. The most
common types of manufacturing processes are casting, forging and powdered metallurgy. A

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connecting rod consists of a pin-end, a shank section, and a crank-end. Pin-end and crank-end
pinholes at the upper and lower ends are machined to permit accurate fitting of bearings.

Fig.3 Connecting Rod

Buckling is the instable phenomenon. The buckling happens only at one load, and that load is
called as critical buckling load which is given by, Euler formula for columns,

Pcr = π2EI/ le2

Where,
E- Young’s modulus
I-Moment of Inertia
Le-Effective length of the column

When the maximum stress of the structure is less than ultimate strength and it is said to be safe, at
that time critical buckling load becomes design driver i.e. if the applied load is greater than the
critical buckling load, the structure will fail even though it is designed with respect to its strength.
The ratio of critical buckling load to applied load is called as Buckling Factor (B.F) which is used
to know whether the structure is buckled or not.

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Problem statement

Each day consumers are looking for the best from the best. That’s why the material optimization
is really important in industry. Material Optimization of the component is to make the less time to
produce the product that is stronger, lighter and less cost. The design and weight of the connecting
rod influence on performance. Hence, it is effect on the manufacture credibility. The tensile and
compressive stresses are produced due to pressure, and bending stresses are produced due to
centrifugal effect & eccentricity. So the connecting rods are designed generally of I- section to
provide maximum rigidity with minimum weight. Change in the structural design and also material
will be significant increments in weight and performance Pneumatic Compressors are subjected to
less dynamic loads as compared to automotive engines. Exercise work has been done on
automotive Connecting Rods in terms of thermal and structural optimization.

Objectives

• The main aim of the project is to determine the Von Misses stresses, Shear stresses, and
Equivalent Alternating stress, Total Deformation, Fatigue Analysis and Material
Optimization in the existing Connecting rod.

• The result comparison between the Aluminum material and Plastic material of connecting
rod.

• In this Project, the static FEA of the connecting rod has been performed by the use of the
software. This work can be extended to study the effect of loads on the connecting rod
under dynamic conditions.

• Experimental stress analysis of Model using Strain gauging & lifting load applied through
UTM.

• Experimental buckling analysis can also be used to calculate the stresses which will provide
more reasons to compare the different values obtained.

• Comparative analysis between FEA & Experimental results.

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Scope

To obtain weight optimized connecting rod of an compressor which can withstand the load acting
on it due to compressed gases.
Less material required for the production
Production time reduce.

Methodology

1. Modeling current connecting rod.

2. Analyzing for stresses and deformation.

3. Topological optimization for the model.

4. Results from topological optimization will be implemented on existing model.

5. Analyzing for stresses and deformation on optimized model.

6. Machining the existing connecting rod as per optimization result.

7. Finding high strain portion from CAE software.

8. Mounting strain gauge on same portion.

9. Preparing fixtures to hold connecting rod for experimental testing.

10. Correlating results of both CAE and experimental.

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Organization of Dissertation

Connecting rod and piston from a car engine

The connecting rod is the connecting link between the piston and the crankshaft. On one side the
connecting rod is connected to the piston by piston pin and on the other side it is connected to the
crankshaft by connecting rod cap. Both these connections of the connecting rod enable converting
the rotary motion of the crankshaft into the reciprocating motion of the piston inside the cylinder.
The connecting rod is usually made up of carbon steel forging.

connecting rod is a mechanic linkage used by water mills to convert rotating motion of
the water wheel into reciprocating motion[1]

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2. Literature Review

K.Kiran Kumar et al. [1] This paper discusses the various definitions of The Energy consumption
of air compressor in the improving efficiency of the reciprocating compressor to improve the
compressors performance that can be improves the electric motor efficiency, internal losses system
effects, speed variation and interaction of valve stress and compressor performance. To improve
the heat transfer in reciprocating compressor using the finite element methods. Reciprocating
compressor is one of the most popular machine uses in the industries. Reciprocating air
compressors in vehicles compress air and supply it to the air brakes. Many of the components
constituting the reciprocating air compressor are having design features based more on standard
practices rather than on sound scientific analysis. One of the systematic investigations reported
recently is on the pressure variation inside the air compressor as a function of the crank angle. Rod
load, including historical and current API-618 definitions, manufacturer’s ratings, and various user
interpretations Reciprocating compressors are usually rated in terms of horsepower, speed and rod
load. Horsepower and speed are easily understood; every year in China, many of the accidents in
refineries are caused by the common faults of reciprocating compressors.

S. Om Prakash et al. [2] The main objective of this work is to explore weight and cost reduction
opportunities in the design and production of a connecting rod, achieved by performing a detailed
load analysis. The study deals with load and stress analysis of the connecting rod is done and then
optimization is achieved by reducing the weight and cost. First part of the study analysis includes
the determination of loads acting on the connecting rod as a function of time. This is done for
finding out the minimum stress area and to remove the material in those areas. The relationship
between the load and acceleration of the connecting rod for a given constant speed of the crankshaft
are also determined. Finite element analysis was performed at several crank angles. The connecting
rod can be designed and optimized under the loads ranging from tensile load, corresponding to 360
degree crank angle at the maximum engine speed as one

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extreme load and compressive load corresponding to the peak gas pressure as the other extreme
load.

C. Juarez et al [3] this paper presents the results of a failure analysis investigation conducted in a
connecting rod from a diesel engine used in the generation of electrical energy. The investigation
included an extensive analysis of the con-rod material as well as the fracture zone. The
investigation involved the following experimental procedures and testing techniques: visual
inspection, fractography, magnetic particle inspection, chemical analysis, tensile and hardness
testing, metallographic, and microanalysis. The connecting rod was fabricated from an AISI/SAE
4140 low alloy steel; chemical composition, mechanical properties and microstructure were
appropriate for the application. The connecting rod fractured at the body in a section close to the
head; the origin of the fracture was located at the con-rod lubrication channel. The lubrication
channel exhibited an area containing a tungsten based material, presumably from a machining tool,
embedded in its surface as a result of a deficient manufacturing process. This area acted as
nucleation site for cracks that propagate through the connecting rod section by a fatigue
mechanism, reducing its section and finally producing its catastrophic failure.

G Gopala et al. [4] The paper deals with study of an assembly of the Piston, Connecting rod and
Crank shaft of a four-wheeler petrol engine. The components of the assembly have to be rigid and
the assembly has to move as a mechanism. Hence, the analysis should involve a rigid-body analysis
and flexible-body analysis. So, the forces in the components as the engine reciprocates have to be
calculated and these forces are used to calculate the dynamic stresses in the component of interest
i.e. the connecting rod. It is proposed to replace with two new sets of materials for the components
of the assembly and check the parameters by performing the static, dynamic and thermal analysis
In this project, the main parts of the assembly i.e. engine piston, connecting rod and crankshaft are
modeled and assembled as per the given design. And the Finite Element Analysis is done in Ansys.
The meshing is done in Hyper Mesh.

K. Bari et al. [5] In the present work, a failed connecting rod from a motorcycle engine was
investigated for the root cause of and possible mechanisms leading to its premature failure. In
addition to finding the root cause, the expectation from this study was to possibly improve the
existing designs or practices to avoid similar failures in future. These results were validated using
a finite element analysis (FEA) simulation. A Scanning Electron Microscope was used for
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investigating the mechanisms of fracture modes, optical microscopy for studying the
microstructures and visual inspection were primarily utilized to determine the root cause of the
failure. In conclusion, it was determined that the root cause for the premature failure of the
connecting rod was the presence of scale build-up inclusions, which led to micro cracking during
fatigue loading of the component.
Zhou Shia et al. [6] Quality defects of fracture surface are easily produced in the fracture splitting
process of connecting rod. At present, the resulting mechanism of this type of defect is lacking in
evidence and there is no effective control method. Based on fracture mechanics and the actual
production, this study simulates the process of connecting rod fracture splitting using finite element
method. Three-dimensional crack propagation state is described, and the stress and deformation of
the crack tip are analyzed. The essence of the fracture surface defects, such as drop dregs, steps,
and crack bifurcations, are mainly due to the change of the crack path and structure during crack
propagation. These defects mainly occur at the boundary positions of the fracture surface such as
bolt hole and end faces, which is due to the boundary’s stress and deformation characteristics of
the fracture surface. The boundary is in the plane stress state; the crack tip undergoes shear
deformation and has a large plastic zone which leads to severe twist of the crack tip opening angle.
That causes the crack propagation path to be twisted and bent, thus resulting in fracture-splitting
defects.
Slavko Rakić et al. [7] this paper presents failure analysis of the connecting rod used in a 12-
cylinder diesel engine set on a special vehicle. The fracture of the connecting rod occurred during
the engine test in laboratory conditions. Chemical and metallographic analysis as well as
mechanical testing has confirmed that the material properties of the connecting rod met the
requirements of standard specification and technical documentation. Linear finite element (FE)
analysis was performed to evaluate stress state of the connecting rod under maximum load. The
results of FE analysis showed that the position of the fracture is consistent with the zone of highest
stress. Fractographic analysis has not been able to reveal the main cause of mechanism of fracture
due to substantially damaged fracture surface. Inadequate machining, absence of polishing and
highest stress in the region of fracture were identified as the main causes of failure. Finally, the
engine had been working at maximum load for a longer period of time that also led to the breakage
of the connecting rod.

D.Gopinatha et al. [8] every vehicle that uses an internal combustion engine requires at least one

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connecting rod depending upon the number of cylinders in the engine. It undergoes high cyclic
loads of the order of 108 to109 cycles, which range from high compressive loads due to
combustion, to high tensile loads due to inertia. Therefore, durability of the component is of critical
importance. Due to these factors the connecting rod has been the topic of research for different
aspects such as production, materials, performance simulation, etc. The main objective of research
was to explore weight reduction opportunities for the production of forged steel, aluminium and
titanium connecting rods. This has entailed performing a detailed load analysis. Therefore, this
study has dealt with two subjects, first, static load stress analysis of the connecting rod for three
materials, and second, optimization for weight of forged steel connecting rod. In this research,
firstly a proper geometrical model was developed using CATIA. Mohammed Mohsin Ali Ha et al.
[9] The Connecting rod transmits the piston load to the crank causing the latter to turn, thus
converting the reciprocating motion of the piston into a rotary motion of the crankshaft. Connecting
rods are subjected to forces generated by mass and fuel combustion. Connecting rod is modeled
using CATIA software and FE analysis is carried out using ANSYS Software. Load distribution
plays important role in fatigue life of the structure. Bush failure changes the loading direction and
distribution. Present study is concentrated around the fatigue life due to concentrated load and
cosine type load distribution on the bigger end.
Zhu Jun-chao et al. [10] Dynamic lubrication analysis of connecting rod is a very complex problem.
Some factors have great effect on lubrication, such as clearance, oil viscosity, oil supplying hole
and surface roughness. This work establish the EHD characteristic of bearing and bush to analyze
the peak oil film pressure, min oil film thickness and nodes force with consideration of deformation
and cavitation. Then create connecting rod components to calculate the stress distribution with
consideration of film lubrication or not. Finally contract the results of two conditions. The results
show that: the stress distribution of two conditions are different in individual positions, but the
stress calculation method considering the oil film lubrication is more consistent with the actual
working conditions.

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3. Design of proposed work

Company of Compressor = Speed

H.P.= 7.5

RPM = 640

Tank in Size = 21*52 (In Inch) = 290 PSI

Working Pressure = 183 PSI = 1.26 MPa

Bore*Stroke = 70*70 (In mm)

Piston Displacement = 27mm

BASIC CALCULATION:

Area = l*b = 3.2*3.8 mm2

Pressure = Force / Area

Force = Pressure*Area = 1.26*1216

= 1532.16N

DESIGN:
CAD:-

Computer-aided design (CAD) is the use of computer systems (or workstations) to aid in the
creation, modification, analysis, or optimization of a design. CAD software is used to increase the
productivity of the designer, improve the quality of design, improve communications through
documentation, and to create a database for manufacturing. CAD output is often in the form of
electronic files for print, machining, or other manufacturing operations. The term
CADD (for Computer Aided Design and Drafting) is also used.

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Its use in designing electronic systems is known as electronic design automation (EDA). In
mechanical design it is known as mechanical design automation (MDA) or computer-aided
drafting (CAD), which includes the process of creating a technical drawing with the use of
computer software.

CAD software for mechanical design uses either vector-based graphics to depict the objects of
traditional drafting, or may also produce raster graphicsshowing the overall appearance of designed
objects. However, it involves more than just shapes. As in the manual drafting of
technical and engineering drawings, the output of CAD must convey information, such as
materials, processes, dimensions, and tolerances, according to application- specific conventions.

CAD may be used to design curves and figures in two-dimensional (2D) space; or curves, surfaces,
and solids in three-dimensional (3D) space.

CAD is an important industrial art extensively used in many applications, including

automotive, shipbuilding, and aerospace industries, industrial and architectural design,
prosthetics, and many more. CAD is also widely used to produce computer animation for
special effects in movies, advertising and technical manuals, often called DCC digital content
creation. The modern ubiquity and power of computers means that even perfume bottles and
shampoo dispensers are designed using techniques unheard of by engineers of the 1960s. Because
of its enormous economic importance, CAD has been a major driving force for research in
computational geometry, computer graphics (both hardware and software), and discrete differential
geometry.

The design of geometric models for object shapes, in particular, is occasionally called computer-
aided geometric design (CAGD)

USES:

Computer-aided design is one of the many tools used by engineers and designers and is used in
many ways depending on the profession of the user and the type of software in question.

CAD is one part of the whole Digital Product Development (DPD) activity within the Product
Lifecycle Management (PLM) processes, and as such is used together with other tools, which are
either integrated modules or stand-alone products, such as:

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• Computer-aided engineering (CAE) and Finite element analysis (FEA)

• Computer-aided manufacturing (CAM) including instructions to Computer Numerical
Control (CNC) machines
• Photorealistic rendering and Motion Simulation.
• Document management and revision control using Product Data Management (PDM).

CAD is also used for the accurate creation of photo simulations that are often required in the
preparation of Environmental Impact Reports, in which computer-aided designs of intended
buildings are superimposed into photographs of existing environments to represent what that locale
will be like, where the proposed facilities are allowed to be built. Potential blockage of view
corridors and shadow studies are also frequently analyzed through the use of CAD.

CAD has been proven to be useful to engineers as well. Using four properties which are history,
features, parameterization, and high-level constraints. The construction history can be used to look
back into the model's personal features and work on the single area rather than the whole model.
Parameters and constraints can be used to determine the size, shape, and other properties of the
different modeling elements. The features in the CAD system can be used for the variety of tools
for measurement such as tensile strength, yield strength, electrical or electromagnetic properties.
Also its stress, strain, timing or how the element gets affected in certain temperatures, etc.

TYPES:

There are several different types of CAD, each requiring the operator to think differently about
how to use them and design their virtual components in a different manner for each.

There are many producers of the lower-end 2D systems, including a number of free and open-
source programs. These provide an approach to the drawing process without all the fuss over scale
and placement on the drawing sheet that accompanied hand drafting since these can be adjusted as
required during the creation of the final draft.

3D wireframe is basically an extension of 2D drafting (not often used

today). Each line has to be manually inserted into the drawing. The final product has no mass
properties associated with it and cannot have features directly added to it, such as holes. The
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operator approaches these in a similar fashion to the 2D systems, although many 3D systems allow
using the wireframe model to make the final engineering drawing views.

3D "dumb" solids are created in a way analogous to manipulations of real-world objects (not often
used today). Basic three-dimensional geometric forms (prisms, cylinders, spheres, and so on) have
solid volumes added or subtracted from them as if assembling or cutting real-world objects. Two-
dimensional projected views can easily be generated from the models. Basic 3D solids don't usually
include tools to easily allow motion of components, set limits to their motion, or identify
interference between components.

There are two types of 3D Solid Modeling

1. Parametric modeling allows the operator to use what is referred to as "design intent". The
objects and features created are modifiable. Any future modifications can be made by
changing how the original part was created. If a feature was intended to be located from
the center of the part, the operator should locate it from the center of the model. The feature
could be located using any geometric object already available in the part, but this random
placement would defeat the design intent. If the operator designs the part as it functions
the parametric modeler is able to make changes to the part while maintaining geometric
and functional relationships.
2. Direct or Explicit modeling provide the ability to edit geometry without a history tree. With
direct modeling, once a sketch is used to create geometry the sketch is incorporated into
the new geometry and the designer just modifies the geometry without needing the original
sketch. As with parametric modeling, direct modeling has the ability to include
relationships between selected geometry (e.g., tangency, concentricity).
Top end systems offer the capabilities to incorporate more organic, aesthetics and ergonomic
features into designs. Freeform surface modeling is often combined with solids to allow the
designer to create products that fit the human form and visual requirements as well as they interface
with the machine.

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Fig. 4 CATIA model of connecting rod

Fig. 5Drafting of model

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ANALYSIS OF CONNECTING ROD

A. BOUNDARY CONDITION

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B. TOTAL DEFORMATION

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C. EQUIVALENT STRESS

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D. ELASTIC STRAIN

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4. CONCLUSION

To obtain weight optimized connecting rod of an compressor which can withstand the load
acting on it due to compressed gases. Modelling current connecting rod on catia v5 and
Loading of connecting rod is calculated based upon the gas pressure and compressor
specification. The modeling of the connecting rod is done on Catia

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5. FUTURE PLANS

1. Design of Prototype is to be completed till the mid of November

2. Testing of prototype is to be completed till the end of December
3. The prototype anomalies are to be studied and rectified in the initially weeks of
January
4. The final design is to be completed during the mid of February.

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References

1) Fretting-fatigue induced failure of a connecting rod J. Chao

2) Fatigue Analysis of Sundry I.C Engine Connecting Rods S.V.UmaMaheswara Rao, T.V.
Hanumanta Rao, K.Satyanarayana, B.Nagaraju

3) Failure analysis of a diesel generator connecting rod C. Juarez, F. Rumiche, A. Rozas, J.

Cuisano, P. Lean

4) Analysis of Piston, Connecting rod and Crank shaft assembly G Gopala, Dr L Suresh
Kumar, K Vijaya Bahskar Reddy, M Uma MaheshwaraRaod , G Srinivasulu

5) Forensic Investigation of a Failed Connecting Rod from a Motorcycle Engine

a. K. Bari, A. Rolfe, A. Christofi, C. Mazzuca and K.V. Sudhakar
6) Analysis of quality defects in the fracture surface of fracture splitting connecting rod based
on three-dimensional crack growth Zhou Shia, ShuqingKoua
7) Failure analysis of a special vehicle engine connecting rod Slavko Rakić, Dr
UgljesaBugaric
8) Design and Optimization of Four-Wheeler Connecting Rod Using Finite Element Analysis
D.Gopinatha ,Ch.V.Sushma
9) Analysis of Fatigue Stresses on Connecting Rod Subjected to Concentrated Loads at The
Big End Mohammed Mohsin Ali Ha, Mohamed Haneef
10) A Study on the influence of Oil film lubrication to the Strength of Engine Connecting Rod
Components Zhu Jun-chao, Zhu Han-hua, Fan Shi-dong, Xue Liang-jun, Li You- feng

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