SlideShare a Scribd company logo
1 of 9
Download to read offline
See discussions, stats, and author profiles for this publication at: https://www.researchgate.net/publication/297827838
Design and Analysis of a Connecting Rod for the 117kw Six Cylinders
Turbocharged Diesel Engine
Article · March 2011
CITATIONS
0
READS
5,561
2 authors, including:
Some of the authors of this publication are also working on these related projects:
Transient Thermal Analysis of the Turbine Blade Transient Thermal Analysis of the Turbine Blade View project
Himam Saheb Shaik
IFHE
35 PUBLICATIONS   19 CITATIONS   
SEE PROFILE
All content following this page was uploaded by Himam Saheb Shaik on 12 March 2016.
The user has requested enhancement of the downloaded file.
Abstract--- The main objective of this work was to explore
weight reduction opportunities for forged steel connecting rod
in Ashok Leyland Bharat Stage-II engines. This has
entailed performing a detailed load analysis. An optimization
study was performed on a steel forged connecting rod with a
consideration for improvement in weight and production cost.
The introduction of piston cooling nozzles in AL engines
provides scope for eliminating the oil hole in the connecting
rod and thereby reducing the size 'of the 'I' section.
Furthermore, the existing connecting rod can be replaced with
a new connecting rod with modified I-section. Literature
survey suggests cyclic loads comprised of static tensile and
compressive loads are often used for design and optimization
of connecting rods. However, in this study weight optimization
is performed under a cyclic load comprising dynamic tensile
load and static compressive load as the two extreme loads.
Therefore, this work has further dealt with two subjects, first,
the connecting rod modeling, force calculations and the
second is the finite element analysis and also deals with
Optimization of Gudgeon pin.
Keywords--- Finite Element Analysis Connecting Rod by
using Different Design Software’s like Pro-e, Ansys
Software’s
I. INTRODUCTION
HE engines connecting rods are a high volume
production, and usually manufactured by drop forging
process. The material mostly used for connecting rods varies
from mild carbon steels (0.35 to 0.45 % carbons) to alloy
steels (Chrome Nickel to Chrome molybdenum steels). The
functions of connecting rod includes, providing a connecting
link between Piston and Crankshaft to convert the
reciprocating motion to rotary motion and conveying
lubricating oil from Crankshaft (big end) to Piston pin (small
end) through its central oil hole.
Connecting rods are generally subjected to two types of
inertia forces, one due to masses and friction induced by the
reciprocating parts and other, due to the gas load generated
from combustion process. The small end of the connecting rod
is provided with a bush of phosphor bronze and connected to
Shaik Himam Saheb, Assistant Profess, B.Tech, M.Tech, Singareni
Collieries Polytechnic Singareni Collieries Polytechnic, Adilabad District,
Mancherial-504302. E-mail: himam.mech@gmail.com
P. Sampath Kumar, Assistant Profess, B.Tech, M.Tech, Singareni
Collieries Polytechnic Singareni Collieries Polytechnic, Adilabad District,
Mancherial-504302. E-mail: sampath.pendekatla@gmail.com
A. Ramesh, Assistant Profess, B.Tech, M.Tech, Christhu Jyothi Institute
of Technology and Science (CJITS), Jangaon, Warangal, AP, India. E-mail:
ramesh340mech@gmail.com
gudgeon pin. The big end of the connecting rod is usually
made split into two halves. The split cap is fastened to the big
end with two cap bolts. The bearing shells are made up of
steel, brass or bronze with a thin lining about 0.75 mm of
white metal or Babbitt metal. In this subject, 412 Turbo-
Charged air cooled engine’s power intensity ratio is 0.24, thus
piston cooling is necessary .This is achieved by piston-cooling
nozzles (cooling of piston through a separate jet from oil
gallery to Dissipate combustion heat and to control the piston
ring sticking).
The optimization carried out here, however, is not in the
true mathematical sense, since while reducing mass,
manufacturing feasibility and cost reduction are integral parts
of the optimization. In Addition, software used in this work
imposed restrictions in performing optimization under fatigue
life constraint.
II. THESIS STRUCTURE
The thesis comprises eleven parts. The first part is a review
of the literature on Connecting rod optimization .This survey
is focused on the Work carried out on both forged steel and
powder metallurgy Connecting rod. The second part provides
a detailed load analysis and force calculations of a forged steel
connecting rod. The fourth part provides force calculations of
a forged steel connecting rod .The fifth part explains the Finite
Element Analysis of the Connecting rod Sixth and seventh
part describes the optimization procedure for gudgeon pin and
connecting rod. The sample component development,
conclusions drawn from this project and a list of
recommendations for further work are presented in later
Chapters.
III. OBJECTIVES AND OUTLINE
A. Literature Survey
The connecting rod is subjected to a complex state of
loading. It undergoes high cyclic loads of the order of 108
to
109
cycles, which range from high compressive loads due to
combustion, to high tensile loads due to inertia. Therefore,
durability of this component is of critical importance. Due to
these factors, the connecting rod has been the topic of research
for different aspects such as production technology, materials,
performance simulation, fatigue, etc.
[1] Adila Afzal and Fatemi conducted a comparative study
for the Fatigue properties and life predictions of forged steel
and PM connecting rods. Both the materials are obtained from
specimen testing and then used in life predictions using the S-
N approach.
Design and Analysis of a Connecting Rod for the
117kw Six Cylinders Turbocharged Diesel Engine
Shaik Himam Saheb, P. Sampath Kumar and A. Ramesh
T
Advance Research and Innovations in Mechanical, Material Science, Industrial Engineering and Management - ICARMMIEM-2014 172
ISBN 978-93-82338-97-0 © 2014 Bonfring
The stress concentration factors were obtained from FEA,
and the modified Goodman equation was used to account for
the mean stress effect. Fractography of the connecting fracture
surfaces was also conducted to investigate the failure
mechanisms. Monotonic and cyclic deformation behaviors, as
well as strain-controlled fatigue properties of the two materials
were evaluated and compared.
Fig 1: The Fatigue failure locations on (a) Forged steel and
(b) PM connecting rods(Courtesy: Adila Afzal and Fatemi
[1])The objective of this work was to optimize the weight and
cost of a forged steel connecting rod, to a safe level of factor
of safety in Ashok Leyland Bharat Stage II engines. This
weight reduction project is being taken up, since; the
introduction of piston cooling nozzle which not only cools the
overheating piston but also lubricates the piston pin. Thereby,
it provides a scope for eliminating the central oil hole, and
reducing the ‘I’ section size.
Optimization begins with identifying the correct load
conditions and magnitudes. The idea behind optimizing is to
retain just as much strength is needed. Commercial software’s
such as ProEngineer, ADAMS-View, and I-DEAS Analysis
can be used to obtain the
Variation of quantities such as angular velocity, angular
acceleration, and load. However, usually the worst case load is
considered in the design process.
Literature review suggests that investigators use maximum
inertia load, inertia load, or inertia load of the piston assembly
mass as one extreme load corresponding to the tensile load,
and firing load or compressive gas load corresponding to
maximum torque as the other extreme design load
corresponding to the compressive load. Inertia load is a time
varying quantity and can refer to the inertia load of the piston,
or of the connecting rod.
From the literature review, it is clear that maximum
stresses act at the connecting rod column bottom end and does
not occur at TDC. The maximum bending stress at the column
center is about 25% of the maximum stress at that location.
However, to obtain the bending stress variation over the
connecting rod length, or to know the stress at critical
locations such as the transition regions of the connecting rod, a
detailed analysis is needed. As a result, for the forged steel
connecting rod, a detailed load analysis has to be investigated
by a static FEA to capture the stress variations.
IV. CALCULATION OF FACTOR OF SAFETY
Aim: To calculate existing factor of safety of the
connecting rod using Rankine’s formula in an Excel Spread
sheet.
Given Data’s:
Piston Diameter (d1) =107.277 mm
Stroke Length(L) = 120.65 mm
Crank Radius(r) = (L/2)= 60.325 mm
Length of connecting rod (ℓ)=223.558 mm
Ratio (ℓ/r)= 3.70
Maximum Explosion Pressure (Pmax=12.236 N/mm2
Engine Speed (N) = 2400 rpm
Mass of Reciprocating Parts(M)= 3.154 Kg
Web Thickness (t)= 5.08 mm
Radius of Gyration (E)= 2.06 x 105
N/mm2
STEP 1:
Yield Strength of connecting Rod (σ Y) = 570 N/mm2
Tensile Strength of connecting Rod (σ u) =770 N/mm2
STEP 2:
Load due to Gas pressure (FG) = (π/4 * d1
2
* Pmax)
= (π/4 * 107.277 2
* 12.236) = 110600.3997 N
STEP 3:
For an I-section A = 11t2,
Kxx = 1.78t.
Therefore, A = 283.87 mm2
& Kxx = 9.0424 mm
Shank Design
Flange Thickness = t
Depth of section = 5t
Width of section = 4t
Area of section (A) = 11t2.,
Ixx = 1
/12 (BH3
– bh3
=1/12 [(1t) x (5t2
) – (3t) x (3t3
)] = 419t2
/ 12
Iyy = 1
/12 (2t*B3
+ ht3
)= 1
/12 [(2t * 4t3
) + (3t * t3
)]= 131
/12 t4
K2
xx = Ixx / A = 419t2
/ (12*11t2
)
K2
xx = 3.18 t2
…………………… (i)
K2
yy = Iyy / A = 131t2
/ (12*11t2
),K2
yy = 0.995 t2
STEP 4:
Rankine’s formula:
The buckling load (WB) of the component can be
calculated
WB = ((σc * A) / {1+a [ℓ/Kxx
2
]}……………… (ii)
Where,
σc (Direct compressive stress + Bending Stress) = 770
N/mm2
Advance Research and Innovations in Mechanical, Material Science, Industrial Engineering and Management - ICARMMIEM-2014 173
ISBN 978-93-82338-97-0 © 2014 Bonfring
a = 1/ 7500 constant, ℓ = 223.558 mm, Kxx = 9.0424 mm
A1, I-section area with hole = 859.550 mm2
A2 , I-section area without hole = 891.220 mm2
Here A1, A2 are the values obtained from CAD software.
WB =Maximum gas force * Factor of safety
=Pmax * Piston area * n=110600 n from equation (ii),
F.O.S without hole (n1) = 5.7371, F.O.S with hole (n2) =
5.533
The above F.O.S values fits only to the I-Section of the
Connecting rod.
V. PARAMETRIC MODELING OF CONNECTING ROD
A solid model of the connecting rod was generated using
Pro/Engineer Wildfire2.0. Due to the symmetry of the
geometry, the component was first half modeled. The model
was designed without forging flash, bolts, and crank or pin
hole bearings, as these details are not expected to have any
significant influence on the obtained results at the critical
regions (i.e. failure locations, simplification of the model.
Different modeling techniques have been adopted on modeling
of the existing connecting rod. Thus, a final optimized
geometry of connecting rod has been created using assembly
cut procedure from the Pro/Engineer.
Fig. 2: Parametric Model of Existing Connecting Rod
VI. FORCE CALCULATIONS - ADAMS/VIEWER
A. Introduction
The Automatic Dynamic Analysis of Mechanical Systems
(ADAMS/Viewer) is used in the field of Mechanical System
Simulation (MSS) to simulate both large and small-scale
motion of mechanical systems. These motions are induced by
the action of applied forces or excitations that act upon the
system.
This package allows to import geometry from most major
CAD systems or to build a solid model of the mechanical
system from scratch. A full library of joints and constraints is
available for creating articulated mechanisms. Once the virtual
prototype is complete, Adams checks the model and then runs
simultaneous equations for kinematics, static, quasi-static, and
dynamic simulations. Results are viewable as graph, data
plots, reports, or colorful animations. This package allows
users to determine the magnitude of the loads acting on the
connecting rod at any position of time with respect to crank
angle rotations, to determine forces acting due to the cylinder
pressure, o determine forces acting along connecting rod at
crank end and piston end and to determine forces
perpendicular to connecting rod.
B. Inputs For ADAMS
The following are the inputs required to perform ADAMS
force calculations.
Piston Diameter (d1) =107.3 mm Stroke Length (L) =
120.6 mm, Crank Radiu(r) = (L/2)=60.3 mm
Length of connecting rod (ℓ)= 223.5 mm
Maximum Explosion Pressure (Pmax)= 120 bar
Engine Speed (N) = 2400 rpm
Mass of Reciprocating Parts (M)
M = {Weight of piston + Weight of Gudgeon pin + Weigh
Piston rings +/3 weight of connecting rod = 2.358 + 1
/3
(2.394) = 3.154Kg
Mass of Connecting Rod: 2.392 kg
Ratio (ℓ/r) :3.70Ultimate strength : 770 N/mm2
Yield strength 570 N/mm2
Hardness: 241 to 285 BHN
Material Specification DIN 17200 41CR 4STEEL
Connecting rod model : In step file, part file formats
Piston & Piston pin model:In step file, part file formats
C. Modeling Process
The step-by-step modeling and analysis procedure of a
connecting rod is described below:
1. Creating a model, setting units and gravity
The assembled 3D model of connecting rod, piston, piston
pin part files are being imported to ADAMS physical model
environment through Step / iges file format.
2. Creating parts and joints
The connecting rod is connected to the piston pin with a
revolute joint; similarly, the either ends of pins are connected
to the piston using a lock joint to prevent the movement in all
directions.
The Big end side of connecting rod is connected to a bar
link with a spline defined revolute joint, i.e., the movement of
connecting rod depends upon the Pressure Vs Crank angle
diagram.
This spline curve is defined by a set of xy axis values.
Other end of the bar link is provided a revolute joint.
3. Running and animating a simulation
The maximum gas load, taken as a point load on the piston
surface at C.G. axis. Now, the force vectors are made visible
(Both the axial force at top and bottom).
Advance Research and Innovations in Mechanical, Material Science, Industrial Engineering and Management - ICARMMIEM-2014 174
ISBN 978-93-82338-97-0 © 2014 Bonfring
Figure 4.1: Pressure Crank angle diagram for the existing
engine showing the peak firing pressure as 120 bars
From the geometry of 3D model & material properties, the
corresponding mass properties are being calculated.
The material properties include:
Piston : Aluminium alloy Piston: 15 Cr Ni 6
Connecting rod: Steel to DIN 17200 41 Cr 4
The masses of reciprocating parts are taken as tensile
inertia force. Thus, the simulation is made to run for few steps.
4. Plotting Results
After the completion of simulation, the corresponding
graphs are obtained from the ADAMS/View
• Maximum Bending force perpendicular to connecting rod
axis.
• Maximum compressive force obtained from peak firing
pressure.
Condition - I
The maximum gas load acts at the small end region,
caused by peak combustion pressures. The corresponding
axial load developed in this region is obtained through this
analysis.
Peak firing pressure = 120 bars
Cylinder bore / Piston diameter = 107.25 mm
Fig. 3: Maximum Compressive Load Condition
Results
The Axial load developed upon the connecting rod with
respect to maximum gas load is95740 N.
Condition - II
The tensile inertia load is caused by mass of reciprocating
parts. Now, the ADAMS software calculates the
corresponding bending force. The maximum force
perpendicular to connecting rod axis in both bending and axial
moments is shown below
Fig. 4: Angular loads caused due to mass of reciprocating
parts
Results: When the force is 8127 N, then the maximum
bending force obtained perpendicular to the connecting rod
axis is 4622 N and the corresponding axial force is 6416 N.
VII. METHODOLOGY
Each FEA consists of two kinds of boundary conditions.
Boundary Condition I - vertical load of 95.74 kN is applied
at small end central node and the Big-end is constrained in all
directions Boundary Condition II - The small end of
connecting rod is fully constrained and a resultant load (Fr) of
8.127kN at an angle 34.660
to vertical (Fy = 6.685kN, Fx =
4.622kN) is applied at Figure 5 (a) & 5 (b) shows two
different kinds of boundary conditions to be applied for
individual connecting rods.
A. Current Design - Connecting Rod with Hole, Boundary
Condition I
Figure 6: Displacement plot with compressive load of 95.74
kN at piston pin end while the crank end was restraine
Observations
Big end fully constrained and a vertical load of 95.74 kN
It can be observed that big end bottom and small end top
almost of zero stress due to rigid
Maximum displacement of 0.1 mm observed for the given
constraint
Maximum stress of 36.5 kgf /mm2
observed near the small
end, may be due to rigid connection given to apply load at
small end, that need to be verified by defining a contact.
Near the web, stress is around 17.8 kgf / mm2
Advance Research and Innovations in Mechanical, Material Science, Industrial Engineering and Management - ICARMMIEM-2014 175
ISBN 978-93-82338-97-0 © 2014 Bonfring
Boundary Condition II
Figure 6 von Mises stress distribution plot with static
tensile load of 8.127kN at an angle 34.660
to vertical (Fy =
6.685kN, Fx = 4.622kN) at the crank end while the pin end
was restrained Figure 6.1: Displacement plot with static tensile
load of 8.127kN at an angle 34.660
to vertical (Fy = 6.685kN,
Fx = 4.622kN) at the crank end while the pin end was
restrained.
Observations
Small end constrained fully and a resultant load of
8.127kN at an angle of 34.660
to vertical (Fy = 6.685kN, Fx =
4.62kN)
It can be observed that big end bottom and small end top
almost of zero stress due to rigidity.
Maximum displacement of 1.1 mm observed for the given
constraint
B. Current Design - Connecting Rod without OILHOLE
Boundary Condition I Maximum stress of 21.9 kgf/mm2
observed near the web and 9 kgf/mm2
observed near the hole
at small en
Figure 7(a) von Mises stress distribution plot with
compressive load of 95.74 kN at Piston pin end while the
crank end was restrained
Figure7 (b): Displacement plots with compressive load of
95.74 kN at piston pin end while the crank end was restrained.
Observations
Big end fully constrained and a vertical load of 95.74 kN.
It can be observed that big end bottom and small end top
almost of zero stress due to rigid
Maximum displacement of 0.1 mm observed for the given
constraint
Maximum stress of 32.3 kgf /mm2
observed near the small
end, may be due to rigid connection given to apply load at
small end, that need to be verified by defining a contact.
Near the oil hole removed region small end stress of 24.5 kgf/
mm2
Near the web, stress is around 16.7 kgf/mm2
Observations
Small end constrained fully and a resultant load of
8.127kN at an angle of 34.660
to vertical (Fy = 6.685kN,
Fx=4.622kN)
It can be observed that big end bottom and small end top
almost of zero stress due to rigidity.
Maximum displacement of 0.1 mm observed for the given
constraint
Near the web, stress is around 21.6 kgf/
Boundary Condition II
Figure7.1: von Mises stress distribution plot with static
tensile load of 8.127kN at an angle 34.660 to vertical (Fy =
6.685kN, Fx = 4.622kN) at the crank end while the pin end
was restrain
Figure 7.2: Displacement plot with static tensile load of
8.127kN at an angle 34.660
to vertical (Fy = 6.685kN, Fx =
4.622kN) at the crank end while the pin end was restrain Yield
stress = 59.6 kg/mm2
Below table describes the comparative chart of change in
the F.O.S values for the existing and optimized connecting
rod.
Optimization of Gudgeon Pin
The gudgeon pin (which connects the piston to the
connecting rod in a conventional internal combustion engine,
ICE) is subjected to a combination of shearing and bending
loads. There will inevitably be some deformation of the
bushes that hold the gudgeon pin in both the piston and the
connecting rod. Considering the maximum loading conditions
several iterations piston pin have been completely optimized.
Based on pin diameters, the existing gudgeon pin (15 cr Ni 6)
yield strength is 165 kg/mm2.
Existing Piston Pin – The existing pin has 1.6” diameter
and the F.O.S values are described below.
Von Mises stress: 116 kg/mm2
F.O.S: 1.422
Figure 8: Existing Gudgeon pin of 1.6” Diameter
Finite Element Analysis of Gudgeon Pin
The objective of FEA was to investigate stress and
displacements experienced by the Gudgeon pin. From the
resulting stress contours, the state of stress, as well as stress
concentration factors can be obtained and consequently used
for life predictions. Piston pin is subjected to three different
Advance Research and Innovations in Mechanical, Material Science, Industrial Engineering and Management - ICARMMIEM-2014 176
ISBN 978-93-82338-97-0 © 2014 Bonfring
kinds of loadings considering the static analysis (Axial load,
Angular Load and Experimental Load).Similarly the resultant
load of 669 kgf is applied and at last the experimental value of
962 kgf is applied.
The 3-D geometry was created using I-DEAS 9.0. The pin
surface is splitted into three surfaces. Two surfaces for load
application and the other to constraint the pin in opposite
direction. Three different loading conditions were analyzed in
this analysis. Maximum gas pressure load of 9574 kgf
1) Vertical load 669 kgf from ADAMS inputs
2) Experimental Load of 966 kgf
Existing Gudgeon Pin
The existing pin has been analyzed with three different
loading conditions. Maximum gas pressure load of 9574 kgf
for piston pin of 1.6”Diameter
Table 1: Existing vs Optimized Gudgeon pin comparison
Loading Connecting
rod
Stress
(kg/mm2
)
Deflection
(mm)
FOS
(With
respect to
Yield
Stress)
Case1:
Downwa
rd load
of 95.74
kN
Existing
With oil
hole
36.5 near
oil hole 0.1
1.63 near
oil hole
Without
hole
32.3 near
Small end
16.7 near
web
0.1
1.85 near
small end
3.57 near
web
Case 2:
vertical
load
8.127kN
@ an
angle of
34.660
Existing
With oil
hole
21.9
1.1 2.72
Without
hole
21.6
1.0 2.76
Fig. 9: Change in the F.O.S values of Existing vs Optimized
Gudgeon pin diameters
Thus, we have selected 1.3” diameter as the best choice for
the gudgeon pin. The corresponding small end region in the
Connecting rod optimization is carried out.
Fig 10: Shows the Existing Gudgeon pin with Outer
Diameter of 41.27mm .Shows the Modified Gudgeon pin with
Outer Diameter o
Comparison of Results
Several iterations on the Connecting rod has been
conducted and their corresponding failure index values have
been calculated and shown in the below graph, i.e. various
Connecting rod vs change in the F.O.S values. From the graph
it is seen evidently a steep fall in the value of F.O.S from
various I sections. Yield strength: 59.6 kg/mm2
Table 2: Shows existing and optimized Connecting rod
comparison
Loading Gudgeon
pin
Stress
(kg/mm2
)
Deflection
(mm)
FOS
(with
respect
to
Yield
Stress)
Case1:
Downward
load of 95.74
kN
Existing 116 0.09 1.422
Optimized 125 0.14 1.32
Case 2:
vertical load
8.127 kN
Existing 7.8 0.01 21.15
Optimized 8.2 0.01 20.12
Case 3:
Experimental
Load of 966
kgf
Existing 11.6 0.01 14.22
Optimized 12.5 0.01 13.2
Connecting rod F.O.S Vs Different I-Sections
1.4
1.45
1.5
1.55
1.6
1.65
0 1 2 3 4 5
I-Sections
Connecting
rod
F.O.S
Change in F.O.S
values
Advance Research and Innovations in Mechanical, Material Science, Industrial Engineering and Management - ICARMMIEM-2014 177
ISBN 978-93-82338-97-0 © 2014 Bonfring
Fig. 11: The geometry of the optimized connecting rod.
Figure 12: Drawing of the Existing Connecting rod
showing all major dimensions
Figure 13: Drawing of the Optimized Connecting rod showing
all major dimensions
Component Development
After the analysis of both Connecting rod and Gudgeon pin
a prototype component was developed. For the component
development activities, the Optimized Connecting rod
sketches have been sent to M/s Shard low Industries Ltd. Later
the forging drawing has been studied and minimal
modifications have been made in the forging die design. With
combined efforts from Ashok Leyland and Shard low
Industries Optimized Connecting rod has been produced
successfully.
Samples of ten sets of component have been procured for
testing purposes.
Figure 14: Existing & Figure 15: Existing & Optimized
Optimized Connecting rods Optimized Gudgeon pins 1.6d
After the procurement of sample components, the
connecting rod I – Sections was studied.
After the procurement of sample components, the
connecting rod I – Sections was studied.
Figure 16: Existing & Optimized Connecting rod I-sections,
Connecting rod I-sections similarly the small ends of the
Connecting rod were examined and Connecting rod small end
diameter
Economic Cost Factor
Cost of 1.6” Gudgeon pin = Rs.71.54/-
Cost of 1.3” Gudgeon pin = Rs.47.68/-
Forging cost of Existing Connecting rod = Rs.289.26/-
Forging cost of Optimized Connecting rod = Rs.250.07/-
Cost saving in Gudgeon pin= Rs.23.86/-
Cost saving in Connecting rod = Rs.39.19/-
Total Cost savings=Rs.63.05x6cylinders=Rs.378.3 per
Engine
Considering Annual sales of 8000 Engines Total cost
savings = Rs.30, 26,400
Optimization Potential
Table 3: Shows the Optimization Potential of the Connecting
Rod Assembly
VIII. RESULTS
Weight reduction in the connecting rod contributes
=0.303kg
Weight reduction in the Gudgeon pin contributes = 0.246 k
BIBLIOGRAPHY
[1] IC engines by V ganesan
[2] Webster, W. D., Coffell R., and Alfaro D., “A Three Dimensional Finite
Element Analysis of a High Speed Diesel Engine Connecting Rod,”
SAE Technical Paper Series, Paper No. 831322, 1983.
[3] Norton, R. L., “Machine Design - An Integrated Approach, ”Prentice-
Hall, 1996.
[4] Sonsino, C. M. and Esper, F. J., “Fatigue Design for PM Components,”
European Powder Metallurgy Association (EPMA), 1994.
[5] Makino, T. and Koga, T., “Crank Bearing Design Based on 3-D Elasto
hydrodynamic Lubrication Theory,” Mitsubishi Heavy Industries, Ltd.,
Technical Review, Vol. 39, No. 1, 2002.
[6] Clark, J. P., Field III, F.R., and Nallicheri, N.V.,“Engine state-of-the-art:
A competitive assessment of steel, cost estimates and performance
analysis, “Research Report BR 89-1, Automotive Applications
Committee, American Iron and Steel Institute, 1989.
[7] Serag, S., Sevien, L., Sheha, G., and El-Beshtawi, I., “Optimal design of
the connecting-rod”, Modelling, Simulation and Control, B, AMSE
Press, Vol. 24, No.3, 1989, pp. 49-63.
[8] Auto mobile engineering by kirpal singh. Iste & Asme journals
Advance Research and Innovations in Mechanical, Material Science, Industrial Engineering and Management - ICARMMIEM-2014 178
ISBN 978-93-82338-97-0 © 2014 Bonfring
Shaik Himam Saheb, Assistant Profess, B.Tech,
M.Tech, Singareni Collieries Polytechnic Singareni
Collieries Polytechnic, Adilabad District,
Mancherial-504302. E-mail: himam.mech@gmail.com
P. Sampath Kumar, Assistant Profess, B.Tech,
M.Tech, Singareni Collieries Polytechnic Singareni
Collieries Polytechnic, Adilabad District, Mancherial-
504302. E-mail: sampath.pendekatla@gmail.com
A. Ramesh, Assistant Profess, B.Tech, M.Tech,
Christhu Jyothi Institute of Technology and Science
(CJITS), Jangaon, Warangal, AP, India. E-mail:
ramesh340mech@gmail.com
Advance Research and Innovations in Mechanical, Material Science, Industrial Engineering and Management - ICARMMIEM-2014 179
ISBN 978-93-82338-97-0 © 2014 Bonfring
View publication stats
View publication stats

More Related Content

Similar to 35.pdf

Design and Analysis of Crankshaft for Internal Combustion Engine
Design and Analysis of Crankshaft for Internal Combustion EngineDesign and Analysis of Crankshaft for Internal Combustion Engine
Design and Analysis of Crankshaft for Internal Combustion Engineijtsrd
 
Review on Design and Analysis of Two Wheeler Connecting Rod
Review on Design and Analysis of Two Wheeler Connecting RodReview on Design and Analysis of Two Wheeler Connecting Rod
Review on Design and Analysis of Two Wheeler Connecting RodIRJET Journal
 
Design and Analysis to Improve Buckling Strength of Light Vehicle Connecting Rod
Design and Analysis to Improve Buckling Strength of Light Vehicle Connecting RodDesign and Analysis to Improve Buckling Strength of Light Vehicle Connecting Rod
Design and Analysis to Improve Buckling Strength of Light Vehicle Connecting RodIRJET Journal
 
Stress analysis and optimization of crankshaft under dynamic loading 2
Stress analysis and optimization of crankshaft under dynamic loading 2Stress analysis and optimization of crankshaft under dynamic loading 2
Stress analysis and optimization of crankshaft under dynamic loading 2IAEME Publication
 
design and analysis of HCCI Engine.pptx
design and analysis of HCCI Engine.pptxdesign and analysis of HCCI Engine.pptx
design and analysis of HCCI Engine.pptxsumithra48
 
IRJET - Optimization of Crankshaft by Modification in Design and Material
IRJET - Optimization of Crankshaft by Modification in Design and MaterialIRJET - Optimization of Crankshaft by Modification in Design and Material
IRJET - Optimization of Crankshaft by Modification in Design and MaterialIRJET Journal
 
INVESTIGATE THE EFFECT OF PHOSPHATE SURFACE COATING ON THE FATIGUE PERFORMA...
  INVESTIGATE THE EFFECT OF PHOSPHATE SURFACE COATING ON THE FATIGUE PERFORMA...  INVESTIGATE THE EFFECT OF PHOSPHATE SURFACE COATING ON THE FATIGUE PERFORMA...
INVESTIGATE THE EFFECT OF PHOSPHATE SURFACE COATING ON THE FATIGUE PERFORMA...IAEME Publication
 
Theoretical Analysis of Stress and Design of Piston Head using CATIA & ANSYS
	Theoretical Analysis of Stress and Design of Piston Head using CATIA & ANSYS	Theoretical Analysis of Stress and Design of Piston Head using CATIA & ANSYS
Theoretical Analysis of Stress and Design of Piston Head using CATIA & ANSYSinventionjournals
 
International Journal of Computational Engineering Research(IJCER)
International Journal of Computational Engineering Research(IJCER)International Journal of Computational Engineering Research(IJCER)
International Journal of Computational Engineering Research(IJCER)ijceronline
 
Static Analysis and Mass Optimization of Automotive Valve Spring
Static Analysis and Mass Optimization of Automotive Valve SpringStatic Analysis and Mass Optimization of Automotive Valve Spring
Static Analysis and Mass Optimization of Automotive Valve SpringIRJET Journal
 
Thermal and Structural Analysis Using Fea on Pillar Vains Type Ventilated Dis...
Thermal and Structural Analysis Using Fea on Pillar Vains Type Ventilated Dis...Thermal and Structural Analysis Using Fea on Pillar Vains Type Ventilated Dis...
Thermal and Structural Analysis Using Fea on Pillar Vains Type Ventilated Dis...IJSRD
 
Design Evaluation and Optimization of IC Engine Connecting Rods '“ A Review
Design Evaluation and Optimization of IC Engine Connecting Rods '“ A ReviewDesign Evaluation and Optimization of IC Engine Connecting Rods '“ A Review
Design Evaluation and Optimization of IC Engine Connecting Rods '“ A Reviewijtsrd
 
IRJET- Analysis of Automobile Rim on Strain Criteria
IRJET- Analysis of Automobile Rim on Strain CriteriaIRJET- Analysis of Automobile Rim on Strain Criteria
IRJET- Analysis of Automobile Rim on Strain CriteriaIRJET Journal
 
Failure of Piston in IC Engines: A Review
Failure of Piston in IC Engines: A ReviewFailure of Piston in IC Engines: A Review
Failure of Piston in IC Engines: A ReviewIJMER
 
Contact Pressure Analysis of Steam Turbine Casing
Contact Pressure Analysis of Steam Turbine CasingContact Pressure Analysis of Steam Turbine Casing
Contact Pressure Analysis of Steam Turbine CasingIRJET Journal
 
Stress Analysis of I.C.Engine Connecting Rod by FEM and Photoelasticity
Stress Analysis of I.C.Engine Connecting Rod by FEM and PhotoelasticityStress Analysis of I.C.Engine Connecting Rod by FEM and Photoelasticity
Stress Analysis of I.C.Engine Connecting Rod by FEM and PhotoelasticityIOSR Journals
 
Contact Pressure Validation of Steam Turbine Casing for Static Loading Condition
Contact Pressure Validation of Steam Turbine Casing for Static Loading ConditionContact Pressure Validation of Steam Turbine Casing for Static Loading Condition
Contact Pressure Validation of Steam Turbine Casing for Static Loading ConditionIJMER
 
Connecting_Rod_Report_Kramer_Suls_Moon (1)
Connecting_Rod_Report_Kramer_Suls_Moon (1)Connecting_Rod_Report_Kramer_Suls_Moon (1)
Connecting_Rod_Report_Kramer_Suls_Moon (1)Jordan Suls
 

Similar to 35.pdf (20)

Design and Analysis of Crankshaft for Internal Combustion Engine
Design and Analysis of Crankshaft for Internal Combustion EngineDesign and Analysis of Crankshaft for Internal Combustion Engine
Design and Analysis of Crankshaft for Internal Combustion Engine
 
Review on Design and Analysis of Two Wheeler Connecting Rod
Review on Design and Analysis of Two Wheeler Connecting RodReview on Design and Analysis of Two Wheeler Connecting Rod
Review on Design and Analysis of Two Wheeler Connecting Rod
 
Design and Analysis to Improve Buckling Strength of Light Vehicle Connecting Rod
Design and Analysis to Improve Buckling Strength of Light Vehicle Connecting RodDesign and Analysis to Improve Buckling Strength of Light Vehicle Connecting Rod
Design and Analysis to Improve Buckling Strength of Light Vehicle Connecting Rod
 
Stress analysis and optimization of crankshaft under dynamic loading 2
Stress analysis and optimization of crankshaft under dynamic loading 2Stress analysis and optimization of crankshaft under dynamic loading 2
Stress analysis and optimization of crankshaft under dynamic loading 2
 
design and analysis of HCCI Engine.pptx
design and analysis of HCCI Engine.pptxdesign and analysis of HCCI Engine.pptx
design and analysis of HCCI Engine.pptx
 
IRJET - Optimization of Crankshaft by Modification in Design and Material
IRJET - Optimization of Crankshaft by Modification in Design and MaterialIRJET - Optimization of Crankshaft by Modification in Design and Material
IRJET - Optimization of Crankshaft by Modification in Design and Material
 
INVESTIGATE THE EFFECT OF PHOSPHATE SURFACE COATING ON THE FATIGUE PERFORMA...
  INVESTIGATE THE EFFECT OF PHOSPHATE SURFACE COATING ON THE FATIGUE PERFORMA...  INVESTIGATE THE EFFECT OF PHOSPHATE SURFACE COATING ON THE FATIGUE PERFORMA...
INVESTIGATE THE EFFECT OF PHOSPHATE SURFACE COATING ON THE FATIGUE PERFORMA...
 
32-IJRERD-B412.pdf
32-IJRERD-B412.pdf32-IJRERD-B412.pdf
32-IJRERD-B412.pdf
 
Theoretical Analysis of Stress and Design of Piston Head using CATIA & ANSYS
	Theoretical Analysis of Stress and Design of Piston Head using CATIA & ANSYS	Theoretical Analysis of Stress and Design of Piston Head using CATIA & ANSYS
Theoretical Analysis of Stress and Design of Piston Head using CATIA & ANSYS
 
A044020105
A044020105A044020105
A044020105
 
International Journal of Computational Engineering Research(IJCER)
International Journal of Computational Engineering Research(IJCER)International Journal of Computational Engineering Research(IJCER)
International Journal of Computational Engineering Research(IJCER)
 
Static Analysis and Mass Optimization of Automotive Valve Spring
Static Analysis and Mass Optimization of Automotive Valve SpringStatic Analysis and Mass Optimization of Automotive Valve Spring
Static Analysis and Mass Optimization of Automotive Valve Spring
 
Thermal and Structural Analysis Using Fea on Pillar Vains Type Ventilated Dis...
Thermal and Structural Analysis Using Fea on Pillar Vains Type Ventilated Dis...Thermal and Structural Analysis Using Fea on Pillar Vains Type Ventilated Dis...
Thermal and Structural Analysis Using Fea on Pillar Vains Type Ventilated Dis...
 
Design Evaluation and Optimization of IC Engine Connecting Rods '“ A Review
Design Evaluation and Optimization of IC Engine Connecting Rods '“ A ReviewDesign Evaluation and Optimization of IC Engine Connecting Rods '“ A Review
Design Evaluation and Optimization of IC Engine Connecting Rods '“ A Review
 
IRJET- Analysis of Automobile Rim on Strain Criteria
IRJET- Analysis of Automobile Rim on Strain CriteriaIRJET- Analysis of Automobile Rim on Strain Criteria
IRJET- Analysis of Automobile Rim on Strain Criteria
 
Failure of Piston in IC Engines: A Review
Failure of Piston in IC Engines: A ReviewFailure of Piston in IC Engines: A Review
Failure of Piston in IC Engines: A Review
 
Contact Pressure Analysis of Steam Turbine Casing
Contact Pressure Analysis of Steam Turbine CasingContact Pressure Analysis of Steam Turbine Casing
Contact Pressure Analysis of Steam Turbine Casing
 
Stress Analysis of I.C.Engine Connecting Rod by FEM and Photoelasticity
Stress Analysis of I.C.Engine Connecting Rod by FEM and PhotoelasticityStress Analysis of I.C.Engine Connecting Rod by FEM and Photoelasticity
Stress Analysis of I.C.Engine Connecting Rod by FEM and Photoelasticity
 
Contact Pressure Validation of Steam Turbine Casing for Static Loading Condition
Contact Pressure Validation of Steam Turbine Casing for Static Loading ConditionContact Pressure Validation of Steam Turbine Casing for Static Loading Condition
Contact Pressure Validation of Steam Turbine Casing for Static Loading Condition
 
Connecting_Rod_Report_Kramer_Suls_Moon (1)
Connecting_Rod_Report_Kramer_Suls_Moon (1)Connecting_Rod_Report_Kramer_Suls_Moon (1)
Connecting_Rod_Report_Kramer_Suls_Moon (1)
 

Recently uploaded

FULL NIGHT — 9999894380 Call Girls In Delhi | Delhi
FULL NIGHT — 9999894380 Call Girls In Delhi | DelhiFULL NIGHT — 9999894380 Call Girls In Delhi | Delhi
FULL NIGHT — 9999894380 Call Girls In Delhi | DelhiSaketCallGirlsCallUs
 
FULL NIGHT — 9999894380 Call Girls In Ashok Vihar | Delhi
FULL NIGHT — 9999894380 Call Girls In Ashok Vihar | DelhiFULL NIGHT — 9999894380 Call Girls In Ashok Vihar | Delhi
FULL NIGHT — 9999894380 Call Girls In Ashok Vihar | DelhiSaketCallGirlsCallUs
 
Bobbie goods coloring book 81 pag_240127_163802.pdf
Bobbie goods coloring book 81 pag_240127_163802.pdfBobbie goods coloring book 81 pag_240127_163802.pdf
Bobbie goods coloring book 81 pag_240127_163802.pdfMARIBEL442158
 
Storyboard short: Ferrarius Tries to Sing
Storyboard short: Ferrarius Tries to SingStoryboard short: Ferrarius Tries to Sing
Storyboard short: Ferrarius Tries to SingLyneSun
 
FULL NIGHT — 9999894380 Call Girls In Dwarka Mor | Delhi
FULL NIGHT — 9999894380 Call Girls In Dwarka Mor | DelhiFULL NIGHT — 9999894380 Call Girls In Dwarka Mor | Delhi
FULL NIGHT — 9999894380 Call Girls In Dwarka Mor | DelhiSaketCallGirlsCallUs
 
Mayiladuthurai Call Girls 8617697112 Short 3000 Night 8000 Best call girls Se...
Mayiladuthurai Call Girls 8617697112 Short 3000 Night 8000 Best call girls Se...Mayiladuthurai Call Girls 8617697112 Short 3000 Night 8000 Best call girls Se...
Mayiladuthurai Call Girls 8617697112 Short 3000 Night 8000 Best call girls Se...Nitya salvi
 
Sirmaur Call Girls Book Now 8617697112 Top Class Pondicherry Escort Service A...
Sirmaur Call Girls Book Now 8617697112 Top Class Pondicherry Escort Service A...Sirmaur Call Girls Book Now 8617697112 Top Class Pondicherry Escort Service A...
Sirmaur Call Girls Book Now 8617697112 Top Class Pondicherry Escort Service A...Nitya salvi
 
Jeremy Casson - Top Tips for Pottery Wheel Throwing
Jeremy Casson - Top Tips for Pottery Wheel ThrowingJeremy Casson - Top Tips for Pottery Wheel Throwing
Jeremy Casson - Top Tips for Pottery Wheel ThrowingJeremy Casson
 
VIP Ramnagar Call Girls, Ramnagar escorts Girls 📞 8617697112
VIP Ramnagar Call Girls, Ramnagar escorts Girls 📞 8617697112VIP Ramnagar Call Girls, Ramnagar escorts Girls 📞 8617697112
VIP Ramnagar Call Girls, Ramnagar escorts Girls 📞 8617697112Nitya salvi
 
Moradabad Call Girls - 📞 8617697112 🔝 Top Class Call Girls Service Available
Moradabad Call Girls - 📞 8617697112 🔝 Top Class Call Girls Service AvailableMoradabad Call Girls - 📞 8617697112 🔝 Top Class Call Girls Service Available
Moradabad Call Girls - 📞 8617697112 🔝 Top Class Call Girls Service AvailableNitya salvi
 
GENUINE EscoRtS,Call Girls IN South Delhi Locanto TM''| +91-8377087607
GENUINE EscoRtS,Call Girls IN South Delhi Locanto TM''| +91-8377087607GENUINE EscoRtS,Call Girls IN South Delhi Locanto TM''| +91-8377087607
GENUINE EscoRtS,Call Girls IN South Delhi Locanto TM''| +91-8377087607dollysharma2066
 
Call Girls Ludhiana Just Call 98765-12871 Top Class Call Girl Service Available
Call Girls Ludhiana Just Call 98765-12871 Top Class Call Girl Service AvailableCall Girls Ludhiana Just Call 98765-12871 Top Class Call Girl Service Available
Call Girls Ludhiana Just Call 98765-12871 Top Class Call Girl Service AvailableSeo
 
FULL NIGHT — 9999894380 Call Girls In Shivaji Enclave | Delhi
FULL NIGHT — 9999894380 Call Girls In Shivaji Enclave | DelhiFULL NIGHT — 9999894380 Call Girls In Shivaji Enclave | Delhi
FULL NIGHT — 9999894380 Call Girls In Shivaji Enclave | DelhiSaketCallGirlsCallUs
 
Admirable # 00971529501107 # Call Girls at dubai by Dubai Call Girl
Admirable # 00971529501107 # Call Girls at dubai by Dubai Call GirlAdmirable # 00971529501107 # Call Girls at dubai by Dubai Call Girl
Admirable # 00971529501107 # Call Girls at dubai by Dubai Call Girlhome
 
FULL NIGHT — 9999894380 Call Girls In Mahipalpur | Delhi
FULL NIGHT — 9999894380 Call Girls In Mahipalpur | DelhiFULL NIGHT — 9999894380 Call Girls In Mahipalpur | Delhi
FULL NIGHT — 9999894380 Call Girls In Mahipalpur | DelhiSaketCallGirlsCallUs
 
❤️Call girls in Chandigarh ☎️8264406502☎️ Call Girl service in Chandigarh☎️ C...
❤️Call girls in Chandigarh ☎️8264406502☎️ Call Girl service in Chandigarh☎️ C...❤️Call girls in Chandigarh ☎️8264406502☎️ Call Girl service in Chandigarh☎️ C...
❤️Call girls in Chandigarh ☎️8264406502☎️ Call Girl service in Chandigarh☎️ C...Sheetaleventcompany
 
FULL NIGHT — 9999894380 Call Girls In Najafgarh | Delhi
FULL NIGHT — 9999894380 Call Girls In Najafgarh | DelhiFULL NIGHT — 9999894380 Call Girls In Najafgarh | Delhi
FULL NIGHT — 9999894380 Call Girls In Najafgarh | DelhiSaketCallGirlsCallUs
 
Young⚡Call Girls in Uttam Nagar Delhi >༒9667401043 Escort Service
Young⚡Call Girls in Uttam Nagar Delhi >༒9667401043 Escort ServiceYoung⚡Call Girls in Uttam Nagar Delhi >༒9667401043 Escort Service
Young⚡Call Girls in Uttam Nagar Delhi >༒9667401043 Escort Servicesonnydelhi1992
 

Recently uploaded (20)

FULL NIGHT — 9999894380 Call Girls In Delhi | Delhi
FULL NIGHT — 9999894380 Call Girls In Delhi | DelhiFULL NIGHT — 9999894380 Call Girls In Delhi | Delhi
FULL NIGHT — 9999894380 Call Girls In Delhi | Delhi
 
Dubai Call Girl Number # 0522916705 # Call Girl Number In Dubai # (UAE)
Dubai Call Girl Number # 0522916705 # Call Girl Number In Dubai # (UAE)Dubai Call Girl Number # 0522916705 # Call Girl Number In Dubai # (UAE)
Dubai Call Girl Number # 0522916705 # Call Girl Number In Dubai # (UAE)
 
FULL NIGHT — 9999894380 Call Girls In Ashok Vihar | Delhi
FULL NIGHT — 9999894380 Call Girls In Ashok Vihar | DelhiFULL NIGHT — 9999894380 Call Girls In Ashok Vihar | Delhi
FULL NIGHT — 9999894380 Call Girls In Ashok Vihar | Delhi
 
Bobbie goods coloring book 81 pag_240127_163802.pdf
Bobbie goods coloring book 81 pag_240127_163802.pdfBobbie goods coloring book 81 pag_240127_163802.pdf
Bobbie goods coloring book 81 pag_240127_163802.pdf
 
Storyboard short: Ferrarius Tries to Sing
Storyboard short: Ferrarius Tries to SingStoryboard short: Ferrarius Tries to Sing
Storyboard short: Ferrarius Tries to Sing
 
FULL NIGHT — 9999894380 Call Girls In Dwarka Mor | Delhi
FULL NIGHT — 9999894380 Call Girls In Dwarka Mor | DelhiFULL NIGHT — 9999894380 Call Girls In Dwarka Mor | Delhi
FULL NIGHT — 9999894380 Call Girls In Dwarka Mor | Delhi
 
Mayiladuthurai Call Girls 8617697112 Short 3000 Night 8000 Best call girls Se...
Mayiladuthurai Call Girls 8617697112 Short 3000 Night 8000 Best call girls Se...Mayiladuthurai Call Girls 8617697112 Short 3000 Night 8000 Best call girls Se...
Mayiladuthurai Call Girls 8617697112 Short 3000 Night 8000 Best call girls Se...
 
Sirmaur Call Girls Book Now 8617697112 Top Class Pondicherry Escort Service A...
Sirmaur Call Girls Book Now 8617697112 Top Class Pondicherry Escort Service A...Sirmaur Call Girls Book Now 8617697112 Top Class Pondicherry Escort Service A...
Sirmaur Call Girls Book Now 8617697112 Top Class Pondicherry Escort Service A...
 
Dubai Call Girl Number # 00971588312479 # Call Girl Number In Dubai # (UAE)
Dubai Call Girl Number # 00971588312479 # Call Girl Number In Dubai # (UAE)Dubai Call Girl Number # 00971588312479 # Call Girl Number In Dubai # (UAE)
Dubai Call Girl Number # 00971588312479 # Call Girl Number In Dubai # (UAE)
 
Jeremy Casson - Top Tips for Pottery Wheel Throwing
Jeremy Casson - Top Tips for Pottery Wheel ThrowingJeremy Casson - Top Tips for Pottery Wheel Throwing
Jeremy Casson - Top Tips for Pottery Wheel Throwing
 
VIP Ramnagar Call Girls, Ramnagar escorts Girls 📞 8617697112
VIP Ramnagar Call Girls, Ramnagar escorts Girls 📞 8617697112VIP Ramnagar Call Girls, Ramnagar escorts Girls 📞 8617697112
VIP Ramnagar Call Girls, Ramnagar escorts Girls 📞 8617697112
 
Moradabad Call Girls - 📞 8617697112 🔝 Top Class Call Girls Service Available
Moradabad Call Girls - 📞 8617697112 🔝 Top Class Call Girls Service AvailableMoradabad Call Girls - 📞 8617697112 🔝 Top Class Call Girls Service Available
Moradabad Call Girls - 📞 8617697112 🔝 Top Class Call Girls Service Available
 
GENUINE EscoRtS,Call Girls IN South Delhi Locanto TM''| +91-8377087607
GENUINE EscoRtS,Call Girls IN South Delhi Locanto TM''| +91-8377087607GENUINE EscoRtS,Call Girls IN South Delhi Locanto TM''| +91-8377087607
GENUINE EscoRtS,Call Girls IN South Delhi Locanto TM''| +91-8377087607
 
Call Girls Ludhiana Just Call 98765-12871 Top Class Call Girl Service Available
Call Girls Ludhiana Just Call 98765-12871 Top Class Call Girl Service AvailableCall Girls Ludhiana Just Call 98765-12871 Top Class Call Girl Service Available
Call Girls Ludhiana Just Call 98765-12871 Top Class Call Girl Service Available
 
FULL NIGHT — 9999894380 Call Girls In Shivaji Enclave | Delhi
FULL NIGHT — 9999894380 Call Girls In Shivaji Enclave | DelhiFULL NIGHT — 9999894380 Call Girls In Shivaji Enclave | Delhi
FULL NIGHT — 9999894380 Call Girls In Shivaji Enclave | Delhi
 
Admirable # 00971529501107 # Call Girls at dubai by Dubai Call Girl
Admirable # 00971529501107 # Call Girls at dubai by Dubai Call GirlAdmirable # 00971529501107 # Call Girls at dubai by Dubai Call Girl
Admirable # 00971529501107 # Call Girls at dubai by Dubai Call Girl
 
FULL NIGHT — 9999894380 Call Girls In Mahipalpur | Delhi
FULL NIGHT — 9999894380 Call Girls In Mahipalpur | DelhiFULL NIGHT — 9999894380 Call Girls In Mahipalpur | Delhi
FULL NIGHT — 9999894380 Call Girls In Mahipalpur | Delhi
 
❤️Call girls in Chandigarh ☎️8264406502☎️ Call Girl service in Chandigarh☎️ C...
❤️Call girls in Chandigarh ☎️8264406502☎️ Call Girl service in Chandigarh☎️ C...❤️Call girls in Chandigarh ☎️8264406502☎️ Call Girl service in Chandigarh☎️ C...
❤️Call girls in Chandigarh ☎️8264406502☎️ Call Girl service in Chandigarh☎️ C...
 
FULL NIGHT — 9999894380 Call Girls In Najafgarh | Delhi
FULL NIGHT — 9999894380 Call Girls In Najafgarh | DelhiFULL NIGHT — 9999894380 Call Girls In Najafgarh | Delhi
FULL NIGHT — 9999894380 Call Girls In Najafgarh | Delhi
 
Young⚡Call Girls in Uttam Nagar Delhi >༒9667401043 Escort Service
Young⚡Call Girls in Uttam Nagar Delhi >༒9667401043 Escort ServiceYoung⚡Call Girls in Uttam Nagar Delhi >༒9667401043 Escort Service
Young⚡Call Girls in Uttam Nagar Delhi >༒9667401043 Escort Service
 

35.pdf

  • 1. See discussions, stats, and author profiles for this publication at: https://www.researchgate.net/publication/297827838 Design and Analysis of a Connecting Rod for the 117kw Six Cylinders Turbocharged Diesel Engine Article · March 2011 CITATIONS 0 READS 5,561 2 authors, including: Some of the authors of this publication are also working on these related projects: Transient Thermal Analysis of the Turbine Blade Transient Thermal Analysis of the Turbine Blade View project Himam Saheb Shaik IFHE 35 PUBLICATIONS   19 CITATIONS    SEE PROFILE All content following this page was uploaded by Himam Saheb Shaik on 12 March 2016. The user has requested enhancement of the downloaded file.
  • 2. Abstract--- The main objective of this work was to explore weight reduction opportunities for forged steel connecting rod in Ashok Leyland Bharat Stage-II engines. This has entailed performing a detailed load analysis. An optimization study was performed on a steel forged connecting rod with a consideration for improvement in weight and production cost. The introduction of piston cooling nozzles in AL engines provides scope for eliminating the oil hole in the connecting rod and thereby reducing the size 'of the 'I' section. Furthermore, the existing connecting rod can be replaced with a new connecting rod with modified I-section. Literature survey suggests cyclic loads comprised of static tensile and compressive loads are often used for design and optimization of connecting rods. However, in this study weight optimization is performed under a cyclic load comprising dynamic tensile load and static compressive load as the two extreme loads. Therefore, this work has further dealt with two subjects, first, the connecting rod modeling, force calculations and the second is the finite element analysis and also deals with Optimization of Gudgeon pin. Keywords--- Finite Element Analysis Connecting Rod by using Different Design Software’s like Pro-e, Ansys Software’s I. INTRODUCTION HE engines connecting rods are a high volume production, and usually manufactured by drop forging process. The material mostly used for connecting rods varies from mild carbon steels (0.35 to 0.45 % carbons) to alloy steels (Chrome Nickel to Chrome molybdenum steels). The functions of connecting rod includes, providing a connecting link between Piston and Crankshaft to convert the reciprocating motion to rotary motion and conveying lubricating oil from Crankshaft (big end) to Piston pin (small end) through its central oil hole. Connecting rods are generally subjected to two types of inertia forces, one due to masses and friction induced by the reciprocating parts and other, due to the gas load generated from combustion process. The small end of the connecting rod is provided with a bush of phosphor bronze and connected to Shaik Himam Saheb, Assistant Profess, B.Tech, M.Tech, Singareni Collieries Polytechnic Singareni Collieries Polytechnic, Adilabad District, Mancherial-504302. E-mail: himam.mech@gmail.com P. Sampath Kumar, Assistant Profess, B.Tech, M.Tech, Singareni Collieries Polytechnic Singareni Collieries Polytechnic, Adilabad District, Mancherial-504302. E-mail: sampath.pendekatla@gmail.com A. Ramesh, Assistant Profess, B.Tech, M.Tech, Christhu Jyothi Institute of Technology and Science (CJITS), Jangaon, Warangal, AP, India. E-mail: ramesh340mech@gmail.com gudgeon pin. The big end of the connecting rod is usually made split into two halves. The split cap is fastened to the big end with two cap bolts. The bearing shells are made up of steel, brass or bronze with a thin lining about 0.75 mm of white metal or Babbitt metal. In this subject, 412 Turbo- Charged air cooled engine’s power intensity ratio is 0.24, thus piston cooling is necessary .This is achieved by piston-cooling nozzles (cooling of piston through a separate jet from oil gallery to Dissipate combustion heat and to control the piston ring sticking). The optimization carried out here, however, is not in the true mathematical sense, since while reducing mass, manufacturing feasibility and cost reduction are integral parts of the optimization. In Addition, software used in this work imposed restrictions in performing optimization under fatigue life constraint. II. THESIS STRUCTURE The thesis comprises eleven parts. The first part is a review of the literature on Connecting rod optimization .This survey is focused on the Work carried out on both forged steel and powder metallurgy Connecting rod. The second part provides a detailed load analysis and force calculations of a forged steel connecting rod. The fourth part provides force calculations of a forged steel connecting rod .The fifth part explains the Finite Element Analysis of the Connecting rod Sixth and seventh part describes the optimization procedure for gudgeon pin and connecting rod. The sample component development, conclusions drawn from this project and a list of recommendations for further work are presented in later Chapters. III. OBJECTIVES AND OUTLINE A. Literature Survey The connecting rod is subjected to a complex state of loading. It undergoes high cyclic loads of the order of 108 to 109 cycles, which range from high compressive loads due to combustion, to high tensile loads due to inertia. Therefore, durability of this component is of critical importance. Due to these factors, the connecting rod has been the topic of research for different aspects such as production technology, materials, performance simulation, fatigue, etc. [1] Adila Afzal and Fatemi conducted a comparative study for the Fatigue properties and life predictions of forged steel and PM connecting rods. Both the materials are obtained from specimen testing and then used in life predictions using the S- N approach. Design and Analysis of a Connecting Rod for the 117kw Six Cylinders Turbocharged Diesel Engine Shaik Himam Saheb, P. Sampath Kumar and A. Ramesh T Advance Research and Innovations in Mechanical, Material Science, Industrial Engineering and Management - ICARMMIEM-2014 172 ISBN 978-93-82338-97-0 © 2014 Bonfring
  • 3. The stress concentration factors were obtained from FEA, and the modified Goodman equation was used to account for the mean stress effect. Fractography of the connecting fracture surfaces was also conducted to investigate the failure mechanisms. Monotonic and cyclic deformation behaviors, as well as strain-controlled fatigue properties of the two materials were evaluated and compared. Fig 1: The Fatigue failure locations on (a) Forged steel and (b) PM connecting rods(Courtesy: Adila Afzal and Fatemi [1])The objective of this work was to optimize the weight and cost of a forged steel connecting rod, to a safe level of factor of safety in Ashok Leyland Bharat Stage II engines. This weight reduction project is being taken up, since; the introduction of piston cooling nozzle which not only cools the overheating piston but also lubricates the piston pin. Thereby, it provides a scope for eliminating the central oil hole, and reducing the ‘I’ section size. Optimization begins with identifying the correct load conditions and magnitudes. The idea behind optimizing is to retain just as much strength is needed. Commercial software’s such as ProEngineer, ADAMS-View, and I-DEAS Analysis can be used to obtain the Variation of quantities such as angular velocity, angular acceleration, and load. However, usually the worst case load is considered in the design process. Literature review suggests that investigators use maximum inertia load, inertia load, or inertia load of the piston assembly mass as one extreme load corresponding to the tensile load, and firing load or compressive gas load corresponding to maximum torque as the other extreme design load corresponding to the compressive load. Inertia load is a time varying quantity and can refer to the inertia load of the piston, or of the connecting rod. From the literature review, it is clear that maximum stresses act at the connecting rod column bottom end and does not occur at TDC. The maximum bending stress at the column center is about 25% of the maximum stress at that location. However, to obtain the bending stress variation over the connecting rod length, or to know the stress at critical locations such as the transition regions of the connecting rod, a detailed analysis is needed. As a result, for the forged steel connecting rod, a detailed load analysis has to be investigated by a static FEA to capture the stress variations. IV. CALCULATION OF FACTOR OF SAFETY Aim: To calculate existing factor of safety of the connecting rod using Rankine’s formula in an Excel Spread sheet. Given Data’s: Piston Diameter (d1) =107.277 mm Stroke Length(L) = 120.65 mm Crank Radius(r) = (L/2)= 60.325 mm Length of connecting rod (ℓ)=223.558 mm Ratio (ℓ/r)= 3.70 Maximum Explosion Pressure (Pmax=12.236 N/mm2 Engine Speed (N) = 2400 rpm Mass of Reciprocating Parts(M)= 3.154 Kg Web Thickness (t)= 5.08 mm Radius of Gyration (E)= 2.06 x 105 N/mm2 STEP 1: Yield Strength of connecting Rod (σ Y) = 570 N/mm2 Tensile Strength of connecting Rod (σ u) =770 N/mm2 STEP 2: Load due to Gas pressure (FG) = (π/4 * d1 2 * Pmax) = (π/4 * 107.277 2 * 12.236) = 110600.3997 N STEP 3: For an I-section A = 11t2, Kxx = 1.78t. Therefore, A = 283.87 mm2 & Kxx = 9.0424 mm Shank Design Flange Thickness = t Depth of section = 5t Width of section = 4t Area of section (A) = 11t2., Ixx = 1 /12 (BH3 – bh3 =1/12 [(1t) x (5t2 ) – (3t) x (3t3 )] = 419t2 / 12 Iyy = 1 /12 (2t*B3 + ht3 )= 1 /12 [(2t * 4t3 ) + (3t * t3 )]= 131 /12 t4 K2 xx = Ixx / A = 419t2 / (12*11t2 ) K2 xx = 3.18 t2 …………………… (i) K2 yy = Iyy / A = 131t2 / (12*11t2 ),K2 yy = 0.995 t2 STEP 4: Rankine’s formula: The buckling load (WB) of the component can be calculated WB = ((σc * A) / {1+a [ℓ/Kxx 2 ]}……………… (ii) Where, σc (Direct compressive stress + Bending Stress) = 770 N/mm2 Advance Research and Innovations in Mechanical, Material Science, Industrial Engineering and Management - ICARMMIEM-2014 173 ISBN 978-93-82338-97-0 © 2014 Bonfring
  • 4. a = 1/ 7500 constant, ℓ = 223.558 mm, Kxx = 9.0424 mm A1, I-section area with hole = 859.550 mm2 A2 , I-section area without hole = 891.220 mm2 Here A1, A2 are the values obtained from CAD software. WB =Maximum gas force * Factor of safety =Pmax * Piston area * n=110600 n from equation (ii), F.O.S without hole (n1) = 5.7371, F.O.S with hole (n2) = 5.533 The above F.O.S values fits only to the I-Section of the Connecting rod. V. PARAMETRIC MODELING OF CONNECTING ROD A solid model of the connecting rod was generated using Pro/Engineer Wildfire2.0. Due to the symmetry of the geometry, the component was first half modeled. The model was designed without forging flash, bolts, and crank or pin hole bearings, as these details are not expected to have any significant influence on the obtained results at the critical regions (i.e. failure locations, simplification of the model. Different modeling techniques have been adopted on modeling of the existing connecting rod. Thus, a final optimized geometry of connecting rod has been created using assembly cut procedure from the Pro/Engineer. Fig. 2: Parametric Model of Existing Connecting Rod VI. FORCE CALCULATIONS - ADAMS/VIEWER A. Introduction The Automatic Dynamic Analysis of Mechanical Systems (ADAMS/Viewer) is used in the field of Mechanical System Simulation (MSS) to simulate both large and small-scale motion of mechanical systems. These motions are induced by the action of applied forces or excitations that act upon the system. This package allows to import geometry from most major CAD systems or to build a solid model of the mechanical system from scratch. A full library of joints and constraints is available for creating articulated mechanisms. Once the virtual prototype is complete, Adams checks the model and then runs simultaneous equations for kinematics, static, quasi-static, and dynamic simulations. Results are viewable as graph, data plots, reports, or colorful animations. This package allows users to determine the magnitude of the loads acting on the connecting rod at any position of time with respect to crank angle rotations, to determine forces acting due to the cylinder pressure, o determine forces acting along connecting rod at crank end and piston end and to determine forces perpendicular to connecting rod. B. Inputs For ADAMS The following are the inputs required to perform ADAMS force calculations. Piston Diameter (d1) =107.3 mm Stroke Length (L) = 120.6 mm, Crank Radiu(r) = (L/2)=60.3 mm Length of connecting rod (ℓ)= 223.5 mm Maximum Explosion Pressure (Pmax)= 120 bar Engine Speed (N) = 2400 rpm Mass of Reciprocating Parts (M) M = {Weight of piston + Weight of Gudgeon pin + Weigh Piston rings +/3 weight of connecting rod = 2.358 + 1 /3 (2.394) = 3.154Kg Mass of Connecting Rod: 2.392 kg Ratio (ℓ/r) :3.70Ultimate strength : 770 N/mm2 Yield strength 570 N/mm2 Hardness: 241 to 285 BHN Material Specification DIN 17200 41CR 4STEEL Connecting rod model : In step file, part file formats Piston & Piston pin model:In step file, part file formats C. Modeling Process The step-by-step modeling and analysis procedure of a connecting rod is described below: 1. Creating a model, setting units and gravity The assembled 3D model of connecting rod, piston, piston pin part files are being imported to ADAMS physical model environment through Step / iges file format. 2. Creating parts and joints The connecting rod is connected to the piston pin with a revolute joint; similarly, the either ends of pins are connected to the piston using a lock joint to prevent the movement in all directions. The Big end side of connecting rod is connected to a bar link with a spline defined revolute joint, i.e., the movement of connecting rod depends upon the Pressure Vs Crank angle diagram. This spline curve is defined by a set of xy axis values. Other end of the bar link is provided a revolute joint. 3. Running and animating a simulation The maximum gas load, taken as a point load on the piston surface at C.G. axis. Now, the force vectors are made visible (Both the axial force at top and bottom). Advance Research and Innovations in Mechanical, Material Science, Industrial Engineering and Management - ICARMMIEM-2014 174 ISBN 978-93-82338-97-0 © 2014 Bonfring
  • 5. Figure 4.1: Pressure Crank angle diagram for the existing engine showing the peak firing pressure as 120 bars From the geometry of 3D model & material properties, the corresponding mass properties are being calculated. The material properties include: Piston : Aluminium alloy Piston: 15 Cr Ni 6 Connecting rod: Steel to DIN 17200 41 Cr 4 The masses of reciprocating parts are taken as tensile inertia force. Thus, the simulation is made to run for few steps. 4. Plotting Results After the completion of simulation, the corresponding graphs are obtained from the ADAMS/View • Maximum Bending force perpendicular to connecting rod axis. • Maximum compressive force obtained from peak firing pressure. Condition - I The maximum gas load acts at the small end region, caused by peak combustion pressures. The corresponding axial load developed in this region is obtained through this analysis. Peak firing pressure = 120 bars Cylinder bore / Piston diameter = 107.25 mm Fig. 3: Maximum Compressive Load Condition Results The Axial load developed upon the connecting rod with respect to maximum gas load is95740 N. Condition - II The tensile inertia load is caused by mass of reciprocating parts. Now, the ADAMS software calculates the corresponding bending force. The maximum force perpendicular to connecting rod axis in both bending and axial moments is shown below Fig. 4: Angular loads caused due to mass of reciprocating parts Results: When the force is 8127 N, then the maximum bending force obtained perpendicular to the connecting rod axis is 4622 N and the corresponding axial force is 6416 N. VII. METHODOLOGY Each FEA consists of two kinds of boundary conditions. Boundary Condition I - vertical load of 95.74 kN is applied at small end central node and the Big-end is constrained in all directions Boundary Condition II - The small end of connecting rod is fully constrained and a resultant load (Fr) of 8.127kN at an angle 34.660 to vertical (Fy = 6.685kN, Fx = 4.622kN) is applied at Figure 5 (a) & 5 (b) shows two different kinds of boundary conditions to be applied for individual connecting rods. A. Current Design - Connecting Rod with Hole, Boundary Condition I Figure 6: Displacement plot with compressive load of 95.74 kN at piston pin end while the crank end was restraine Observations Big end fully constrained and a vertical load of 95.74 kN It can be observed that big end bottom and small end top almost of zero stress due to rigid Maximum displacement of 0.1 mm observed for the given constraint Maximum stress of 36.5 kgf /mm2 observed near the small end, may be due to rigid connection given to apply load at small end, that need to be verified by defining a contact. Near the web, stress is around 17.8 kgf / mm2 Advance Research and Innovations in Mechanical, Material Science, Industrial Engineering and Management - ICARMMIEM-2014 175 ISBN 978-93-82338-97-0 © 2014 Bonfring
  • 6. Boundary Condition II Figure 6 von Mises stress distribution plot with static tensile load of 8.127kN at an angle 34.660 to vertical (Fy = 6.685kN, Fx = 4.622kN) at the crank end while the pin end was restrained Figure 6.1: Displacement plot with static tensile load of 8.127kN at an angle 34.660 to vertical (Fy = 6.685kN, Fx = 4.622kN) at the crank end while the pin end was restrained. Observations Small end constrained fully and a resultant load of 8.127kN at an angle of 34.660 to vertical (Fy = 6.685kN, Fx = 4.62kN) It can be observed that big end bottom and small end top almost of zero stress due to rigidity. Maximum displacement of 1.1 mm observed for the given constraint B. Current Design - Connecting Rod without OILHOLE Boundary Condition I Maximum stress of 21.9 kgf/mm2 observed near the web and 9 kgf/mm2 observed near the hole at small en Figure 7(a) von Mises stress distribution plot with compressive load of 95.74 kN at Piston pin end while the crank end was restrained Figure7 (b): Displacement plots with compressive load of 95.74 kN at piston pin end while the crank end was restrained. Observations Big end fully constrained and a vertical load of 95.74 kN. It can be observed that big end bottom and small end top almost of zero stress due to rigid Maximum displacement of 0.1 mm observed for the given constraint Maximum stress of 32.3 kgf /mm2 observed near the small end, may be due to rigid connection given to apply load at small end, that need to be verified by defining a contact. Near the oil hole removed region small end stress of 24.5 kgf/ mm2 Near the web, stress is around 16.7 kgf/mm2 Observations Small end constrained fully and a resultant load of 8.127kN at an angle of 34.660 to vertical (Fy = 6.685kN, Fx=4.622kN) It can be observed that big end bottom and small end top almost of zero stress due to rigidity. Maximum displacement of 0.1 mm observed for the given constraint Near the web, stress is around 21.6 kgf/ Boundary Condition II Figure7.1: von Mises stress distribution plot with static tensile load of 8.127kN at an angle 34.660 to vertical (Fy = 6.685kN, Fx = 4.622kN) at the crank end while the pin end was restrain Figure 7.2: Displacement plot with static tensile load of 8.127kN at an angle 34.660 to vertical (Fy = 6.685kN, Fx = 4.622kN) at the crank end while the pin end was restrain Yield stress = 59.6 kg/mm2 Below table describes the comparative chart of change in the F.O.S values for the existing and optimized connecting rod. Optimization of Gudgeon Pin The gudgeon pin (which connects the piston to the connecting rod in a conventional internal combustion engine, ICE) is subjected to a combination of shearing and bending loads. There will inevitably be some deformation of the bushes that hold the gudgeon pin in both the piston and the connecting rod. Considering the maximum loading conditions several iterations piston pin have been completely optimized. Based on pin diameters, the existing gudgeon pin (15 cr Ni 6) yield strength is 165 kg/mm2. Existing Piston Pin – The existing pin has 1.6” diameter and the F.O.S values are described below. Von Mises stress: 116 kg/mm2 F.O.S: 1.422 Figure 8: Existing Gudgeon pin of 1.6” Diameter Finite Element Analysis of Gudgeon Pin The objective of FEA was to investigate stress and displacements experienced by the Gudgeon pin. From the resulting stress contours, the state of stress, as well as stress concentration factors can be obtained and consequently used for life predictions. Piston pin is subjected to three different Advance Research and Innovations in Mechanical, Material Science, Industrial Engineering and Management - ICARMMIEM-2014 176 ISBN 978-93-82338-97-0 © 2014 Bonfring
  • 7. kinds of loadings considering the static analysis (Axial load, Angular Load and Experimental Load).Similarly the resultant load of 669 kgf is applied and at last the experimental value of 962 kgf is applied. The 3-D geometry was created using I-DEAS 9.0. The pin surface is splitted into three surfaces. Two surfaces for load application and the other to constraint the pin in opposite direction. Three different loading conditions were analyzed in this analysis. Maximum gas pressure load of 9574 kgf 1) Vertical load 669 kgf from ADAMS inputs 2) Experimental Load of 966 kgf Existing Gudgeon Pin The existing pin has been analyzed with three different loading conditions. Maximum gas pressure load of 9574 kgf for piston pin of 1.6”Diameter Table 1: Existing vs Optimized Gudgeon pin comparison Loading Connecting rod Stress (kg/mm2 ) Deflection (mm) FOS (With respect to Yield Stress) Case1: Downwa rd load of 95.74 kN Existing With oil hole 36.5 near oil hole 0.1 1.63 near oil hole Without hole 32.3 near Small end 16.7 near web 0.1 1.85 near small end 3.57 near web Case 2: vertical load 8.127kN @ an angle of 34.660 Existing With oil hole 21.9 1.1 2.72 Without hole 21.6 1.0 2.76 Fig. 9: Change in the F.O.S values of Existing vs Optimized Gudgeon pin diameters Thus, we have selected 1.3” diameter as the best choice for the gudgeon pin. The corresponding small end region in the Connecting rod optimization is carried out. Fig 10: Shows the Existing Gudgeon pin with Outer Diameter of 41.27mm .Shows the Modified Gudgeon pin with Outer Diameter o Comparison of Results Several iterations on the Connecting rod has been conducted and their corresponding failure index values have been calculated and shown in the below graph, i.e. various Connecting rod vs change in the F.O.S values. From the graph it is seen evidently a steep fall in the value of F.O.S from various I sections. Yield strength: 59.6 kg/mm2 Table 2: Shows existing and optimized Connecting rod comparison Loading Gudgeon pin Stress (kg/mm2 ) Deflection (mm) FOS (with respect to Yield Stress) Case1: Downward load of 95.74 kN Existing 116 0.09 1.422 Optimized 125 0.14 1.32 Case 2: vertical load 8.127 kN Existing 7.8 0.01 21.15 Optimized 8.2 0.01 20.12 Case 3: Experimental Load of 966 kgf Existing 11.6 0.01 14.22 Optimized 12.5 0.01 13.2 Connecting rod F.O.S Vs Different I-Sections 1.4 1.45 1.5 1.55 1.6 1.65 0 1 2 3 4 5 I-Sections Connecting rod F.O.S Change in F.O.S values Advance Research and Innovations in Mechanical, Material Science, Industrial Engineering and Management - ICARMMIEM-2014 177 ISBN 978-93-82338-97-0 © 2014 Bonfring
  • 8. Fig. 11: The geometry of the optimized connecting rod. Figure 12: Drawing of the Existing Connecting rod showing all major dimensions Figure 13: Drawing of the Optimized Connecting rod showing all major dimensions Component Development After the analysis of both Connecting rod and Gudgeon pin a prototype component was developed. For the component development activities, the Optimized Connecting rod sketches have been sent to M/s Shard low Industries Ltd. Later the forging drawing has been studied and minimal modifications have been made in the forging die design. With combined efforts from Ashok Leyland and Shard low Industries Optimized Connecting rod has been produced successfully. Samples of ten sets of component have been procured for testing purposes. Figure 14: Existing & Figure 15: Existing & Optimized Optimized Connecting rods Optimized Gudgeon pins 1.6d After the procurement of sample components, the connecting rod I – Sections was studied. After the procurement of sample components, the connecting rod I – Sections was studied. Figure 16: Existing & Optimized Connecting rod I-sections, Connecting rod I-sections similarly the small ends of the Connecting rod were examined and Connecting rod small end diameter Economic Cost Factor Cost of 1.6” Gudgeon pin = Rs.71.54/- Cost of 1.3” Gudgeon pin = Rs.47.68/- Forging cost of Existing Connecting rod = Rs.289.26/- Forging cost of Optimized Connecting rod = Rs.250.07/- Cost saving in Gudgeon pin= Rs.23.86/- Cost saving in Connecting rod = Rs.39.19/- Total Cost savings=Rs.63.05x6cylinders=Rs.378.3 per Engine Considering Annual sales of 8000 Engines Total cost savings = Rs.30, 26,400 Optimization Potential Table 3: Shows the Optimization Potential of the Connecting Rod Assembly VIII. RESULTS Weight reduction in the connecting rod contributes =0.303kg Weight reduction in the Gudgeon pin contributes = 0.246 k BIBLIOGRAPHY [1] IC engines by V ganesan [2] Webster, W. D., Coffell R., and Alfaro D., “A Three Dimensional Finite Element Analysis of a High Speed Diesel Engine Connecting Rod,” SAE Technical Paper Series, Paper No. 831322, 1983. [3] Norton, R. L., “Machine Design - An Integrated Approach, ”Prentice- Hall, 1996. [4] Sonsino, C. M. and Esper, F. J., “Fatigue Design for PM Components,” European Powder Metallurgy Association (EPMA), 1994. [5] Makino, T. and Koga, T., “Crank Bearing Design Based on 3-D Elasto hydrodynamic Lubrication Theory,” Mitsubishi Heavy Industries, Ltd., Technical Review, Vol. 39, No. 1, 2002. [6] Clark, J. P., Field III, F.R., and Nallicheri, N.V.,“Engine state-of-the-art: A competitive assessment of steel, cost estimates and performance analysis, “Research Report BR 89-1, Automotive Applications Committee, American Iron and Steel Institute, 1989. [7] Serag, S., Sevien, L., Sheha, G., and El-Beshtawi, I., “Optimal design of the connecting-rod”, Modelling, Simulation and Control, B, AMSE Press, Vol. 24, No.3, 1989, pp. 49-63. [8] Auto mobile engineering by kirpal singh. Iste & Asme journals Advance Research and Innovations in Mechanical, Material Science, Industrial Engineering and Management - ICARMMIEM-2014 178 ISBN 978-93-82338-97-0 © 2014 Bonfring
  • 9. Shaik Himam Saheb, Assistant Profess, B.Tech, M.Tech, Singareni Collieries Polytechnic Singareni Collieries Polytechnic, Adilabad District, Mancherial-504302. E-mail: himam.mech@gmail.com P. Sampath Kumar, Assistant Profess, B.Tech, M.Tech, Singareni Collieries Polytechnic Singareni Collieries Polytechnic, Adilabad District, Mancherial- 504302. E-mail: sampath.pendekatla@gmail.com A. Ramesh, Assistant Profess, B.Tech, M.Tech, Christhu Jyothi Institute of Technology and Science (CJITS), Jangaon, Warangal, AP, India. E-mail: ramesh340mech@gmail.com Advance Research and Innovations in Mechanical, Material Science, Industrial Engineering and Management - ICARMMIEM-2014 179 ISBN 978-93-82338-97-0 © 2014 Bonfring View publication stats View publication stats