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[ Course: Computer Aided Engineering Design
(AML 7010)]
[ABHISHEK KUMAR PANDEY]
[2025AMA2223]
Introduction
A connecting rod is a critical component in internal combustion engines,
reciprocating compressors, and pumps. Its primary function is to transmit the thrust
from the piston to the crankshaft, converting the reciprocating motion of the piston
into the rotational motion of the crankshaft. Consequently, it undergoes complex
cyclic loading, including high compressive loads from combustion and tensile loads
from inertia.
Objective
The primary objectives of this analysis are:
1. To perform a Finite Element Analysis (FEA) using ANSYS Mechanical.
2. To determine the stress distribution, strain distribution and deformation under
a compressive load in three different materials (forged steel, aluminium alloy
and titanium alloy).
Methodology
STEP-1
Geometry and Material properties
First, we go for Static Structural and we insert our SolidWorks step file in geometry
section. After inserting we go for Engineering data where we add our materials and
their properties given in below pictures.
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STEP-2
After adding the materials data, we go for model section in which we first update the
data. After updating the data, we double click the model section then mechanical
section open.
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STEP-3
In mechanical section we first go for geometry where we assign materials to our
connecting rod. Let’s just first we select the forged steel in assignment.
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STEP-4 Meshing
After assigning the material we go for meshing section in which we first take the
element size as 1 and after that we generate mesh.
STEP-5 Boundary Conditions and Loading
After meshing we go for static structural section in, we first give the boundary
condition in which we select the fixed support and select the surface which we want
to be fixed. After boundary condition we go for force in which we change define by
vectors to define by component and select the surface where we want force to act
and we add the force in that direction.
FORCE CALCULATION
I am analysing for horizontal IC Engine.
N = 1800 RPM
Mass of piston (Taken from ANSYS after importing it in geometry)
Dia of piston = 60mm
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Pressure of gas = 3.15 MPa (Reference literature in files)
F gas = Area of piston x Pressure = 8906.41N.
F inertia = Mrw^2(cos a + cos 2a/n); a is the angle the crank makes with the
horizontal.
Taking n = l/r= 5; l is length of connecting rod and r is radius of crank; l = 135 mm
from SolidWorks so r= 27mm.
During the full cycle connecting rod experiences both tension and compression but
compressive forces are much larger in magnitude so we analyse for compressive
forces.
Max F inertia when a = 0
M = mass of piston + (1/3 of connecting rod mass) = 564.08 N (Reference literature in
files)
Neglecting friction force F net = F gas + F inertia = 9470.49 N.
Axial force transmitted to connecting rod = F net / cos b; b is angle made by
connecting rod with horizontal.
Max axial force = F net = 9470.5 N.
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STEP-6
Results and Discussion
The solution was obtained after running the static structural analysis. The following
results were extracted and are discussed below.
Total Deformation
The maximum deformation was found to be 0.051743 mm, located at the small end.
This is an acceptably small deflection, confirming the component's high stiffness.
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Equivalent (von-Mises) Stress
The von Mises stress is the primary criterion for predicting yielding in ductile
materials. The maximum stress was 199.91 MPa, concentrated at the inner fillet of
the small end. This is a known stress concentration region
Equivalent (von-Mises) Strain
The maximum strain was 0.00099983
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GRAPH BETWEEN STRESS AND DEFORMATION
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ANSYS FILE LINK
[Link]
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