International Journal of Scientific & Engineering Research, Volume 5, Issue 5, May-2014 1292
ISSN 2229-5518

Comparative Study of the Connecting Rod Manufactured Using Forging and Sintering Kadiam Bhargav V Siva Kumar

Abstract— Connecting rod is a major part inside of an internal combustion engine. The rod connects the crankshaft with the piston. The connecting rod pushes the piston up, and is helped back down by the piston's reciprocal motion. In this paper a structural and thermal analysis is conducted on a connecting rod of a two cylinder 4-stroke S217 engine. The model is developed using Solid modeling software i.e. PRO/E. Further finite element analysis is done to determine the von-misses stresses shear stress, strains and heat distribution for the given loading conditions.

Keywords — ANSYS W orkbench, connecting rod, Finite Element analysis, PRO/E

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1 INTRODUCTION

Connecting rod is a component produced in large volumes in the internal combustion engine. Connecting rod is an integral component of internal combustion engine and it is classified under functional component. It acts as a linkage between piston and crank shaft. The main function of connecting rod is to transmit the translational motion of piston to rotational motion of crank shaft. It connects the piston to the crank shaft .The connecting rod transfers power from the piston to the crankshaft and delivers it in to transmission. There are several types of materials and manufacturing processes used in the production of connecting rods like casting, forging, and powdered metallurgy.

2 DESIGN CALCULATIONS FOR CONNECTING ROD

2.1 Engine specifications

Type-S217 --- two cylinders, Four Stroke, Direct injection

Bore--- 92 mm

Stroke --- 127 mm

Cubic Capacity --- 1.7 litres

Compression Ratio --- 18.5:1

2.2 Dimensions of the connecting rod

Length of connecting rod----- 232 mm

Small end radius------ 12.50 mm

Big end radius------ 30 mm

3 FINITE ELEMENT MODEL

Fig shows the 3-Dimensional model in PRO/E

environment.

The procedure of using FEM usually consists of following steps. (a) Applying the material; (b) meshing; (c) determining and imposing loads and boundary conditions; (d) solving ; (e)simulation.

4 MESHING

Figure shows the meshed model in ansys consisting of

23307 nodes and 13367 elements.

5 DEFINING MATERIAL PROPERTIES

The ansys demands for material properties which are defined using module engineering data.

International Journal of Scientific & Engineering Research, Volume 5, Issue 5, May-2014 1293
ISSN 2229-5518

7 OUTPUT OF THE ANALYSIS

7.1 Structural analysis

Forging

6 LOADS AND BOUNDARY CONDITIONS

6.1 Boundary Conditions for structural analysis

The big end of the connecting rod is fixed in all degrees of freedom.

At the small end pressure of 8Mpa is distributed on the outer end .Considering the following calculation….. Compressive peak pressure=80 bar=8*106 Pa

Weight of the piston for the engine (m) =0.6 kg

a= area of the piston= π*B2/4=6.647e-3 m2

Pressure (p) = F/a=884.61 Pa

Total pressure on piston end =8 MPa

6.2 Boundary Conditions for thermal analysis

Temperature at the big end: 35oc

Temperature at the small end: 315oc

Sintering

INFERENCE

Forged connecting rod has value greater than sintering due to higher density of forging process

7.2 Thermal analysis

Forging

International Journal of Scientific & Engineering Research, Volume 5, Issue 5, May-2014 1294

ISSN 2229-5518

10 REFERENCES

Sintering

INFERENCE

Due to higher density for the forged connecting rod it has greater total heat flux.

8 RESULTS

[1 ] Modeling and Analysis of Two Wheeler Connecting Rod by Using Ansys B. Anusha, C.Vijaya Bhaskar Reddy (1Department of Mechanical Engineering, P.G Student, Sri Kalahasteeswara,Institute of Technology, Srikalahasti,) (2Sr.Asst.Prof, Department of Mechanical Engineering, srikalahasti,)
[2] Static Structural Analysis of Connecting Rod by Finite
Element Analysis Ajay Kumar Choubey Research Associate, Central Institute of Agricultural Engineering, Bhopal
[3] Analysis of oxygen mixture in intake manifold instead of air
mixture in single cylinder ic engine. A.srinivaas
[4] Gupta, R.K., Recent Developments in Materials and Processes
for Automotive Connecting Rods, SAE International Congress and Exposition, Society of
Automotive Engineers, 1993.
[5] Nakamura, S., K. Mizuno, T. Matsubara, and Y. Sato,
Development of High Fatigue Strength Free Machining
Microalloyed Steel for Connecting Rods, SAE International Congress and Exposition, Society of Automotive Engineers, 1993. [6] Olaniran, M. and C. Stickels, Machinable, strong, but crackable low ductility steel forging, USPTO, 1992, Ford Motor Company:United States.
[7] Olarinan, M. and C. Stickels, Separation of Forged Steel
Connecting Rods and Caps by Fracture Splitting.
Society of Automotive Engineers, 1993. 930033.
[8] James, W.B., Powder Forging.Reviews in Particulate
Materials, 1994. 2: p. 173-214.
[9] Paek, S.Y., H.S. Ryou, J.S. Oh, and K.M. Choo, Application of
High Performance Powder Metal Connecting Rod in the V6
Engine.Society of Automotive
Engineers, 1997. 970427.
[10] Whittaker, D., The Competition for Automotive Connecting
Rod Markets.Metal Powder Report, 2001: p.32-37.
[11] Repgen, B., Optimized Connecting Rods to Enable Higher Engine Performance and Cost Reduction.Society of Automotive Engineers 1998. 980882
[12] Park, H., Y.S. Ko, J. S.C., S. B.T., J. Y.H., L. B.C., and L. J.D., Development of Fracture Split Steel Connecting Rods.Society of Automotive Engineers, 2003.
[13] Imahashi, K., C. Tsumuki, and I. Nagare, Development of
Powder-Forged Connecting Rods, Society of Automotive
Engineers, Society of Automotive
Engineers, 1984.

9 CONCLUSIONS

• The von-mises stress for the forged connecting rod is higher than that of the sintered one

• The analysis results shows that the connecting rod produced by sintering has less total deformation and strain energy than the connecting rod manufactured by forging.

• The total heat flux, directional heat flux and thermal error are higher for the forged connecting

rod compared to the sintered connecting rod