International Journal of Analytical, Experimental and Finite Element Analysis (IJAEFEA), Issue. 1, Vol. 2, March 2015.

e-ISSN: 2394-5141, p-ISSN: 2394-5133, pp 12-16.

Size and Shape Optimization of a

Two Wheeler Connecting Rod by
Lingaraj. K. Ritti 1 Structural Analysis
[email protected]
Abstract— Connecting rod is the intermediate link between the piston and the crank and is
Pavan Kumar 2 responsible to transmit the push and pull from the piston pin to crank pin, thus converting the
[email protected] reciprocating motion of the piston to rotary motion of the crank. Connecting rod in
automotives should be lighter and lighter, should consume less fuel. In the case of four stroke
Ambarish M 3 engines, during compression and power strokes the connecting rod is subjected to compressive
[email protected] loads and during the last part of the exhaust and the beginning of the suction strokes, to tensile
loads. Since the compressive forces are much higher than the tensile force, therefore the cross-
section of the connecting rod is analyzed and optimized based on the compressive load. In this
Assistant Professors,
work two wheeler connecting rod is selected, solid edge software is used for the modelling and
Department of Mechanical ANSYS software is used for the analysis to find the stresses developed in connecting rod under
Engineering, Shri Madhwa Vadiraja static loading with compression at pin end and constraints at the crank end and these stress
Institute of Technology, values are used to perform shape optimization. Size optimization is performed by reducing the
Bantakal-574115, Udupi, India web thickness of the connecting rod to optimize the size and the further analysis is carried out
to find stress distribution, based on that shape optimization is done by considering shape
finder as a design variable, maximum stress as a constraint and mass reduction as an objective
of the connecting rod.

Index terms— Connecting rod, Finite Element Method, Size and Shape
Optimization, ANSYS.

statement of engineering design problems, the design tasks to

I. INTRODUCTION which it can be applied are inexhaustible
Size optimization involves a modification of the cross-
Connecting rod is the intermediate link between the section or thickness of finite elements. The optimization is
piston and the crank. And is responsible to transmit the carried out by mathematical optimization algorithms with
push and pull from the piston pin to crank pin, thus different objective functions e. g. maximum stiffness or
converting the reciprocating motion of the piston to rotary minimum weight. Many programming approaches were
motion of the crank. Connecting rod, automotives should tested and implemented in finite element programs or special
be lighter and lighter, should consume less fuel and at the optimization programs. Due to the easy calculation of
same time they should provide comfort and safety to sensitivities for size optimization purposes even realistic
passengers, that unfortunately leads to increase in weight problems can be handled. Today these approaches can be
of the vehicle. This tendency in vehicle construction led considered as state of the art.
the invention and implementation of quite new materials The basic concept of shape optimization design is to place
which are light and meet design requirements material in areas that truly need it and thin out unnecessary
In the case of four stroke engines, during compression material from areas that are not important for correct function
and power strokes the connecting rod is subjected to in order to obtain the minimum shape that satisfies all the
compressive loads and during the last part of the exhaust necessary functional requirements, such as mechanical
and the beginning of the suction strokes, to tensile loads. strength and rigidity. Spurred by the lightening needs
Since the compressive forces are much higher than the mentioned above, recently the demand for the ability to
tensile force, therefore the cross-section of the connecting determine optimal shapes easily has been mounting.
rod is analyzed and optimized based on the compressive However, currently available software packages are not
load. powerful enough to fulfill this demand.
Design optimization refers to the process of
generating improved designs. That means a design that II. DETERMINATION OF FORCES ACTING ON THE
possesses some optimal characteristics, such as minimum CONNECTING ROD.
weight, maximum first natural frequency. It is performed
by an optimizer. An optimizer is nothing but a formal A connecting rod is a machine member which is
plan or algorithm that is used to search for a best design subjected to alternating direct compressive and tensile
Engineering applications include structural design, forces. In the case of four stroke engines, during
chemical process design, aerodynamic optimization, compression and power strokes the connecting rod is
nonlinear control system design, mechanical component subjected to compressive loads and during the last part of
design, multi-discipline system design, and a variety of the exhaust and the beginning of the suction strokes, to
others. Because the statement of the numerical tensile loads. Since the compressive forces are much higher
optimization problem is so close to the traditional than the tensile force, therefore the cross-section of the
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 International Journal of Analytical, Experimental and Finite Element Analysis (IJAEFEA), Issue. 1, Vol. 2, March 2015.
e-ISSN: 2394-5141, p-ISSN: 2394-5133, pp 12-16.

connecting rod is analyzed and optimized based on the FI = 2794.47 N

compressive load.
Combined Load or Net Load acting on the connecting
Specifications of Connecting rod rod:
Diameter at the crank end, dic = 30.1mm F = Fg ± FI
Diameter at the piston end, dip = 14mm ‘-‘ve → acceleration
Thickness at the crank end, t1 = 4.4mm ‘+’ve → retardation
Thickness at the crank end, t2 = 2.5mm Net load, F =Fg - FI = 30336.004–2794.47= 27541.534 N
Length of connecting rod, c = 92.5mm Hence, the compressive load acting along the connecting
Thickness of I – section = 3mm is equal to 27.5 kN
Piston and cylinder
Diameter of piston, D = 50mm Inertia of the Connecting Rod:
Diameter Bore = 52mm Inertia/unit length
F = ρAω2rsinα
When α = 90o, F = Fmax
Fmax = ρAω2r
Where,
ρ = 7750 kg/m3
A = 68.4 x 10-6 m2
2�� 2� � 8000
ω= 60
= 60 = 837.76 rad/sec
Fig 1: Standard I section of the connecting rod. ��� � � �� ℎ
r = 2
= 24.83 mm = 24.83 x 10-3 m
Properties of forged steel l = 92.5 mm = 92.5 x 10 -3 m
Young’s modulus, E = 221 GPa Fmax = 7750 x 68.4 x 10-6 x (837.76)2 x 24.83 x 10 -3
Density, ρ = 7750 kg/m3 Fmax = 9237.91 N/m
Yield strength, yc= 625 MPa
Ultimate strength, yu= 827 MPa 1 1
Fic= 2Fmax x l= 2x 9237.91 x 92.5 x 10-3 = 427.25 N
Weight of connecting rod = 0.117 kg
Weight of piston = 0.068 kg
Weight of gudgeon pin = 0.02

Pressure Calculation for 100cc Engine

Density of Petrol C8 H18 = 737.22kg/m3

Mass of the petrol M = 737.22 x 10 -9 x 97.5 x 103

= 0.072 kg
From gas equation, PV = MRT
8.3143
R= = 72.786
0.114228

0.072 x 72.786 x 288 .85 Fig .2: two wheeler connecting rod
P= = 15.5 MPa
97.5 x 10^3
III STATIC STRESS ANALYSIS OF CONNECTING ROD
Force Due to Gas Pressure: BY FINITE ELEMENT METHOD
πd^2 π x 50^2
Fg= x Pf = x 15.45= 30336.004 N
4 4
The finite element analysis is carried out on forged
Inertia Load at Θ = 0 steel connecting rod. A 3-D model of connecting is used
for analysis in ANSYS. The loading conditions are
0.01095 Wrn 2 1 assumed to be static. The pressure load is applied at the
FI = g
� (1 + ′)
piston end .The crank end of the connecting rod is
Where, subjected to pure rotation therefore all the translations
W = Weight of reciprocating parts = Piston weight are fixed.
+ (0.33 x weight of connecting rod) = 0.088 + The element chosen is tetrahedral element with 3
(0.33 x 0.117) = 0.1242 N degrees of freedom at each node. The meshed model of
Crank radius, r = 24.83 mm connecting rod is as shown in figure 3.
Max. Speed of engine, n = 8000 rpm
92.5 The following material properties are defined for the
n’ = � = = 3.725 analysis of forged steel connecting rod Young’s
24.83
modulus, E= 221 GPa Poisson’s ratio= 0.3, Density =
g = 9810 mm/sec2 7750 kg/m3.
0.01095 � 1.242 � 24.83 � 8000 ^� 1
FI = � (1 + )
9810 3.725
© 2015 RAME IJAEFEA 13
Research Association of Masters of Engineering www.rame.org.in
 International Journal of Analytical, Experimental and Finite Element Analysis (IJAEFEA), Issue. 1, Vol. 2, March 2015.
e-ISSN: 2394-5141, p-ISSN: 2394-5133, pp 12-16.

increased as shown in figure 8. The stress distribution

along critical section of the connecting rod is from 308
MPa to 387 MPa. The following figures show the
displacements, strains and stress distribution along the
connecting rod.

Fig 3: Meshed model of connecting rod

The boundary conditions are applied on the crank

end of the connecting rod is shown in figure 4.The big
end of the connecting rod is subjected to pure rotation
therefore the big end of the connecting rod is fixed.
(Translations along x, y and z directions are
constrained).
Fig 6: Deformation plot of the connecting rod having web thickness
2.5mm

Fig 4 Fixed crank end of the connecting rod.

The figure 5 shows the pressure load applied on the

connecting rod at the piston end. The Compressive
Load 27.54kN is applied at the piston end of the
connecting rod as pressure load. Fig 7: Strain plot of the connecting rod having web thickness 2.5mm
.

Fig 5: Loaded piston end of the connecting rod

Fig 8: Von Misses stress distribution of the connecting rod having web
IV. SIZE AND SHAPE OPTIMIZTION OF thickness 2.5mm
CONNECTING ROD
B. Shape Optimization of a existing Connecting Rod
The objective of the optimization is to minimize Objective of the shape optimization is to minimize the
the mass of the connecting rod under the effect of peak mass of the connecting rod (I-section). The weight of
compressive gas load at 8000 rev/min (at 360o crank optimized connecting rod is certainly lower than the
angle), such that the maximum, minimum, and the weight of original connecting rod. The following factors
equivalent stress amplitude are within the limits of the are considered during the optimization- load factor,
allowable stresses. The production cost of the stresses under the loads.
connecting rod is also minimized
Objective: Minimize Mass and Cost
A. Size optimization of a existing connecting rod Subject to:
Size optimization is done based on the stress a) Compressive load = peak compressive gas load.
analysis of the existing connecting rod, and it is b) Maximum stress < Allowable stress
performed by reducing the web thickness of the c) Constraints (Component dimensions)
connecting rod from 3mm to 2.5mm and once again
the same stress analysis is carried out. The stress
distribution along the shank of the connecting rod is
© 2015 RAME IJAEFEA 14
Research Association of Masters of Engineering www.rame.org.in
 International Journal of Analytical, Experimental and Finite Element Analysis (IJAEFEA), Issue. 1, Vol. 2, March 2015.
e-ISSN: 2394-5141, p-ISSN: 2394-5133, pp 12-16.

Comparison of FEA results for the existing connecting

rod against the allowable stresses indicate that the shank
region of the connecting rod offers the greatest potential
for weight reduction. Regions near fillets of the big end are
already highly stressed.

Table 1 Stress analysis of existing connecting rod (web thickness 3mm)

Fig 9: Shape optimization of existing connecting rod.

In the shank region, the rib and the web thicknesses are
reduced, however, only to a certain limit to maintain forge
ability. The section modulus of the optimized connecting
rod should be high enough to prevent high bending
stresses. The stress results are shown in table 2 the stress
distribution along the critical section is 150.29 MPa to 395
Mpa that is less than the allowable stress

Table 2 Stress analysis of connecting rod with web thickness 2.5mm

Fig 10 Shape optimization of connecting rod having web thickness
2.5mm

V. RESULTS AND DISCUSSIONS

The deformation strain and von misses stress
distribution obtained by finite element method. The
deformation is more at the piston end of the connecting
rod and strain, stress value is maximum at the fillets of
the crank end. The stress distribution along the shank After several iterations, which involved determining
of the connecting rod is 353.83 MPa and maximum the loads and performing FEA for the resulting geometry
stress is 778.4 MPa of each iteration step, an optimized geometry was
obtained, shown in Figure 9 and 10. Mass of the optimized
connecting rod is 0.10041kg which is lower than the mass
of the original connecting rod by 4%. This geometry was
found to satisfy the design constraints

Table 3: Shape optimization results of existing connecting rod (web

thickness 3mm)
Optimization Original Optimize Weight
type weight d weight reduction
in kg in kg in %
Shape finder 0.10649 0.10224 4
Fig 11: Deformation plot of the connecting rod
Table .4: Shape optimization results of connecting rod having web
thickness 2.5mm

Original Optimized Weight

Optimization
weight weight reduction
type
in kg in kg in %

Shape finder 0.1057 0.10137 4

IV. CONCLUSIONS

In the case of four stroke engines, during compression and

Fig 12: Strain plot of the connecting rod power strokes the connecting rod is subjected to compressive
loads and during the last part of the exhaust and the beginning

© 2015 RAME IJAEFEA 15

Research Association of Masters of Engineering www.rame.org.in
 International Journal of Analytical, Experimental and Finite Element Analysis (IJAEFEA), Issue. 1, Vol. 2, March 2015.
e-ISSN: 2394-5141, p-ISSN: 2394-5133, pp 12-16.

of the suction strokes, to tensile loads. Since the Engineering (IOSR-JMCE) e-ISSN: 2278-1684,p-ISSN:
compressive forces are much higher than the tensile force, 2320-334X, Volume 6, Issue 5 (May. - Jun. 2013), PP 83-87
therefore the cross-section of the connecting rod is [4] Anil kumar et al Optimization of Connecting Rod Parameters
analyzed and optimized based on the compressive load. using CAE Tools International Journal of Latest Trends in
The following conclusions are made Engineering and Technology (IJLTET)
1) Based on the analytical method the compressive load [5] Christy V Vazhappilly, P.Sathiamurthi Stress Analysis of
due to gas pressure is 27.5 kN. Connecting Rod for Weight Reduction-A Review
2) Based on the numerical analysis the stress International Journal of Scientific and Research Publications,
distribution along the critical section of the Volume 3, Issue 2, February 2013
connecting rod is from 141.6MPa to 424.2MPa [6] Mr. H. B. Ramani, Mr. Neeraj Kumar, Mr. P. M. Kasundra
3) Based on size optimization analysis the stress Analysis of Connecting Rod under Different Loading
distribution along the critical section of the Condition Using Ansys Software International Journal of
connecting rod is from 154.9MPa to 464.73MPa and Engineering Research & Technology (IJERT) Vol. 1 Issue 9,
these stress are less than the allowable stress, November- 2012 ISSN: 2278-0181
therefore the web thickness of connecting rod is [7] Abhinav Gautam, K Priya Ajit Static Stress Analysis of
reduced from 3mm to 2.5mm. Connecting Rod Using Finite Element Approach IOSR
4) Based on shape optimization the mass of the Journal of Mechanical and Civil Engineering (IOSR-JMCE)
connecting rod is reduced by 4% e-ISSN: 2278-1684,p-ISSN: 2320-334X, Volume 10, Issue 1
(Nov. - Dec. 2013), PP 47-51
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Parameters Using FEM Suraj Pal1, Sunil kumar2
[1] Yogesh Kumar Bharti, Vikrant Singh, et al Stress
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analysis and optimization of connecting rod using finite
Research, Vol.-2, Issue-6, December 2012 ISSN No.: 2250-
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[2 ] K. Sudershn Kumar, Dr. K. Tirupathi Reddy et al
© 2013 htt Design And Analysis of Connecting Rod Using
Modeling and Analysis of Two Wheeler Connecting Rod
Forged steel Leela Krishna Vegi1, Venu Gopal Vegi2
International Journal of Modern Engineering Research
Vol.2, Issue.5, Sep-Oct. 2012 pp-3367-3371 [10] Pravardhan S. Shenoy and Ali Fatemi Connecting Rod
Optimization for Weight and Cost Reduction
[3] B. Anusha, C.Vijaya Bhaskar Reddy Modeling and
Analysis of Two Wheeler Connecting Rod by Using [11] P S Shenoy and A Fatemi_ Dynamic analysis of
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