International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395 -0056
Volume: 04 Issue: 03 | Mar -2017
p-ISSN: 2395-0072
www.irjet.net
Experimental Stress Analysis and Optimization of Connecting Rod Ghadoje Sagar S1, Gite Hemant S2, Gawali Dipak P3 , Gayke Dnyaneshwar S.4 Mechanical Engineering 1,2,3,4, SND COE & RC, Yeola1,2,3,4 Email: ghadoje4engg@gmail.com1,hemant.gite95@gmail.com2 dipakgawali59@gmail.com3, gaikednyan025@gmail.com4 ---------------------------------------------------------------------***---------------------------------------------------------------------
Abstract - The main objective of this study was to explore
structural analysis for static load to check stresses, deformation, strain locations & second part of project is topology optimization for mass reduction without much altering strength using CAE tool (Ansys). Experimental is carried out by machining existing connecting rod as per topological optimization using EDM. Strain gauge will be mounted at high strain location on the connecting rod defined from FEA to get deformation while testing on UTM.
weight and cost reduction Opportunities for a production forged steel connecting rod. This has entailed performing a detailed load analysis. Therefore, this study has dealt with two subjects, first, stress analysis of the connecting rod, and second, optimization for weight and cost. It is the conclusion of this study that the connecting rod can be designed and optimized under a load range comprising tensile load corresponding to 360o crank angle at the maximum engine speed as one extreme load, and compressive load corresponding to the peak gas pressure as the other extreme load.
2. OBJECTIVES (1) (2) (3) (4)
Modeling current connecting rod. Analyzing for stresses and deformation. Topological optimization for the model. Analyzing for stresses and deformation on optimized model. (5) Results from topological optimization will be implemented on existing model. (6) Machining the existing connecting rod as per optimization result. (7) Mounting strain gauge on same portion. (8) Preparing fixtures to hold connecting rod for experimental testing. (9) Correlating results of both CAE and experimental
Key Words: Connecting Rod, Finite Element Analysis, Stress, optimization, Design .
1. INTRODUCTION Connecting rod is the intermediate link between the piston and the crank. And is responsible to transmit the push and pull from the piston pin to crank pin, thus converting the reciprocating motion of the piston to rotary motion of the crank. Connecting rods manufactured by forging either from wrought steel or powdered metal. They could also be cast. However, castings could have blow-holes which are detrimental from durability and fatigue points of view. The fact that forgings produce blow-hole-free and better rods gives them an advantage over cast rods. Between the forging processes, powder forged or drop forged, each process has its own pros and cons. Powder metal manufactured blanks have the advantage of being near net shape, reducing material waste. However, the cost of the blank is high due to the high material cost and sophisticated manufacturing techniques. With steel forging, the material is inexpensive and the rough part manufacturing process is cost effective. Bringing the part to final dimensions under tight tolerance results in high expenditure for machining as the blank usually contains more excess material. The connecting rod can be designed and optimized under a load range, corresponding to 360o crank angle at the maximum engine speed as one extreme load, and compressive load corresponding to the peak gas pressure as the other extreme load. In this project we are going to model the connecting rod using CAD tool (CATIA V5) to do static
© 2017, IRJET
|
Impact Factor value: 5.181
3. PROBLEM STATEMENT Connecting rods are widely used in variety of engine. Currently, connecting rods contains excess material, leads to increase in weight of the vehicle. Directly affects the mileage and cost. In this thesis, modeling existing connecting rod in CAD software and analyzing it for induced stresses and deformation in CAE software. Then using Topology optimization material will be removed. Again, analysis will be done on optimized model for stresses and deformation. It is also tested experimentally and results were correlated it with analysis results.
3.1 Engine & Transmission Specification
|
Engine: Cummins 6BTAA, DI Turbocharged, with Viscous fan Emission Norms: BSIII Engine Cylinders: 6 Displacement (cc): 5883
ISO 9001:2008 Certified Journal
|
Page 1681