Failure Analysis of Connecting Rod at Big End
1
Citation
0
Reference
10
Related Paper
Citation Trend
A connecting rod is one of the most critical parts in engine assembly which transfers energy from the piston to the crankshaft. The connecting rod mainly undergoes tensile and compressive loading under engine cyclic process. The forces acting on the connecting rod are forces due to maximum combustion pressure and forces due to the inertia of the connecting rod. This research aimed to analyze the design of the connecting rod of single-cylinder four-stroke engines. This study used CAD software for modeling and structural design. Stresses generated across all the locations of the connecting rod were evaluated using FEA Software. Elastic linear analysis of model design was also performed. The simulation results in this study have led to the conclusion that failure occurred due to the incorrect selection of materials. Among all materials under study, AA 6061 is considered the most suitable material for use at high RPM. In fact, aluminum is preferable for use at high RPM.
Rod
Piston (optics)
Stroke
Tension (geology)
Crosshead
Cite
Citations (3)
The relevance of the topic of the article is due to the unresolved problem of failures of automobile engines, in particular, modern mass-produced engines of the KAMAZ-740.10, 7403 families, due to cranking of the connecting rod bearings, and the need for deeper studies of the processes and phenomena that lead to them, and the development of solutions that exclude them in operation. The purpose of the study is to ensure the reliability of automobile engines by reducing the risk of crankshaft connecting rod bearings turning in operation by developing a method for studying their shape change and applying it when substantiating and implementing various design, technological and operational solutions. A prototype is described and a developed method and device for determining the clearance in a connecting rod bearing, suitable for studying the formation of connecting rod bearings under engine test bench conditions. The prototype was a differential-type pneumatic device used in active control devices for honing cylinder liners. With the use of the described device, a method for studying the formation of connecting rod bearings under the conditions of bench tests of KAMAZ-740.10 diesel engines was developed and tested. The use of new methods, devices and techniques makes it possible to investigate the patterns of shape changes of connecting rod bearings in relation to lubrication conditions, temperature and load conditions of the engine, and other factors. The presented experimental results show that the gap in the connecting rod bearing is not stable, is caused not only by wear, but also by the resulting deflection of the liner, and significantly depends on the temperature regime of the engine - with an increase in oil temperature, the gap decreases due to an increase in deflection. The authors explain the formation of deflection and shape change of the liners by the loss of its stability from the action of loads and internal stresses under conditions of instability of the oil supply. The results of experimental studies presented in the article have a scientific novelty, since a previously undescribed and not fixed decrease in the gap due to the deflection of the liners, which is formed immediately from the start of operation after the engine is assembled, is established, and its value is variable and determined by the temperature regime. Practical significance – the developed method makes it possible to study the formation patterns of crankshaft connecting rod bearings to test the effectiveness of design, technological and operational solutions to prevent their turning during the operation of an automobile engine. The main directions of promising research is the substantiation of practical solutions to ensure the stability of the shape of the liners during long-term operation of the engine.
Main bearing
Test bench
Honing
Cite
Citations (0)
Connecting rod is one of the engine's key components which connect the piston to the crankshaft and converts the piston's reciprocating motion into the crankshaft's rotation. Connecting rod must be sufficiently strong to withstand the thrust from the piston during the combustion process. During its lifespan, it faces a lot of tensile and compressive loads. The objective of this paper is to modify the connecting rod design and changing the material of connecting rod for weight reduction possibilities. Model of the connecting rod is designed with the help of INVENTOR and analysis was performed by using ANSYS.
Reciprocating motion
Piston (optics)
Piston rod
Crosshead
Cite
Citations (4)
Samand is one of the numerous vehicles in Iran. Also this vehicle is national vehicle of Iran. Above reasons necessitate a complete research about different component of engine of this vehicle. In this study, detailed load analysis was performed for connecting rod of Samand engine, after that in order to calculate stress in connecting rod, the connecting rod was modeled then was meshed and finally calculated forces were exerted on connecting rod in ANSYS software. The maximum stresses in different parts of Samand connecting rod were determined. Results of this research can be effective for optimization of connecting rod.
Cite
Citations (0)
The automobile engine connecting rod is a high volume production and critical component. 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. Generally
connecting rods are manufactured using carbon steel and in recent days aluminium alloys are finding its
application in connecting rod. In automotive engines, the connecting rod is subjected to high cyclic loads. These are
represented by high compressive loads due to combustion, and high tensile loads due to the connecting rod mass of
inertia. The main objective of this study is to review the weight optimization of a connecting rod in an automobile
engine. To get the idea about designing the connecting rod, various stresses to be considered while designing the
connecting rod and different materials used and comparing the result of all materials. To know the different
software and Finite Element Method (FEM) packages useful for the modeling and analysis of connecting rod.
Crank
Piston (optics)
Reciprocating motion
Rod
Piston rod
Cite
Citations (3)
The automobile engine connecting rod is a high volume production, critical component. It connects reciprocating piston to rotating crankshaft, transmitting the thrust(power) of the piston to the crankshaft. Every vehicle that uses an internal combustion engine requires at least one connecting rod depending upon the number of cylinders in the engine. Connecting rods for automotive applications are typically manufactured by forging from either wrought steel or powdered metal. They could also be cast. Here unwanted stresses found on crank and piston ends of connecting rod while transmitting power from piston to crankshaft. The main objective of this study was to explore weight and cost reduction opportunities for a production forged wrought steel and Composite HM Carbon/Epoxy connecting rods. This has entailed performing a detailed load analysis. The most important factors that are concentrated are stress distribution and deflections. Connecting rod is designed by Unigraphics software and Ansys software is used for analysis of connecting rod.
Piston (optics)
Crank
Rod
Piston rod
Reciprocating motion
Four-stroke engine
Cite
Citations (0)
In this paper, all parts of the gasoline engine connecting rod were assembled and the stress analysis was executed in two working cases of the maximum explosion pressure and the maximum inertia force based on ABAQUS. According to the simulation results from two above working cases, the engine connecting rod strength was evaluated comprehensively, which could satisfy the rod design strength requirement. And meanwhile the high cycle fatigue analysis of the connecting rod was also completed in fatigue safe module. The fatigue simulation result showed that the safety factor was greater than the specified value and the connecting rod was reliable.
Fatigue limit
Safety factor
Cite
Citations (0)
The connecting rod is one of the most important parts of an engine system. It fits in between the crosshead and the crankshaft and converts the piston’s reciprocating motion to rotary motion with the crankshaft. The connecting rod is subjected to a complex state of loading. High compressive loads and high tensile loads are due to combustion and connecting rod’s mass of inertia, respectively. This is why the connecting rod is the most stressed part of an engine system. If the engine is operating, connecting rod fails, this could cause a critical situation. Therefore, the connecting rod should be able to withstand tremendous load and transmit a great deal of power smoothly. In general, the failure occurs at the big end of connecting rod. Hence, the connecting rod’s big end corner radius was taken as a design variable. Also, three dimensional finite element analyses were performed. From these results, the stress distribution was estimated and the value of the corner radius was optimized.
Reciprocating motion
Crosshead
Piston (optics)
Crank
Rod
Piston rod
Cite
Citations (5)
Cite
Citations (0)
Connecting rod are found in most combustion engines and transmits thrust from the piston to the crankshaft. The connecting rod needs to withstand forces from the piston and inertia forces which res ...
Piston (optics)
Rod
Piston rod
Cite
Citations (0)