Indian Institute of Technology Roorkee Mechanical & Industrial Department

INDIAN INSTITUTE OF TECHNOLOGY ROORKEE
MECHANICAL & INDUSTRIAL DEPARTMENT
MIN-291 - Engineering Analysis And Design
PROJECT REPORT
TOPIC: CRANKSHAFT AND CONNECTING ROD
GROUP NO.(28) MEMBERS:- PRESENTED TO:-

SHASHI KUMAR DR. AVINASH PARASHAR
SHIVAM KUMAR Assistant Professor
SHIVAM JEE MIED
SHREY SHUKLA
SHUBHAM JAIN
SHUBHAM MALVIYA
ACKNOWLEDGEMENT
We would like to express our deepest appreciation to all those who provided
us the responsibility to complete this report. A special gratitude to Dr. Avinash
Parashar, whose contribution in simulating suggestions and encouragement,
helped us to complete this project.
Secondly, we would like to thank our team members for their immense
support and coordination during the whole timeline of preparation of this
project report.
CONTENTS
1. Abstract
2. Introduction
3. Modelling Detail
4. Results And Discussion
5. Conclusion
6. References
1. Abstract
Safety aspect in the automotive engineer is of prime importance.

The connecting is the intermediate member between the piston and
the Crankshaft. Its primary function is to transmit the push and pull
from
Crankshaft and Connecting rod are an integral part of Internal

Combustion Engine. The main function of the IC engine is to transmit
the energy to the crankshaft through the connecting rod.
Structural analysis is used to determine displacements and stresses

under static and buckling loads.
The aim of this project is to model and assemble the connecting rod
and crankshaft for a 150cc Engine by theoretical calculation & the
structural analysis of Crankshaft and Connecting rod. The scientific
calculations prove the conditions required for the optimised size of
the connecting rod.
2. Introduction
Internal combustion engines are seen every day in automobiles, trucks, and buses. Spark
ignition engines take a mixture of fuel and air, compress it, and ignite it using a spark
plug. The name `reciprocating' is given because of the motion that the crank mechanism
goes through. The piston-cylinder engine is basically a crank-slider mechanism, where
the slider is the piston in this case. The piston is moved up and down by the rotary
motion of the two arms or links. The crankshaft rotates which makes the two links
rotate. The piston is encapsulated within a combustion chamber. The bore is the
diameter of the chamber. The valves on top represent induction and exhaust valves
necessary for the intake of an air-fuel mixture and exhaust of chamber residuals. In a
spark-ignition engine, a spark plug is required to transfer an electrical discharge to ignite
the mixture.
2.1 Connecting Rod

In a reciprocating piston engine, the connecting rod connects the piston to the crank or
crankshaft. The small end attaches to the piston pin, gudgeon pin or wrist pin & big end
connects to the bearing journal on the crank throw, running on replaceable bearing
shells accessible via the connecting rod bolts which hold the bearing "cap" onto the big
end; typically there is a pinhole bored through the bearing and the big end of the con
rod so that pressurized lubricating motor oil squirts out onto the thrust side of the
cylinder wall to lubricate the travel of the pistons and piston rings.
2.2 Crankshaft
The crankshaft, sometimes casually abbreviated to crank, is the part of an engine which
translates reciprocating linear piston motion into rotation. To convert the reciprocating
motion into rotation, the crankshaft has "crank throws" or "crankpins", additional
bearing surfaces whose axis is offset from that of the crank, to which the "big ends" of
the connecting rods from each cylinder attach. It typically connects to a flywheel, to
reduce the pulsation characteristic of the four-stroke cycle, and sometimes a torsional or
vibrational damper at the opposite end, to reduce the torsion vibrations often caused
along the length of the crankshaft by the cylinders farthest from the output end acting
on the torsional elasticity of the metal.
3. Modelling
3.1 Software used: Dassault Solidworks (2016/2018)
3.2 Dimensions: Before proceeding to design a connecting rod, we need to

perform certain calculations to obtain the required dimensions.
Length of connecting rod (L) = 2 times the stroke = 2*58.6 mm = 117.2 mm
Radius of crank (r) = stroke length/2 = 58.6 mm/2 = 29.3 mm
S.no. Parameters(mm)
1. The thickness of the connecting rod = 3.4
2. Width of the section (B = 4t) = 12.8
3. Height of the section (H = 5t) = 16
4. Height at the big end = 1.1H to 1.125H = 17.6
5. Height at the small end = 0.9H to 0.75H = 14.4
6. The inner diameter of the small end = 17.94
7. The outer diameter of the small end = 31.94
8. The inner diameter of the big end = 23.88
9. The outer diameter of the big end = 47.72
Connecting Rod 3D CAD Model
4. Analysis
4.1 Software Used: Ansys Workbench (18.1/19.2)
4.2 Shape Selection: A connecting rod is subjected to alternating direct compressive

and tensile forces. Since the compressive forces are much higher than the tensile force,
therefore the cross-section of the connecting rod is designed as a strut and the Rankine
formula is used. A connecting rod subjected to an axial load W may buckle with x-axis as
neutral axis in the plane of motion of the connecting rod, {or} y-axis is a neutral axis. The
connecting rod is considered like both ends hinged for buckling about x-axis and both
ends fixed for buckling about y-axis. A connecting rod should be equally strong in
buckling about either axis.
By applying Rankine formula and equating the moment of inertia about x and y axes:
We get, Ixx = 4*Iyy (The value is usually taken between 3 and 3.5.)
Let the thickness of flange & web of the section = t
Width of section B= 4t
Since the value of Ixx/Iyy lies between 3 and 3.5 m therefore I-section chosen is quite
satisfactory.
4.3 Material selection and manufacturing
In mass-produced automotive engines, the connecting rods are most usually made of steel.
Other materials include T6-2024 aluminium or T651-7075 aluminium alloy, which are used
for lightness and the ability to absorb high impact at the expense of durability. Titanium is a
more expensive option which reduces the weight. Cast iron can be used for cheaper, lower
performance applications such as motor scooters. In our analysis of this project, we have
used forged steel due to its high strength to weight ratio compared to other steels and
low cost compared to titanium.
In high-performance applications, "billet" connecting rods can be used, which are machined
out of a solid billet of metal, rather than being cast or forged.
Properties of forged steel
4.4 Pressure Calculation for 150cc Engine

Bore x Stroke (mm) = 57×58.6
Displacement = 149.5 CC
Density of Petrol C8H18 = 737.22 kg/m3 = 737.22 * 109 kg/mm3
Temperature = 60 °F = 288.855 K
Mass = Density × Volume = 737.22 x 149.5 * 10-6 = 0.11kg
Molecular Weight of Petrol = 114.228 g/mole
From Gas Equation we know that:
PV = (m/M) *R*T
= (0.11/0.114228) *8.314*288.85
P = 2312.61/149.5*10-6
= 15.469 MPa
F = (π/4)*572*15.469 = 39473.156 N
4.5 Ansys Details
5. Results
 The material used for connecting rod and crankshaft analysis –
Forged steel
 Maximum Pressure on Piston – 15.469 MPa
 Maximum Force applied by gas on Piston – 39473.156 N
 The factor of safety of Connecting Rod (Von Misses criteria) – 1.411
 The factor of safety of Connecting Rod (Tresca criteria) – 1.384
 The factor of safety of Crank Shaft (Von Misses criteria) – 1.7509
 The factor of safety of Crank Shaft (Tresca criteria) – 1.517
6. Conclusion
We analysed the different shapes of the connecting rod as well as that of
the crankshaft and concluded that I cross-section gives the value that is
suitable for use.
We concluded that titanium is too costly a metal to
be used and aluminium is too weak a metal to be used. We, thus settled
for different types of steel and out of them forged steel was chosen for
analysis based on its favourable properties.
We also analysed how a
little amount of change in the thickness of the connecting rod has a
notable effect on the factor of safety of the material.
7. References
 Assembly Analysis of Piston, Connecting Rod & Crankshaft

International Journal of Science and Research (IJSR)
ISSN (Online): 2319-7064
 Design And Analysis of Connecting Rod Using Forged steel
International Journal of Scientific & Engineering Research, Volume 4,
Issue, ISSN 2229-5518
 Material Optimization and Structural Analysis Of Internal Combustion
Engine Connecting Rod And Crank Shaft
International Journal of Scientific & Engineering Research, Volume 4
Issue 11 | ISSN: 2349-6002
 https://en.wikipedia.org/wiki/Connecting_rod

Indian Institute of Technology Roorkee Mechanical & Industrial Department

Uploaded by

Document Informationclick to expand document information

Copyright:

Available Formats

Indian Institute of Technology Roorkee Mechanical & Industrial Department

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Indian Institute of Technology Roorkee Mechanical & Industrial Department

Uploaded by

Copyright:

Available Formats

INDIAN INSTITUTE OF TECHNOLOGY ROORKEE

MECHANICAL & INDUSTRIAL DEPARTMENT

MIN-291 - Engineering Analysis And Design

TOPIC: CRANKSHAFT AND CONNECTING ROD

GROUP NO.(28) MEMBERS:- PRESENTED TO:-

Safety aspect in the automotive engineer is of prime importance.

Crankshaft and Connecting rod are an integral part of Internal

Structural analysis is used to determine displacements and stresses

2.1 Connecting Rod

3.2 Dimensions: Before proceeding to design a connecting rod, we need to

4.1 Software Used: Ansys Workbench (18.1/19.2)

4.2 Shape Selection: A connecting rod is subjected to alternating direct compressive

4.4 Pressure Calculation for 150cc Engine

 Assembly Analysis of Piston, Connecting Rod & Crankshaft

You might also like