International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056

Volume: 04 Issue: 09 | Sep -2017 www.irjet.net p-ISSN: 2395-0072

REVIEW ON DESIGN AND ANALYSIS OF TWO WHEELER

CONNECTING ROD
Mansi S.Satbhai1, P.S.Talmale2

1Research Scholar, Mechanical Engineering, Late G.N.Sapkal COE, Nashik, Maharashtra,India.

2 Assistant Professor, Mechanical Engineering, Late G.N.Sapkal COE, Nashik, Maharashtra,India.
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Abstract - A Connecting rod is the link between the 1.1. OBJECTIVE
reciprocating piston and rotating crank shaft. Small finish
of the connecting rod is hooked up to the piston by the use of This paper focus on the literature review associated with
gudgeon pin. The operation of the connecting rod is to the design and analysis of connecting rod.
convert the reciprocating movement of the piston into the
rotary movement of the crankshaft. This work focus on the 2. LITERATURE SURVEY
experimental investigation of connecting rod of Pulsar-220
for weight optimization with enhancement in existing This chapter sets the background for up-coming sections.
design. In this work the attempt is to modify the existing It is an assessment of the present state of art of the wide
design of connecting rod by satisfying the desired design and and complex field of optimization of electro discharge
application constraints by the brief literature review. With machining by design of experiment and its application. In
the brief literature review methodology is formulated and addition, this chapter separately reviews what did in the
the modified connecting rod design is proposed for the past in the area of application.
modification of connecting rod for the Pulsar.
Sarkate et al [1] had carried out the study concluded that
Key Words: chemical composition, desired constraints. the stress analysis of connecting used in engine has been
presented and discuss in this paper. The results obtain by
1. INTRODUCTION FEA for both Aluminum 7068 alloy and AISI 4340 alloy
steel are satisfactory for all possible loading conditions. By
A Connecting rod is the link between the reciprocating using Aluminum 7068 alloy instead of AISI 4340 alloy
piston and rotating crank shaft. Small finish of the steel can reduce weight up to 63.95%. Also equivalent
connecting rod is hooked up to the piston by the use of stresses for Aluminum 7068 alloy is less by 3.59%. The
gudgeon pin. The operation of the connecting rod is to factor of safety of connecting rod will reduce by 9.77% in
convert the reciprocating movement of the piston into the case tensile load applied at crank end but it will increase in
rotary movement of the crankshaft. A blend of axial and all other load conditions if Aluminum7068 alloy is used
bending stresses act on the rod in operation. The axial instead of AISI 4340.
stresses are produce due to cylinder fuel strain and the
inertia force bobbing up on account of reciprocating Anusha et al [2] had carried out study on “Comparison of
motion. Whereas bending stresses are triggered due to the Materials For Two-Wheeler Connecting Rod Using Ansys”
centrifugal effects. To furnish the highest stress with The modeled connecting rod imported to the analysis
minimal weight, the move element of the connecting rod is software i.e. ANSYS. Static analysis is done to determine
made as I – part. Small finish of the rod is a superior eye or von-misses stresses, strain, shear stress and total
a break up eye, this end holds the piston pin. The big finish deformation for the given loading conditions using
relaxation on the crank pin and are continuously cut up for analysis software i.e. ANSYS. In this analysis two materials
heavy engines. In some connecting rods, a hole is drilled are selected and analyzed. The software results of two
between two ends for carrying lubricating oil from the big materials are compared and utilized for designing the
finish to the small finish for lubrication of piston and the connecting rod.
piston pin. The intermediate component between crank
and piston is known as connecting rod. The objective of CR Kumar et al. [3] analyzed Two Wheeler Connecting Rod. In
is to transmit push & pull from the piston pin to the crank this work connecting rod was replaced by Aluminum
pin and then converts reciprocating motion of the piston reinforced with Boron carbide for Suzuki GS150R
into the rotary motion of crank motorbike. A 2D drawing was drafted from the
calculations. A parametric model of connecting rod was
modeled using PRO-E 4.0 software. Analysis was carried
out by using ANSYS software. Finite element analysis of
connecting rod was done by considering two materials,
viz. Aluminum Reinforced with Boron Carbide and
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 International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 04 Issue: 09 | Sep -2017 www.irjet.net p-ISSN: 2395-0072

Aluminum 360. The best combination of parameters like It is found that, traditional frequency of Aluminium LM9
Von misses stress and strain, Deformation, Factor of safety connecting rod is bigger than current carbon steel
and weight reduction for two wheeler piston were done in (16MnCr5) connecting rod. Additionally it is located that
ANSYS software. Compared to carbon steel, aluminum the Aluminium LM9 connecting rod is gentle in weight
boron carbide and aluminum 360, Aluminum boron than present carbon metal (16MnCr5) connecting rod.
carbide is found to have working factor of safety is nearer
to theoretical factor of safety, 33.17% to reduce the Herakal & Goud [8] carry out study in order to analyze the
weight, to increase the stiffness by 48.55% and to reduce rod under the fatigue load by using the fully reversed
the stress by10.35% and most stiffer. loading condition. To check out the behavior of rod under
the fatigue load with Goodman’s criteria &to check out the
Sahu & Jayant [4] had carried out study for a contact up to how many cycle it can work without failure. From
analysis is to be carried out to analyze the stresses arising the experiment it s concluded by the stress analysis that,
from the interference of the connecting-rod bearing and maximum stress is at the small region. Also maximum
the piston-pin bushing.. It’s been found that most of the stress is at the small region. The connecting rod is
connecting rod of IC Engine are made of Cast iron. But on operating within the S-N curve of the structural steel so
comparison of different materials for similar boundary it’s never fail as it is working under the 105 cycles.
conditions & loading conditions it’s been observed that out
of the three materials Aluminum alloy is the most suitable Singh[9] had conducted study replace the conventional
material on the basis of Stress, Safety factor, Life, Thermal material of connecting rod i.e., steel with the Composite
Resistivity, fatigue & damage because such connecting rod material (E-Glass/ Epoxy). In this study von misses
does not fails even at varying loads unlike Cast iron rod stresses, deformations and other parameters are
And by using aluminum alloy we can also reduce the ascertained which has been done by doing the FEA of the
weight of the connecting rod. connecting rod. Linear static analysis was performed on
MSC.PATRAN of the connecting rod for the conventional as
Ramakrishna & Venkat esh [5] had carryout study of well as for the E-Glass/Epoxy to get the varied results. On
connecting rod of LML freedom is studied for the comparing the von-misses stresses in the two materials it
optimization of the material can be reduced by changing was found that there is reduction of 33.99% of stresses
the material of the current 4340 alloy steel connecting rod when convention steel was replaced with the orthotropic
to AlSiC-9. The optimized connecting rod is 61.6560% E-Glass/Epoxy. For connecting rod it is suggested to
lighter than the current connecting rod. replace Conventional steel with E-Glass/Epoxy. When the
Displacement component was compared, again there was
Reddy et al [6] had carried out study to determine Von reduction of 0.026% displacement when material used
misses stress and pressure, deformation, aspect of defense was E-Glass/Epoxy
and weight discount for two wheeler pistons and
concluded that Fatigue strength is the principal driving Agarwal et al [10]The objective of present study is carried
factor for the design of connecting rod and it's determined out the analysis of a two wheeler connecting rod of
that the fatigue results are in good agreement with the different materials and making a meaningful comparison
present outcomes. The stress is determined maximum on among results of analysis, which can be helpful for getting
the piston finish so the material is improved within the suitable material for the manufacturing of connecting rod.
stressed portion to shrink stress. Study also incorporates the fabrication of material by
changing the chemical constituents to find the new
Jaganathan & Dinesh [7] studied the Modal analysis material. A comparative study is made between Forged
method is used to determine natural frequencies of a Steel, Titanium Alloy, and Aluminium Alloy 7075. The
connecting rod and compare results with FFT analyzer. results show that Aluminium Alloy 7075 is having lesser
This work investigated suitable better fabric for value of Von-Mises Stress and Strain, so it is chosen for
connecting rod. Modal evaluation used to be performed to further study. Next the fabrication of materials by
the connecting rod with laptop centered FEA simulation changing the Silicon and Aluminium percentage in
instruments. EMA used to be then carried out using FFT Aluminium 7075 is done and mechanical properties are
analyzer to search out ordinary frequencies of connecting find out using tensile testing. Then analysis is performed
rod. The following conclusions may also be drawn from to evaluate Von-Misses stress and Strain against the
this be taught. The natural frequencies decided with the mechanical properties increasing the Silicon percentage to
aid of utilizing FEA procedure are almost much like the some extent in Aluminium Alloy, the Stress and Strain get
common frequencies decided via utilizing EMA approach reduced
for current carbon metal (16MnCr5) connecting rod. The
common frequencies determined by utilizing FEA process Gupt & Nawajis [11] in this work existing connecting rod
are nearly just like the traditional frequencies decided by material is replaced by beryllium alloy and magnesium
utilizing EMA method for Aluminium LM9 connecting rod. alloy. Maximum von misses strain and Maximum

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 International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 04 Issue: 09 | Sep -2017 www.irjet.net p-ISSN: 2395-0072

displacement is minimum in connecting rod of Beryllium Al-7068 connecting rod is 0.0052979 mm/mm. Shear
alloy in comparison of rest of two materials comparing the stress for C-70 connecting rod is 214.51 MPa and Al-7068
different results obtained from the analysis. The stress connecting rod is 202.08 MPa. The reduction of shear
induced in the Beryllium alloy is less than other for the stress is 5.79%. The bending stress of C-70 connecting rod
present investigation. Here beryllium alloy can be used for is 230.63 MPa and Al-7068 is 229.47 MPa. The reduction
production of connecting rod for long durability. in bending stress is 0.5%. The reduction of mass is 63.61%
by using Al-7068 material connecting rod.
Aishwarya and Ramanamurthy [12] paper describes about
a real time problem of using Cast Iron connecting rod in Peeyush & Sethi [15] had carried out study on the design
Hero Honda Splendor + motorbike it’s modeling and evaluation of connecting rod using FEM for high cycle
analysis and optimization of connecting rod. Here, the fatigue strength. From the study that the following
connecting rod is replaced by various materials like conclusions are drawn from high cycle fatigue behavior of
stainless steel, aluminium, C70 steel and also a design connecting rod, Mean and alternating stresses calculated
change by inducing truss member is suggested. This work for the connecting rod are on a moderate level. Resulting
also tends to optimize the design by calculating weight and factors of safety are uncritical at shank of Connecting rod.
stiffness for various materialistic designs by using the The required minimum factor of safety is 1.5. The
output values of mass and volume of the connecting rod. occurring minimum is 1.71 at the connection between
From that they concluded that A truss type connecting rod shank and big end. The results obtained are logical and can
modeling is done using CATIA software and the feasible be used to improve or modify the parts, shapes and
parameters are been obtained. From the analysis it is clear performance of the whole
that the stress and strain obtained by the modified design
is less when compared to the existing design. Weight Bagri & Telang [16] Focus on optimized value for shank
reduction can be clearly viewed in the comparison graph fillet radius to reduce maximum equivalent von misses
between the solid and truss design. stress by Parametric optimization it is found that shank
fillet radius has big influence on the stress distribution on
Ram et al [13] in this Static analysis is carried out on the the shank portion of the connecting rod. It was found that
piston pin end and crank pin end of connecting rod then at shank fillet radius of 20mm get the minimum von
further study was show to explore weight reduction misses stress of 747 MPa compared to other parametric
possibility. It was concluded that The Peak stresses mostly studies. Modal analysis is performed with changed shank
occurred in the transition area between pin end, crank end fillet radius and reduced deformation was observed in the
and shank region. Forces at pin end are lower in model and compared with the initial model.
comparison to the forces in crank end so strength of pin
end should ideally be lower in comparison to the strength Webster et. al. [17] was explained the loading of
of crank region. Factor of safety was greater than 3.7 in connecting rod in diesel engine. The Tension and
both tensile as well as compressive loading cases for both compression loadings were used based on experimental
original as well as optimized model. Percentage weight results. It is highest stress occurred at four location of
reduction was about 13% which will save material directly connecting rod. The upper area of cap end on the axis of
to reduce the manufacturing cost with increased engine symmetry, the transition region of bolt section and the
efficiency. lower rib, the transition region of the lower rib and
connecting rod’s bolt head. Pranav et. al. [18] carried out
Sushant, & Gambhir [14] had carried out study on the FEA and optimization of connecting rod using ANSYS
aluminum and carbon steel by FEA, When force is applied Workbench. The study two type of analysis, static analysis
at small end, von-misses stress for C-70 connecting rod is and fatigue analysis. The main objective of this study was
398.52 MPa and Al-7068 connecting rod having von- explore the weight of connecting rod. The weight
misses stress is 380.83 MPa. The reduction of von-misses reduction of achieved by 9.24% under static loading
stress is 4.43 %. The equivalent elastic strain for C-70 conditions of existing connecting rod. Pravardhan et. al.
connecting rod is 0.0021785 mm/mm and Al-7068 [19] presented the FEA procedure for optimization for
connecting rod is 0.0053424 mm/mm. Shear stress for C- connecting rod weight and cost reduction. Weight
70 connecting rod is 212.87 MPa and Al-7068 connecting reduction forged steel connecting rod by iterative
rod is 200.93 MPa. The reduction of shear stress is 5.60%. procedure. This study result was in an optimized
The bending stress for C-70 connecting rod is 205.69 MPa connecting rod 10% lighter and 25% less expensive as
and Al-7068 connecting rod is 202.58 MPa. The reduction compared to existing connecting rod. Vasile et.al.[20] Was
in bending stress is 1.5%. When force is applied at big end, presented a method used to verify the stress and
von-misses stress for C-70 connecting rod is 399.6 MPa deformation of connecting rod using FEM with ANSYS. The
and Al-7068 connecting rod is 381.48 MPa. The reduction obtained results by this method to compared results
of von-misses stress is 4.53 %. The equivalent elastic obtained by classic calculation, in similar conditions of
strain for C-70 connecting rod is 0.0020713 mm/mm and application, and after wards conclusion were drawn.

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 International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
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3. Methodology

Appli •Pulser 220 is selected

cation
•Connecting rod of available
Select dimensions is selected

•Maximim pressure & Force by

Deter considering actual dimensions
mine

Condu •Test on UTM

ct
Fig 4.1 Dimension of I section of Connecting rod
Analy •Analysis with ANSYS
sis 4.1 Determination of Thickness of Connecting Rod

•Mateial with varing compositions 38870 = (415×11t2)/[(1)+(1/7500(124.4/1.78)2)]

Select By solving above equation t = 2.94 mm
Where Kxx = (Ixx/A)(1/2)
Valida •By comparison = [(419/12)×(t4)×(1/11t2)](1/2) = 1.78t
tion For C-70 σc = 415N/mm2, .
Thus the dimensions of I section connecting rod by
considering bearing pressure of other geometrical
4. Dimensions of I Section For Connecting Rod consideration are as follows
Check section chosen is satisfactory or not is very Table 1: Dimensions of connecting rod for C-70 material
important, Connecting rod is considered like both ends
hinged for buckling about X-axis and both ends fixed for Thickness of flange(t) 2.94 mm
buckling about Y-axis. So connecting rod should be equally Width of section(B) 4*t = 11.76 mm
strong in buckling about both axes. So Ixx = 4Iyy, Where
Depth of Ht.(H) 5*t = 14.7
Ixx = Moment of inertia of the section about X-axis
Depth near beg end(H1) 1.1*H = 16.6
Iyy = Moment of inertia of section about Y-axis, Ixx is kept
Depth near Small end(H2) 0.8*H = 11.76 mm
slightly less than 4Iyy
Outer diameter of Big End 44.7 mm
Inner diameter of big end 37.16 mm
Outer diameter of Small end 22.41 mm
Inner diameter of small end 16.41 mm

5. CONCLUSIONS

1. Thus in this paper state of art literature review is

carried out, methodology is formulated.
2. Based on the methodology connecting rod with
the C-70 material is design subjected to the gas
pressure of 38.87KN.
So Section is satisfactory.
Now for dimension of I- section. The connecting rod is
REFERENCES
designed by taking the force on the connecting rod (Fp)
[1] Tukaram S. Sarkateet. al, (2013). “Optimization of Steel
equal to the maximum force on the Piston (FL) due to gas
pressure of 38.87kN Connecting Rod by Aluminum Connecting Rod Using Finite
Element Analysis”, IRD INDIA, Vol. 1, Issue 1, October,
2013

[2] B. Anusha, C.VijayaBhaskar Reddy, “Modeling and

Analysis of Two Wheeler Connecting Rod by Using Ansys”,

© 2017, IRJET | Impact Factor value: 5.181 | ISO 9001:2008 Certified Journal | Page 1058
 International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 04 Issue: 09 | Sep -2017 www.irjet.net p-ISSN: 2395-0072

IOSR-JMCE, Volume 6, Issue 5, e-ISSN: 2278-1684, May

2013.

[3]K. Sudershn Kumar, Dr. K. Tirupathi Reddy, Syed

AltafHussain“ Modeling and Analysis of Two Wheeler
Connecting Rod” International Journal of Modern
Engineering Research Vol.2, Issue.5, Sep- Oct. 2012 pp-
3367-3371.

[4] Haripriya M & Reddy K.M. “Materialized optimization

of connecting rod for four stroke single cylinder engine” 3
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[5] Ramanpreet Singh, Stress analysis of orthotropic and

isotropic connecting rod using finite element method,
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[6] Om prakash,vikas gupta,vinodmittal. Optimizing the

design of connecting rod under static and fatigue
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[7] Ram Bansal, “Dynamic simulation of connecting rod

made of aluminum alloy using finite element analysis
approach”, IOSRJournal of Mechanical and Civil
Engineering, Volume 5.

[8] Webster, W. D., Coffell R., and Alfaro D., 1983, “A Three
Dimensional Finite Element Analysis of a High Speed
Diesel Engine Connecting Rod,” SAE Technical Paper
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[9] Pranav G. Charkha and Dr. Santosh B. Jaju “Analysis

and optimization of a connecting Rod” Second
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[10] Pravardhan S. Shenoy and Ali Fatemi “Connecting Rod

Optimization for Weight and Cost Reduction”, The
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