Stress Analysis and Weight Optimization of Connecting Rod Reinforced with AL based Composites-FEA Approach

The automobile engine connecting rod is a major link inside of an internal combustion engine. It is the intermediate member between the piston and the crankshaft. Its primary function is to transmit the push and pull from the piston pin to the crankpin and thus convert the reciprocating motion of the piston into rotary motion of the crank. Previously connecting rods are manufactured using cast iron but now days AL based alloys finds wide application in manufacturing the connecting rod. In the present study, FEM analysis is carried out by considering two materials viz. cast iron and Al based composite material reinforced with the boron carbide with addition of some amount of fly ash. The parameters like von misses stress, strain and displacements were obtained from ANSYS software. Compared to cast iron the new material found to have less weight (reduction of 70-75%), with more stiffness and 75-80% reduction in displacement.