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Design, Analysis and Optimization of Four Stroke S.I. Engine Connecting Rod using Finite Element Analysis with the help of CAE and CAD software

Author(s):

ANKIT KUMAR PANDEY , Samrat Ashok Technological Institute, Vidisha; PROFF. SANDEEP JAIN, Samrat Ashok Technological Institute, Vidisha; Dr. LOKESH BAJPAI, Samrat Ashok Technological Institute, Vidisha

Keywords:

S.I. engine connecting rod; weight optimization; Static structural analysis; CAE and CAD

Abstract

The aim of this paper is to design, analysis and optimization of connecting rod which is stronger and light-weight with respect to existing connecting rod with the help of CAE and CAD Software. Static structural analysis is done to analyze stresses, strain, total deformation and factor of safety distribution in various parts of the connecting rod to known the effect due to maximum compressive loading using ANSYS 16.2. Solid parametric models of connecting rod have been made using CATIA V5R20. In this study advance materials, aluminium alloy A16T, titanium alloy Ti-6Al-4V, and carbon-fibre reinforced polymer material are used to replace the existing material of connecting rod. These materials have very high strength in compression as well as in tension and have low density 3 to 4 times less than existing forged steel material. Therefore, by replacing existing connecting rod material (forged steel) with these advance materials connecting rod weight will reduce and factor of safety will increase. Shape optimization module is used for weight optimization of the existing connecting rod. Fatigue analysis is done for aluminium alloy connecting rod. Connecting rod made of aluminium alloy A16T, titanium alloy Ti-6Al-4V and carbon-fibre reinforced polymer material has weight reduction percentage with respect to existing material (forged steel) is 59.12%, 48.59% and 77.01% respectively. Factor of safety for connecting rod made of forged steel, aluminium alloy A16T, titanium alloy Ti-6Al-4V and carbon-fibre reinforced polymer material is 1.8348, 1.1562, 2.2056 and 2.4299 respectively. Fatigue life for aluminium alloy connecting rod under the effect of extreme peak compressive gas loading is 99507 cycles and when load is half its minimum life is 108 cycles.

Other Details

Paper ID: IJSRDV4I70123
Published in: Volume : 4, Issue : 7
Publication Date: 01/10/2016
Page(s): 133-140

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