DESIGN AND ANALYSIS OF CONNECTING ROD WITH DIFFERENT GEOMETRIES USING FEA

PROJECT TEAM MEMBERS K SIVA RAMA KRISHNA Y LOKESWARA RAO R MANI KANTA S SATISH D NETAJI

ABSTRACT The automobile engine connecting rod is a high volume production, critical component. It connects reciprocating piston to rotating crankshaft. Designs of connecting rod have been analysed in this report and finally an optimal design has been selected using ANSYS-14.5 Workbench and CATIA V5.

INTRODUCTION One of the important part of the combustion engine is the connecting rod, and the main purpose of the connecting rod is to transfer the energy from the pistons to crankshaft and convert the linear reciprocating motion of a piston into the rotary motion of a crankshaft, from the viewpoint of functionality; also it connects reciprocating piston to rotating crankshaft and some other design connected direct to the crosshead and then transmitting the thrust of the piston to the crankshaft of the combustion engine. The combustion engines connecting rod moves in two way rotating motion and connects both large and small end.

PARTS AND COMPONENTS OF CONNECTING ROD

TYPES OF MANUFACTURING OF CONNECTING- RODS Forged Casting Powdered Metal

STRESS-STRAIN DIAGRAMS

INTRODUCTION TO CATIA Computer Graphics-Aided Three-Dimensional Interactive Application (CATIA) is the world’s leading computer-aided design (CAD)/computer-aided manufacturing (CAM)/computer-aided engineering (CAE) package. Developed by Dassault systems and marketed worldwide by IBM, CATIA delivers one of the best Product Lifecycle. CATIA started as an in-house development in 1977 by French aircraft manufacturer Avionics Marcel Dassault, at that time customer of the CAD/CAM CAD software to develop.

MODELLING PROCEDURE Sketcher: This workbench used to draw simple two dimensional figures that determine the profiles of a three dimensional object such as the cross section of the object. Part design: This workbench used to complete the feature of a three dimensional part of a major model by obtaining the profiles from the sketcher. Wireframe and surface: The wireframe and surface workbench is used to obtain the surfaces and around profiles or creating surfaces of desired shapes and sizes. Assembly: The assembly workbench is a platform for all part design to be imported and assembled by providing proper constraints by the parts movements and limits

REFERENCES Dr.B.K.Roy, Design Analysis and Optimization of Various Parameters of Connecting Rod using CAE Softwares,OM Institute of Technology and Management, Hisar, Haryana, International Journal of New Innovations in Engineering and Technology (IJNIET) Vol. 1  G. Naga Malleshwara Rao, ‘Design Optimization and Analysis of a Connecting Rod using ANSYS’ International Journal of Science and Research (IJSR), India

DESIGN 2-D DIAGRAMS OF CONNECTING ROD USING CATIA EXISTING MODEL

MODIFIED DIMENSIONS MODEL-1

MODIFIED DIMENSIONS MODEL-2

MODIFIED DIMENSIONS MODEL-3

CATIA MODEL OF CONNECTING ROD

preparation of connecting rod in CATIA

preparation of connecting rod in CATIA

CATIA MODEL OF CONNECTING ROD

preparation of connecting rod in CATIA

MESH GENERATION It is the process of discretization or dividing the geometry into a number of suitable finite elements, which are interconnected at the nodes. Comprehensive libraries of finite element are available in software. The element will be linear or parabolic, shell, solid, beam, rod, spring, damper mesh and gap are some of the elements available for the purpose of modeling. FEM software provides extensive capabilities to define loading and boundary conditions correctly stimulate the environment.

MESHING MODEL OF CONNECTING ROD

ANALYSIS PROCEDURE IN ANSYS PREFERENCES PREFERENCES ---- STRUCTURAL PRE PROCESSOR Element type -- SOLID Material model – STRUCTURAL STEEL Real constants – NONE Meshing -- FREE Loads -- TOP GROOVE IF FIXED AND LOAD APPLYING INTHE BOTTOM GROOVE. SOLUTION --- Solve - current L.S ( Solves the problem) GENRAL POST PROCESSOR --- Plot results -- contour plot -- nodal solution(DEFORMATION AND ELONGATION )

STRUCTURAL STEEL PROPERTIES Young's Modulus MPa 2.e+005 Poisson's Ratio 0.3 Bulk Modulus MPa 1.6667e+005 Shear Modulus MPa 76923 Density 7.85e-006 kg mm^-3 Coefficient of Thermal Expansion 1.2e-005 C^-1

STRUCTURAL STEEL PROPERTIES Specific Heat 4.34e+005 KJ kg^-1 C^-1 Thermal conductivity 6.05e-002 W mm^-1 C^-1 Resistivity 1.7e-004 ohm mm Compressive Ultimate strength MPa Compressive Yield strength MPa 250 Tensile Yield strength MPa Tensile Ultimate strength MPa 460

RESULTS OF EXISTING MODEL AT LOAD 4319N

Stress in existing model connecting rod at load 4319N

Total deformation in existing model connecting rod at load 21598N

stress in existing model connecting rod at load 21598N

Total deformation in modified-1 connecting rod at load 4319N

Stress in modified model-1 connecting rod at load 4319N

Total deformation in modified-1 connecting rod at load 21598N

Stress in modified model-1 connecting rod at load 21598N

Total deformation in modified-2 connecting rod at load 4319N

Stress in modified model-2 connecting rod at load 4319N

Total deformation in modified-2 connecting rod at load 21598N

stress in modified model-2 connecting rod at load 21598N

Total deformation in modified-3 connecting rod at load 4319N

Stress in modified model-3 connecting rod at load 4319N

Total deformation in modified-3 connecting rod at load 21598N

Stress in modified model-3 connecting rod at load 21598N

COMPARISION OF RESULTS AT LOAD 4319N SL NO PARAMETERS EXISTING MODEL MODIFIED MODEL-1 MODIFIED MODEL-2 MODIFIED MODEL-3 1 STRESS VON-MISES 124.84 MPa 128.34 MPa 140.28 MPa 120.38 MPa 2 TOTAL DEFORMATION 2.5435 e-002 mm 2.7064e-002 mm 3.1107e-002 mm 2.4828e-002 mm

AT LOAD 21598N SL NO. PARAMETER EXISTING MODEL MODIFIED MODEL-1 STRESS (VON-MISES) 624.27 MPa 641.79 MPa 701.52 MPa 601.97 MPa 2 TOTAL   DEFORMATION 0.12719 mm 0.13534 mm 0.15556 mm 0.12416 mm

COMPRESION LOAD 4319N & 21598N SL NO PARAMET -ER EXIST-ING MOD-EL STRESS VON-MISES 124.84 MPa 128.34 MPa 140.28 MPa 120.38 MPa 624.27 MPa 641.79 MPa 701.52 MPa 601.97 MPa 2 TOTAL  DEFORMATION 2.5435e-002 mm 2.7064e-002 mm 3.1107e-002 mm  2.4828e-002 mm 0.12719 mm 0.13534 mm 0.15556 mm 0.12416 mm

Advantages of connecting rod It carry large amount of loads. It is working at high temperature. It has good mechanical properties. It carries compressive and bending loads.

Disadvantages of connecting rod The design of connecting rod is complicated. High cost. Skilled labor is required for manufacturing. Costly alloys are required for manufacturing. Replacement is difficult.

CONCLUSION Various designs of connecting rod have been analyzed in this report and finally an optimal design has been selected. Using ANSYS-14.5 Workbench and CATIA V5, Various results are found out and compared with the existing results.Current work has concluded up with the fact that slight and careful variation in design parameters can give a good design which can be made feasible by a number of analysis using CAE tools and Software’s. After observing all the four models, Existing model, model-1, model-2,and model-3. Modified model-3 is better than existing model