Optimization of Connecting Rod for Weight Reduction by Finite Element Analysis

The main objective of this work is to explore weight and cost reduction opportunities in the design and production of a connecting rod, achieved by performing a detailed load analysis. The study deals with load and stress analysis of the connecting rod is done and then optimization is achieved by reducing the weight and cost. First part of the study analysis includes the determination of loads acting on the connecting rod as a function of time. This is done for finding out the minimum stress area and to remove the material in those areas. The relationship between the load and acceleration of the connecting rod for a given constant speed of the crankshaft are also determined. Finite element analysis was performed at several crank angles. The connecting rod can be designed and optimized under the loads ranging from tensile load, corresponding to 360 degree crank angle at the maximum engine speed as one extreme load and compressive load corresponding to the peak gas pressure as the other extreme load. Modal analysis is performed in order to find out the natural frequencies. Furthermore, the existing connecting rod material is replaced with a new composite material. The fracture crack ability feature facilitates separation of cap from rod without additional machining of the mating surfaces. Yet, the same performance can be expected in terms of component durability. This aspect is considered in this work and the connecting rod is optimized by reducing the weight and cost