International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395 -0056
Volume: 04 Issue: 03 |Mar -2017
p-ISSN: 2395-0072
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Finite element analysis of polymer based automotive connecting rod 1Raj
kumar, 2Nishant Saxsena, 1Arvind Singh
1Department
of Mechanical Engineering
²Assistant Professor & Head of Mechanical Department Millennium Institute of Technology (MIT), Bhopal, M.P. (India) ---------------------------------------------------------------------***------------------------------------------------------------------Abstract - The research has been done for finite element analysing the polymer based composite material connecting rod. The connecting rod of light weight engines undergoes in high stresses, which causes fatigue failure and buckling effects. Finally damages and break the connecting rods. To overcome with such effects, the conventional material for manufacturing the connecting rod for light weight internal combustion(IC) engines has been compared and replaced by carbon fiber reinforced polymer (PEEK, Polyetheretherketon) which contain 40% of carbon fibers. The connecting rod ‘conrod’ has been analyzed on light weight engine (HONDA CD110 motorbike) before performing the experiment on large scale engines. The 3-dimensional model made on CATIA V5R16 and analyzed on ANSYS17.0. Experiment performed by undertaking a load of 6500N axially on piston pin of connecting rod. The paper discusses the various parameters affecting the connecting rod and defines the better suitability of composite material over conventional material.
the validation of rod’s theoretical data by its practical data by means of calculations. The rod is subjected to axial load along the X-axis of the plane of rod, keeping degree of freedom constant along Y-axis. Generally, in light weight vehicles with the displacement of 100-300cc, the 3-4Mpa of pressure is generated by combustion of gases, which forces the piston down for reciprocating motion.
2.
Webster et al. (1983)[3] performed three dimensional finite element analysis of a high-speed diesel engine connecting rod. For this analysis they used the maximum compressive load which was measured experimentally, and the maximum tensile load which is essentially the inertia load of the piston assembly mass. The load distributions on the piston pin end and crank end were determined experimentally. They modeled the connecting rod cap separately, and also modeled the bolt pretension using beam elements and multi point constraint equations.
Key words: PEEK, ANSYS, CATIA, fatigue strength, alloy steel, composites, carbon fibers. 1.
Literature survey
Folgar et al. (1987)[4] developed a fiber FP/Metal matrix composite connecting rod with the aid of FEA, and loads obtained from kinematic analysis. Fatigue was not addressed at the design stage. However, prototypes were fatigue tested. The investigators identified design loads in terms of maximum engine speed, and loads at the crank and piston pin ends. They performed static tests in which the crank end and the piston pin end failed at different loads. Clearly, the two ends were designed to withstand different loads.
IINTRODUCTION
The connecting rod plays an important role in the internal combustion engines. It transmits the power from piston to the crankshaft in fractions of seconds. The overall power and speed of engine depends on connecting rod, its dimensions, its materials and various factors, which effect or contribute in working of connecting rod. If we succeeded in designing efficient and light weight connecting rod, then we can achieve the maximum, almost 100% mechanical efficiency, without any losses. It all depends on the depth of research and innovation, a keen work is required to be done to achieve an ideal connecting rod. Only technology could not resolve and conclude the desired results.
In a study reported by Repgen (1998)[5], based on fatigue tests carried out on identical components made of powder metal and C-70 steel (fracture splitting steel), he notes that the fatigue strength of the forged steel part is 21% higher than that of the powder metal component. He also notes that using the fracture splitting technology results in a 25% cost reduction over the conventional steel forging process. These factors suggest that a fracture splitting material would be the material of choice for steel forged connecting rods. He also mentions two other steels that are being tested, modified micro-alloyed steel and a modified Alloy Steel SAE-AISI 8620.
Therefore, the most advance PEEK composite i.e. Victrex PEEK90HMF40 [1] containing 40% of carbon fibers, has been selected to replace the conventional ferrous material (AISI-8620 Alloy steel) [2] connecting rod. The following PEEK possesses high wear resistance capacity as well as high strength. The following material can also withstand at high amplitude of buckling and fatigue effects. To perform accurate analysis, the exact replica of rod have been tried to recreate using CATIA V5R16. It also possesses
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