Browse Publications Technical Papers 2020-28-0335
2020-09-25

Improved Calculation methodology for Design of Connecting rod considering Fatigue loads and stresses in IC Engine. 2020-28-0335

In this work, Improved design and structural calculations of connecting rod of IC engine has been performed. From the functionality point of view, connecting rod must have the higher inertia at the lowest weight. The forces acting on connecting rod are: - Peak combustion pressure force, inertia force of reciprocating masses, Weight of Reciprocating parts and frictional forces due to cylinder wall thrust. It experiences complex loading of compression and tensile under cyclic process. Design calculations are analysed for the axial compressive/ tensile loads and considering the fatigue life of connecting rod. Calculations are based on Actual Endurance limit of connecting rod. To find out Actual Endurance limit, its working temperature factor, surface finish factor, Size factor, stress concentration & reliability factor are derived and considered for calculations. To develop failure criteria, stress patterns of fluctuating loads are properly identified. Max combustion pressure occurs few degrees after flame propagation. So considered exact connecting rod inclination (Ѳ) where peak pressure occurs to calculate max compressive force on connecting rod. Length of bolt is decided using Strain Energy concept i.e Impact of Kinetic Energy of reciprocating parts will get converted into Strain Energy of the Bolt. Selection of Bolt size from IS: 1367 according to Proof Load. Effect of Inertial/acceleration force due to reciprocating mass is also considered. It works within factor of safety 2. The calculation methodology is also verified with existing connecting rods of three different engine categories, like small petrol engine, SUV diesel engine and heavy commercial Engine.

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