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Super-knocking event generates high pressure pulse in gasoline engine, the predominant failure mode in these cases is connecting rod buckling. Two major factors which affects the bucking strength of connecting rod are shank dimensions and load offset in crankpin axis. There are standard methods available for calculating buckling strength of connecting rod such as Johnson’s buckling equation, Eigenvalue method, Merchant-Rankine formula etc. Each of these methods have pros and cons. But no method caters to all the considerations accurately such as section variation in shank, load offsets, local material plasticity and geometric nonlinearity as in bending preceded by buckling. In present paper, a new methodology is developed using FEA to evaluate the connecting rod buckling strength and post buckling deformation. Comparison with eigenvalue method and theoretical results are presented. Study related to buckling load sensitivity for load offset is also presented.

With the increasing need to have faster product development and yet achieve the optimum design, thrust on accurate FEA of components and system is felt. The connecting rod is an important component of the crank train and it has a significant mass contribution in multi-cylinder engine. Principal focus is directed to connecting rods having load ratio greater than or equal to 2. As the connecting rod operates in elastic range (i.e. high cycle fatigue life region) stress life approach is adopted for fatigue life evaluation. The three fold purpose of this paper is to establish an accurate FE modelling technique and analysis procedure that simulates the test conditions, aids in accurate fatigue life prediction and most importantly provides a simple procedure for virtual validation of connecting rod. To achieve this objective static strain measurement and fatigue test of connecting rod is carried out on a test bench.