Design and FEA Analysis of Connecting Rod for Engine

This study material discusses the design and FEA analysis of a connecting rod for an engine. It covers topics such as material selection, stress concentration, and more. The content includes tables, figures, and results of the analysis. The subject is mechanical engineering and the course code is not mentioned. The college/university is not mentioned.

Contents
ABSTRACT ...................................................................................................................................................... 4
Connecting Rod-1 .......................................................................................................................................... 5
FEA-1 ............................................................................................................................................................. 6
Model ........................................................................................................................................................ 6
Geometry .............................................................................................................................................. 6
Mesh ..................................................................................................................................................... 9
Static Structural (A5) ............................................................................................................................... 12
Results ................................................................................................................................................. 16
Material Data .......................................................................................................................................... 25
Structural Steel .................................................................................................................................... 25
Explanation- ................................................................................................................................................ 26
Connecting Rod-2 (Reverse Engineering) ................................................................................................... 26
FEA -2 .......................................................................................................................................................... 28
Units ........................................................................................................................................................ 28
Model ...................................................................................................................................................... 28
Geometry ............................................................................................................................................ 28
Mesh ................................................................................................................................................... 31
Static Structural (A5) ............................................................................................................................... 34
Results- ................................................................................................................................................ 38
Material Data .......................................................................................................................................... 47
Structural Steel .................................................................................................................................... 47
Explanation- ................................................................................................................................................ 48
Comparison (Conclusion) ............................................................................................................................ 48
CAM- ........................................................................................................................................................... 49
Process- ................................................................................................................................................... 49
Reference- ................................................................................................................................................... 50

List of Figures
Figure 1 (Meshing) ...................................................................................................................................... 11
Figure 2 (Meshing) ...................................................................................................................................... 11
Figure 3 (Force-1) ........................................................................................................................................ 13
Figure 4 (Force-1) ........................................................................................................................................ 13
Figure 5 (Force-2) ........................................................................................................................................ 14
Figure 6 (Force-2) ........................................................................................................................................ 14
Figure 7 (Force-3) ........................................................................................................................................ 15
Figure 8 (Force-3) ........................................................................................................................................ 15
Figure 9 (Fixed Support) .............................................................................................................................. 16
Figure 10 (Total Deformation-1) ................................................................................................................. 17
Figure 11 (Total Deformation-2) ................................................................................................................. 17
Figure 12 (Equivalent stress-1) ................................................................................................................... 18
Figure 13 (Equivalent stress-2) ................................................................................................................... 18
Figure 14 (Elastic strain-1) .......................................................................................................................... 19
Figure 15 (Elastic strain-2) .......................................................................................................................... 19
Figure 16 (Mechanical safety factor-1) ....................................................................................................... 21
Figure 17 (Mechanical safety factor-2) ....................................................................................................... 21
Figure 18 (Fatigue tool) ............................................................................................................................... 22
Figure 19 (Fatigue tool solution) ................................................................................................................. 23
Figure 20 (Fatigue safety factor-1) .............................................................................................................. 24
Figure 21 (Fatigue safety factor-2) .............................................................................................................. 24
Figure 22 (Connecting rod-2) ...................................................................................................................... 33
Figure 23 (Fixed Support) ............................................................................................................................ 33
Figure 24 (Force-1) ...................................................................................................................................... 35
Figure 25 (Force-1) ...................................................................................................................................... 35
Figure 26 (Force-2) ...................................................................................................................................... 36
Figure 27 (Force-2) ...................................................................................................................................... 36
Figure 28 (Force-3) ...................................................................................................................................... 37
Figure 29 (Force-3) ...................................................................................................................................... 37
Figure 30 (Total Deformation-1) ................................................................................................................. 39
Figure 31 (Total Diformation-2) .................................................................................................................. 39
Figure 32 (Equivalent stress-1) ................................................................................................................... 40
Figure 33 (Equivalent stress-2) ................................................................................................................... 40
Figure 34 (Elastic strain-1) .......................................................................................................................... 41
Figure 35 (Elastic strain-2) .......................................................................................................................... 41
Figure 36 (Mechanical safety factor-1) ....................................................................................................... 43
Figure 37 (Mechanical safety factor-2) ....................................................................................................... 43
Figure 38 (Fatigue tool) ............................................................................................................................... 44
Figure 39 (Fatigue tool solution) ................................................................................................................. 45
Figure 40 (Fatigue safety factor-1) .............................................................................................................. 46
Figure 41 (Fatigue safety factor-2) .............................................................................................................. 46
Figure 42 (Jig fixture for connecting rod) .................................................................................................... 49

List of Tables
Table 1 (Geometry) ....................................................................................................................................... 6
Table 2(Geometry parts) ............................................................................................................................... 8
Table 3(Mesh) ............................................................................................................................................... 9
Table 4(Analysis) ......................................................................................................................................... 12
Table 5(Loads) ............................................................................................................................................. 12
Table 6(Results) ........................................................................................................................................... 16
Table 7(Stress safety tools) ......................................................................................................................... 20
Table 8(Stress tools result).......................................................................................................................... 20
Table 9(Fatigue tools) ................................................................................................................................. 22
Table 10(Fatigue tools result) ..................................................................................................................... 23
Table 11(Material data) .............................................................................................................................. 25
Table 12(Compressive Yield Strength) ........................................................................................................ 25
Table 13(Tensile yield strength) .................................................................................................................. 25
Table 14(Tensile Ultimate strength) ........................................................................................................... 25
Table 15(Alternating stress) ........................................................................................................................ 25
Table 16 (Strain life parameter) .................................................................................................................. 26
Table 17(isotropic elasticity) ....................................................................................................................... 26
Table 18 (Units) ........................................................................................................................................... 28
Table 19 (Geometry) ................................................................................................................................... 28
Table 20 (Geometry parts) .......................................................................................................................... 30
Table 21 (Mesh) .......................................................................................................................................... 31
Table 22 (Analysis) ...................................................................................................................................... 34
Table 23 (Loads) .......................................................................................................................................... 34
Table 24 (Results) ........................................................................................................................................ 38
Table 25 (Stress safety tool) ........................................................................................................................ 42
Table 26 (Stress tool result) ........................................................................................................................ 42
Table 27 (Fatigue tools) .............................................................................................................................. 44
Table 28 (Fatigue tools result) .................................................................................................................... 45
Table 29 (Material data) ............................................................................................................................. 47
Table 30 (Compressive yield strength) ....................................................................................................... 47
Table 31 (Tensile yield strength) ................................................................................................................. 47
Table 32 (Alternating stress) ....................................................................................................................... 47
Table 33 (Strain life parameter) .................................................................................................................. 48
Table 34 (Isotropic elasticity) ...................................................................................................................... 48

ABSTRACT
Connecting rod plays very vital role in engine. It converts reciprocating motion to rotary motion and vice
versa. It connects the piston and crank shaft. As a result of which connecting rod undergo various
deformation under various forces. That’s why material selection and designing of connecting rod should
be done very precisely. Connecting rod must be light in weight and it must have good strength under
fatigue and other loads.
In this assignment first we will design connecting rod according to given dimensions. After that we will
do its FEA in ANSYS. By doing so we will see how stresses going to damage the part or in other words we
will see stress concentration in the connecting rod.

Connecting Rod-1
At this stage first we design our model according to given dimensions in CATIA V5. Detailed drawing of
connecting rod is given below. Material we have chosen is structural steel. More details about its mass,
density, moment of inertia etc. We can see in coming tables.

FEA-1
In this very first analysis we will check our connecting rod against 1000N compressive force. Which will
be acting at the piston side bore. To do this analysis first we need to select the material which is
structural steel then we need to setup all forces and fixed points of the connecting rod. After setting up
the constraints then we will apply forces on it and run the analysis to get max. Stress, total deformation,
mechanical safety factor, fatigue safety factor.
Model
Geometry
Table 1 (Geometry)
Object Name Geometry
State Fully Defined
Definition
Source D:\projects\Projects\connecting rod\IGES files\connecting rod
1.igs
Type Iges
Length Unit Meters
Element Control Program Controlled

Display Style Body Color
Bounding Box
Length X 2.2e-002 m
Length Y 0.21982 m
Length Z 9.e-002 m
Properties
Volume 9.7912e-005 m³
Mass 0.76861 kg
Scale Factor Value 1.
Statistics
Bodies 3
Active Bodies 3
Nodes 46862
Elements 25912
Mesh Metric None
Basic Geometry Options
Solid Bodies Yes
Surface Bodies Yes
Line Bodies No
Parameters Yes
Parameter Key DS
Attributes No
Named Selections No
Material Properties No
Advanced Geometry Options
Use Associativity Yes
Coordinate Systems No
Reader Mode Saves Updated File No
Use Instances Yes
Smart CAD Update No

Attach File Via Temp File Yes
Temporary Directory C:\Users\AppData\Local\Temp
Analysis Type 3-D
Mixed Import Resolution None
Decompose Disjoint Faces Yes
Enclosure and Symmetry
Processing Yes
Table 2(Geometry parts)
Object Name Part 1 Part 2 Part 3
State Meshed
Graphics Properties
Visible Yes
Transparency 1
Definition
Suppressed No
Stiffness Behavior Flexible
Coordinate System Default Coordinate System
Reference Temperature By Environment
Material
Assignment Structural Steel
Nonlinear Effects Yes
Thermal Strain Effects Yes
Bounding Box
Length X 2.2e-002 m 1.e-002 m
Length Y 0.21982 m 4.5e-002 m
Length Z 9.e-002 m 1.1547e-002 m
Properties
Volume 9.3031e-005 m³ 2.4404e-006 m³
Mass 0.7303 kg 1.9157e-002 kg
Centroid X -1.4551e-007 m 1.0325e-010 m 7.6565e-010 m
Centroid Y 0.13458 m 0.17402 m

Centroid Z 1.4373e-006 m 3.7541e-002 m -3.7541e-002 m
Moment of Inertia Ip1 2.8921e-003 kg·m² 3.5775e-006 kg·m²
Moment of Inertia Ip2 4.0096e-004 kg·m² 1.7051e-007 kg·m²
Moment of Inertia Ip3 2.5366e-003 kg·m² 3.5776e-006 kg·m²
Statistics
Nodes 43041 1891 1930
Elements 23918 981 1013
Mesh Metric None
Mesh
Table 3(Mesh)
Object Name Mesh
State Solved
Defaults
Physics Preference Mechanical
Relevance 1
Sizing
Use Advanced Size Function Off
Relevance Center Fine
Element Size Default
Initial Size Seed Active Assembly
Smoothing High
Transition Fast
Span Angle Center Coarse
Minimum Edge Length 3.75e-004 m
Inflation
Use Automatic Inflation None
Inflation Option Smooth Transition
Transition Ratio 0.272
Maximum Layers 5
Growth Rate 1.2

Inflation Algorithm Pre
View Advanced Options No
Patch Conforming Options
Triangle Surface Mesher Program Controlled
Advanced
Shape Checking Standard Mechanical
Element Midside Nodes Program Controlled
Straight Sided Elements No
Number of Retries Default (4)
Extra Retries For Assembly Yes
Rigid Body Behavior Dimensionally Reduced
Mesh Morphing Disabled
Defeaturing
Pinch Tolerance Please Define
Generate Pinch on Refresh No
Automatic Mesh Based Defeaturing On
Defeaturing Tolerance Default
Statistics
Nodes 46862
Elements 25912
Mesh Metric None

Figure 1 (Meshing)
Figure 2 (Meshing)

Static Structural (A5)
Table 4(Analysis)
Object Name Static Structural (A5)
State Solved
Definition
Physics Type Structural
Analysis Type Static Structural
Solver Target Mechanical APDL
Options
Environment Temperature 22. °C
Generate Input Only No
Table 5(Loads)
Object Name Force Force 2 Force 3 Fixed Support
State Fully Defined
Scope
Scoping Method Geometry Selection
Geometry 2 Faces
Definition
Type Force Fixed Support
Define By Components
Coordinate System Global Coordinate System
X Component 0. N (ramped)
Y Component 1000. N (ramped) 0. N (ramped) -1000. N (ramped)
Z Component 0. N (ramped) 500. N (ramped) 0. N (ramped)
Suppressed No

Figure 3 (Force-1)
Figure 4 (Force-1)

Figure 5 (Force-2)
Figure 6 (Force-2)

Figure 7 (Force-3)
Figure 8 (Force-3)

Figure 9 (Fixed Support)
Results
Table 6(Results)
Solution (A6) Results
Minimum 0. m 436.43 Pa 2.5066e-009 m/m
Maximum 2.5521e-004 m 6.9718e+007 Pa 3.4859e-004 m/m
Minimum Occurs On Part 1 Part 3
Maximum Occurs On Part 1
Information
Time 1. s
Load Step 1
Substep 1
Iteration Number 1
Integration Point Results
Display Option Averaged

Figure 10 (Total Deformation-1)
Figure 11 (Total Deformation-2)

Figure 12 (Equivalent stress-1)
Figure 13 (Equivalent stress-2)

Figure 14 (Elastic strain-1)
Figure 15 (Elastic strain-2)

Table 7(Stress safety tools)
Object Name Stress Tool
State Solved
Definition
Theory Max Equivalent Stress
Stress Limit Type Tensile Yield Per Material
Table 8(Stress tools result)
Object Name Safety Factor
State Solved
Scope
Scoping Method Geometry Selection
Geometry All Bodies
Definition
Type Safety Factor
By Time
Display Time Last
Calculate Time History Yes
Identifier
Suppressed No
Integration Point Results
Display Option Averaged
Results
Minimum 3.5859
Minimum Occurs On Part 1
Information
Time 1. s
Load Step 1
Substep 1
Iteration Number 1

Figure 16 (Mechanical safety factor-1)
Figure 17 (Mechanical safety factor-2)

Table 9(Fatigue tools)
Object Name Fatigue Tool
State Solved
Materials
Fatigue Strength Factor (Kf) 1.
Loading
Type Fully Reversed
Scale Factor 1.
Definition
Display Time End Time
Options
Analysis Type Stress Life
Mean Stress Theory None
Stress Component Equivalent (Von Mises)
Life Units
Units Name cycles
1 cycle is equal to 1. cycles
Figure 18 (Fatigue tool)

Figure 19 (Fatigue tool solution)
Table 10(Fatigue tools result)
Object Name Safety Factor
State Solved
Scope
Scoping Method Geometry Selection
Geometry All Bodies
Definition
Design Life 1.e+009 cycles
Type Safety Factor
Identifier
Suppressed No
Results
Minimum 1.2364
Minimum Occurs On Part 1

Figure 20 (Fatigue safety factor-1)
Figure 21 (Fatigue safety factor-2)

Material Data
Structural Steel
Table 11(Material data)
Density 7850 kg m^-3
Coefficient of Thermal Expansion 1.2e-005 C^-1
Specific Heat 434 J kg^-1 C^-1
Thermal Conductivity 60.5 W m^-1 C^-1
Resistivity 1.7e-007 ohm m
Table 12(Compressive Yield Strength)
Compressive Yield Strength Pa
2.5e+008
Table 13(Tensile yield strength)
Tensile Yield Strength Pa
2.5e+008
Table 14(Tensile Ultimate strength)
Tensile Ultimate Strength Pa
4.6e+008
Table 15(Alternating stress)
Alternating Stress Pa Cycles Mean Stress Pa
3.999e+009 10 0
2.827e+009 20 0
1.896e+009 50 0
1.413e+009 100 0
1.069e+009 200 0
4.41e+008 2000 0
2.62e+008 10000 0
2.14e+008 20000 0
1.38e+008 1.e+005 0
1.14e+008 2.e+005 0
8.62e+007 1.e+006 0

Table 16 (Strain life parameter)
Strength
Coefficient Pa
Strength
Exponent
Ductility
Coefficient
Ductility
Exponent
Cyclic Strength
Coefficient Pa
Cyclic Strain
Hardening Exponent
9.2e+008 -0.106 0.213 -0.47 1.e+009 0.2
Table 17(isotropic elasticity)
Temperature C Young's Modulus Pa Poisson's Ratio Bulk Modulus Pa Shear Modulus Pa
2.e+011 0.3 1.6667e+011 7.6923e+010
TABLE 17.1 (Isotropic relative permeability)
Relative Permeability
10000
Explanation-
In this analysis we have applied force of 1000N on piston side bore. Because at the time of power stroke
piston will push back the connecting rod. From above picture results we have seen that there are
maximum stresses of 6.9718e+007 Pa occur at the tip of the connecting rod which has a red color. The
rest of the part is in blue and green color which indicates stress concentration at those points are quite
less as compare to red part. In above picture results and tables we have seen Max stress occurs in
connecting rod, total deformation, mechanical safety factor and buckling safety factor which is very
important to know.
Results of mechanical safety factor and buckling safety factor is quite satisfying. Which is 3.589 and 1.23
respectively. Which means our current design is durable. But our task is to improve the design and to
improve its efficiency we will do iteration to get the best result out of it.
Connecting Rod-2 (Reverse Engineering)
At this point we have already done with analysis of connecting rod-1. And we have seen the various
results. Now our main motive to do reverse engineering. Because by this we can improve the design of
connecting rod and also increase its strength. We also want to reduce its weight. So in this reverse
engineering I removed the extra material from the bottom side of the connecting rod. As we can see in
picture. We also changed the shape of groove which is at the center of the connecting rod. By this it will
remove the extra material from the connecting rod. By doing so we removed total 0.153 Kg weight.
Which might be negligible but in mass production it will make big difference. Detailed drawing of
connecting rod-2 is given below.

FEA -2
Units
Table 18 (Units)
Unit System Metric (m, kg, N, s, V, A) Degrees rad/s Celsius
Angle Degrees
Rotational Velocity rad/s
Temperature Celsius
Model
Geometry
Table 19 (Geometry)
Object Name Geometry
State Fully Defined
Definition
Source D:\projects\Projects\connecting rod\IGES files\connecting rod
2.igs
Type Iges
Length Unit Meters
Element Control Program Controlled
Display Style Body Color

Bounding Box
Length X 2.2e-002 m
Length Y 0.21262 m
Length Z 9.e-002 m
Properties
Volume 7.6366e-005 m³
Mass 0.59948 kg
Scale Factor Value 1.
Statistics
Bodies 3
Active Bodies 3
Nodes 57669
Elements 32012
Mesh Metric None
Basic Geometry Options
Solid Bodies Yes
Surface Bodies Yes
Line Bodies No
Parameters Yes
Parameter Key DS
Attributes No
Named Selections No
Material Properties No
Advanced Geometry Options
Use Associativity Yes
Coordinate Systems No
Reader Mode Saves Updated File No
Use Instances Yes
Smart CAD Update No
Attach File Via Temp File Yes

Temporary Directory C:\Users\Vikramjit singh\AppData\Local\Temp
Analysis Type 3-D
Mixed Import Resolution None
Decompose Disjoint Faces Yes
Enclosure and Symmetry
Processing Yes
Table 20 (Geometry parts)
Object Name Part 1 Part 2 Part 3
State Meshed
Graphics Properties
Visible Yes
Transparency 1
Definition
Suppressed No
Stiffness Behavior Flexible
Coordinate System Default Coordinate System
Reference Temperature By Environment
Material
Assignment Structural Steel
Nonlinear Effects Yes
Thermal Strain Effects Yes
Bounding Box
Length X 2.2e-002 m 1.1e-002 m
Length Y 0.21262 m 3.7e-002 m
Length Z 9.e-002 m 1.2702e-002 m
Properties
Volume 7.6366e-005 m³ 2.1291e-006 m³
Mass 0.59948 kg 1.6713e-002 kg
Centroid X -1.5406e-007 m 1.0969e-009 m 1.9196e-009 m
Centroid Y 0.12039 m 0.17158 m
Centroid Z 5.7935e-007 m -3.7541e-002 m 3.7541e-002 m

Moment of Inertia Ip1 2.4432e-003 kg·m² 2.2099e-006 kg·m²
Moment of Inertia Ip2 3.222e-004 kg·m² 1.6752e-007 kg·m²
Moment of Inertia Ip3 2.156e-003 kg·m² 2.21e-006 kg·m²
Statistics
Nodes 53699 1995 1975
Elements 29912 1058 1042
Mesh Metric None
Mesh
Table 21 (Mesh)
Object Name Mesh
State Solved
Defaults
Physics Preference Mechanical
Relevance 0
Sizing
Use Advanced Size Function Off
Relevance Center Fine
Element Size Default
Initial Size Seed Active Assembly
Smoothing High
Transition Fast
Span Angle Center Coarse
Minimum Edge Length 3.6566e-004 m
Inflation
Use Automatic Inflation None
Inflation Option Smooth Transition
Transition Ratio 0.272
Maximum Layers 5
Growth Rate 1.2

Inflation Algorithm Pre
View Advanced Options No
Patch Conforming Options
Triangle Surface Mesher Program Controlled
Advanced
Shape Checking Standard Mechanical
Element Midside Nodes Program Controlled
Straight Sided Elements No
Number of Retries Default (4)
Extra Retries For Assembly Yes
Rigid Body Behavior Dimensionally Reduced
Mesh Morphing Disabled
Defeaturing
Pinch Tolerance Please Define
Generate Pinch on Refresh No
Automatic Mesh Based Defeaturing On
Defeaturing Tolerance Default
Statistics
Nodes 57669
Elements 32012
Mesh Metric None

Figure 22 (Connecting rod-2)
Figure 23 (Fixed Support)

Static Structural (A5)
Table 22 (Analysis)
Object Name Static Structural (A5)
State Solved
Definition
Physics Type Structural
Analysis Type Static Structural
Solver Target Mechanical APDL
Options
Environment Temperature 22. °C
Generate Input Only No
Table 23 (Loads)
Object Name Force Force 2 Force 3 Fixed Support
State Fully Defined
Scope
Scoping Method Geometry Selection
Geometry 2 Faces
Definition
Type Force Fixed Support
Define By Components
Coordinate System Global Coordinate System
X Component 0. N (ramped)
Y Component 1000. N (ramped) 0. N (ramped) -1000. N (ramped)
Z Component 0. N (ramped) 500. N (ramped) 0. N (ramped)
Suppressed No

Figure 24 (Force-1)
Figure 25 (Force-1)

Figure 26 (Force-2)
Figure 27 (Force-2)

Figure 28 (Force-3)
Figure 29 (Force-3)

Results-
Table 24 (Results)
Object Name Total Deformation Equivalent Stress Equivalent Elastic Strain
State Solved
Scope
Scoping Method Geometry Selection
Geometry All Bodies
Definition
Type Total Deformation Equivalent (von-Mises) Stress Equivalent Elastic Strain
By Time
Display Time Last
Calculate Time History Yes
Identifier
Suppressed No
Results
Minimum 0. m 388.6 Pa 3.9727e-009 m/m
Maximum 2.5445e-004 m 7.5746e+007 Pa 3.7876e-004 m/m
Minimum Occurs On Part 1 Part 3
Maximum Occurs On Part 1
Information
Time 1. s
Load Step 1
Substep 1

Figure 30 (Total Deformation-1)
Figure 31 (Total Diformation-2)

Figure 32 (Equivalent stress-1)
Figure 33 (Equivalent stress-2)

Figure 34 (Elastic strain-1)
Figure 35 (Elastic strain-2)

Table 25 (Stress safety tool)
Object Name Stress Tool
State Solved
Definition
Theory Max Equivalent Stress
Stress Limit Type Tensile Yield Per Material
Table 26 (Stress tool result)
Object Name Safety Factor
State Solved
Scope
Scoping Method Geometry Selection
Geometry All Bodies
Definition
Type Safety Factor
By Time
Display Time Last
Calculate Time History Yes
Identifier
Suppressed No
Integration Point Results
Display Option Averaged
Results
Minimum 3.3005
Minimum Occurs On Part 1
Information
Time 1. s
Load Step 1
Substep 1
Iteration Number 1

Figure 36 (Mechanical safety factor-1)
Figure 37 (Mechanical safety factor-2)

Table 27 (Fatigue tools)
Object Name Fatigue Tool
State Solved
Materials
Fatigue Strength Factor (Kf) 1.
Loading
Type Fully Reversed
Scale Factor 1.
Definition
Display Time End Time
Options
Analysis Type Stress Life
Mean Stress Theory None
Stress Component Equivalent (Von Mises)
Life Units
Units Name cycles
1 cycle is equal to 1. cycles
Figure 38 (Fatigue tool)

Figure 39 (Fatigue tool solution)
Table 28 (Fatigue tools result)
Object Name Safety Factor
State Solved
Scope
Scoping Method Geometry Selection
Geometry All Bodies
Definition
Design Life 1.e+009 cycles
Type Safety Factor
Identifier
Suppressed No
Results
Minimum 1.138
Minimum Occurs On Part 1

Figure 40 (Fatigue safety factor-1)
Figure 41 (Fatigue safety factor-2)

Material Data
Structural Steel
Table 29 (Material data)
Density 7850 kg m^-3
Coefficient of Thermal Expansion 1.2e-005 C^-1
Specific Heat 434 J kg^-1 C^-1
Thermal Conductivity 60.5 W m^-1 C^-1
Resistivity 1.7e-007 ohm m
Table 30 (Compressive yield strength)
Compressive Yield Strength Pa
2.5e+008
Table 31 (Tensile yield strength)
Tensile Yield Strength Pa
2.5e+008
TABLE 30.1 (Tensile ultimate strength)
Tensile Ultimate Strength Pa
4.6e+008
Table 32 (Alternating stress)
Alternating Stress Pa Cycles Mean Stress Pa
3.999e+009 10 0
2.827e+009 20 0
1.896e+009 50 0
1.413e+009 100 0
1.069e+009 200 0
4.41e+008 2000 0
2.62e+008 10000 0
2.14e+008 20000 0
1.38e+008 1.e+005 0
1.14e+008 2.e+005 0
8.62e+007 1.e+006 0

Table 33 (Strain life parameter)
Strength
Coefficient Pa
Strength
Exponent
Ductility
Coefficient
Ductility
Exponent
Cyclic Strength
Coefficient Pa
Cyclic Strain
Hardening Exponent
9.2e+008 -0.106 0.213 -0.47 1.e+009 0.2
Table 34 (Isotropic elasticity)
Temperature C Young's Modulus Pa Poisson's Ratio Bulk Modulus Pa Shear Modulus Pa
2.e+011 0.3 1.6667e+011 7.6923e+010
TABLE 33.1 (Isotropic relative permeability)
Relative Permeability
10000
Explanation-
In this analysis we have applied force of 1000N on piston side bore. Because at the time of power stroke
piston will push back the connecting rod. From above picture results we have seen that there are
maximum stresses of 7.5746e+007 Pa occur at the tip of the connecting rod which has a red color. The
rest of the part is in blue and green color which indicates stress concentration at those points are quite
less as compare to red part. In above picture results and tables we have seen Max stress occurs in
connecting rod, total deformation, mechanical safety factor and buckling safety factor which is very
important to know.
Results of mechanical safety factor and buckling safety factor is quite satisfying. Which is 3.305 and
1.138 respectively. Which is lesser then the previous design but it is efficient.
In this maximum stresses occurring at the middle part of the connecting rod because in previous FEA we
have seen that max. stresses were occurring at the tip of piston side bore. So to improve the design we
increased its wall thickness by 2mm. as a result of which now stress concentration at that point
decreases.
Comparison (Conclusion)
In this assignment we did reverse engineering of connecting rod and we find different ways to reduce its
weight so our connecting rod will become lighter in weight. We change its shape as well so we cn
improve its strength for better durability. Some of the comparison like maximum principal stress,
mechanical safety factor, fatigue safety factor. Results are given below.

Connecting Rod-1 Connecting Rod-2
Mass (Kg) 0.76861 kg 0.6329 kg
Max. stresses 6.9718e+007 Pa 7.5746e+007 Pa
Mechanical safety factor 3.5859 3.305
Fatigue safety factor 1.2364 1.138
CAM-
Process-
Make the part modelling of the connecting rod, then make the jig and fixture for connecting rod. After
that setup the machine coordinates of the part model. Then save as the part modelling in the solid
works file. Then dialog box will open, there is a option in dialog box of save as select it. Another dialog
box will be open. You have to select the origin of the part modelling file. Save it as in para solid file.
Open the VISI CAM file in the file menu. Import para solid. Dialog box will be open then open the file. In
cam navigator select the part which you want to machine it. Select the face which you want to machine.
Ex. Diameter of 25mm which has a depth of 22mm. In a cam navigator add the operation constant Z.
The process is automatically done by the VISI CAM software. In the cam navigator file operation menu
select the post processor. Finally we will get NC file.
For more details of CAM we can use NC coding file which we attached with the assignment. To do the
machining process we will simply put NC code file to the software. Then automatically it will start
machining process.
Figure 42 (Jig fixture for connecting rod)
Above picture shows the fixture of connecting rod. This fixture will hold the connecting rod when it goes
through machining process.
For more details about CAM and NC coding please check CAM files.

Reference-
1. Analysis of connecting rod using ANSYS software, ANSYS.inc
2. Design evaluation and optimization of connecting rod using FEA, International journal of
engineering & management research, vol-2, December 2012.
3. Stress analysis of con. Rod for weight reduction, a review international journal of scientific and
research publication, vol-3, June 2013.
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