Group

Project
AHLI : JAMIUL SATTAR BIN ABDUL RAHIM
MATRIX :
AHLI : WAN MOHD AZROL KHAIRIL BIN WAN MOHD
YASIN
MATRIX : SX070849MMJ08
AHLI :
MATRIX :
AHLI :
MATRIX :
AHLI :
MATRIX :
LECTURE :
AHMAD ZAFRI
BIN
ZAINUDIN
CODE / COURSE : SME 3033 / FINETE ELEMENTS METHOD
TABLE OF CONTENT
INTRODUCTION 3
GEOMETRY, LOADING AND BOUNDARY CONDITIONS!
MATERIAL 9
RESULT AND DISCUSSION"0
INTRODUCTION
In a reciprocating piston engine, the connecting rod or conrod connects
the piston to the crank or crankshat! Together "ith the crank, the# or$ a si$p%e
$echanis$ that con&erts reciprocating $otion into rotating $otion! Connecting ro's
$a# a%so con&ert rotating $otion into reciprocating $otion! (istorica%%#, )eore the
'e&e%op$ent o engines, the# "ere irst *se' in this "a#! As a connecting ro' is rigi',
it $a# trans$it either a p*sh or a p*%% an' so the ro' $a# rotate the crank thro*gh
)oth ha%&es o a re&o%*tion, i!e! piston p*shing an' piston p*%%ing! Ear%ier
$echanis$s, s*ch as chains, co*%' on%# p*%%! In a e" t"o+stroke engines, the
connecting ro' is on%# re,*ire' to p*sh!
To'a#, connecting ro's are )est kno"n thro*gh their *se in interna%
co$)*stion piston engines, s*ch as a*to$oti&e engines! These are o a 'istinct%#
'ierent 'esign ro$ ear%ier or$s o connecting ro's, *se' in stea$ engines an'
stea$ %oco$oti&es! In $o'ern a*to$oti&e interna% co$)*stion engines, the
connecting ro's are $ost *s*a%%# $a'e o stee% or pro'*ction engines, )*t can )e
$a'e o T-+./.0 an' T-12+3/31 a%*$ini*$ a%%o#s
4citation needed5
6or %ightness an' the
a)i%it# to a)sor) high i$pact at the e7pense o '*ra)i%it#8 or titani*$ 6or a
co$)ination o %ightness "ith strength, at higher cost8 or high peror$ance engines,
or o cast iron or app%ications s*ch as $otor scooters! The# are not rigi'%# i7e' at
either en', so that the ang%e )et"een the connecting ro' an' the piston can change
as the ro' $o&es *p an' 'o"n an' rotates aro*n' the crankshat! Connecting ro's,
especia%%# in racing engines, $a# )e ca%%e' 9)i%%et9 ro's, i the# are $achine' o*t o a
so%i' )i%%et o $eta%, rather than )eing cast or orge'!
Problems
Stress and failre
:ai%*re o a connecting ro' is one o the $ost co$$on ca*ses o catastrophic
engine ai%*re! The connecting ro' is *n'er tre$en'o*s stress ro$ the reciprocating
%oa' represente' )# the piston, act*a%%# stretching an' )eing co$presse' "ith e&er#
rotation, an' the %oa' increases to the s,*are o the engine spee' increase! :ai%*re
o a connecting ro', *s*a%%# ca%%e' t!ro"ing a rod, is one o the $ost co$$on
ca*ses o catastrophic engine ai%*re in cars, re,*ent%# p*tting the )roken ro'
thro*gh the si'e o the crankcase an' there)# ren'ering the engine irrepara)%e; it
can res*%t ro$ atig*e near a ph#sica% 'eect in the ro', %*)rication ai%*re in a
)earing '*e to a*%t# $aintenance, or ro$ ai%*re o the ro' )o%ts ro$ a 'eect,
i$proper tightening or o&er+re&&ing o the engine! Re+*se o ro' )o%ts is a co$$on
practice as %ong as the )o%ts $eet $an*act*rer speciications! Despite their re,*ent
occ*rrence on te%e&ise' co$petiti&e a*to$o)i%e e&ents, s*ch ai%*res are ,*ite rare
on pro'*ction cars '*ring nor$a% 'ai%# 'ri&ing! This is )eca*se pro'*ction a*to parts
ha&e a $*ch %arger actor o saet#, an' oten $ore s#ste$atic ,*a%it# contro%!
Ob#ecti$es of std% case
A part ro$ the pro)%e$ $ention a)o&e, "e $a'e a st*'# case to tack%e one
o the pro)%e$s an' to re%ate it in :inite E%e$ent Metho'! The pro)%e$ that "e "ant
to pro&e is <"hat is the critica% point=stress at connecting ro' "hen app%ie' so$e
%oa' in it!> No har' an' ast r*%es can )e gi&en to arri&e at a satisactor# connecting
ro' %ie! Each case $*st )e painstaking%# in&estigate', the ca*se or ca*ses iso%ate'
an' re$e'ia% action taken!
To co$p%# "hat "e ha&e %earn in s*)?ect :inite E%e$ent Metho' , "e *se' a :EMA@
sot"are "hen 'oing the ana%#sis!
&EO'ETR() LOADIN& AND BOUNDAR( CONDITIONS
Figre *+ &eometr% of solid connecting rod
Tota% No'es A 222-2
Tota% E%e$ents A -/31
Figre ,+ A--lied load at t!e to- of connecting rod . /012N
Figre /+ Constraint at t!e bottom of connecting rod
Tec!nical S-ecification
28 Bore in )earing or piston
pin 6ne"8.!2B./ to .!2BC/ in! 611!0.C to 11!00D $$8
Ma7i$*$ per$issi)%e c%earance )et"een
)earing an' piston pin 6"orn8 //C in! 6/!/B $$8
.8 Bore in connecting ro' or )earing, "ith n*ts tight to speciications
0!/30B !///1 in! 62/C!1// E /!/2C $$8
C8 Distance )et"een center o )earings 2/!C// E !//. in! 6.-2!-. /!/1 $$8
08 Dia$eter o piston pin6ne"8 2!DDDB E !///. in! 61/!3D1 E /!//1 $$8
18 Bore in )earing or crankshat C!B.C- to .!B.1B in! 6D3!22D to D3!231 $$8
C%earance )et"een )earing an' crankshat ne"
//.B to !//-- in! 6/!/32 to /!2-B $$8
Ma7i$*$ per$issi)%e c%earance )et"een )earing
an' crankshat 6"orn8 /2/ in! 6/!.1 $$8
-8 Tor,*e on n*t or connecting ro'A
a! @*t engine oi% on threa's an' n*t seat!
)! Tighten )oth n*ts to -/ E - %)! t! 6B. E B N!$8
Mark each n*t an' en' o )o%t!
c! Again tighten )oth n*ts 6ro$ $ark8 2./
si'e c%earance )et"een t"o connecting ro's on sa$e crankshat pin
6ne"8 /22 to !/.D in! 6/!.B to /!30 $$
'ATERIAL
The connecting ro's are $ost *s*a%%# $a'e o stee% or pro'*ction engines,
)*t can )e $a'e o T-+./.0 an' T-12+3/31 a%*$in*$ a%%o#s 6or %ightness an' the
a)i%it# to a)sor) high i$pact at the e7pense o '*ra)i%it#8 or titani*$ 6or a
co$)ination o %ightness "ith strength, at higher cost8 or high peror$ance engines,
or o cast iron or app%ications s*ch as $otor scooters! The# are not rigi'%# i7e' at
either en', so that the ang%e )et"een the connecting ro' an' the piston can change
as the ro' $o&es *p an' 'o"n an' rotates aro*n' the crankshat! Connecting ro's,
especia%%# in racing engines, $a# )e ca%%e' 9)i%%et9 ro's, i the# are $achine' o*t o a
so%i' )i%%et o $eta%, rather than )eing cast or orge'!
RESULT AND DISCUSSION
Figre 3 + Deformed s!a-e
Figre 2 + 4ig!er stress at to-
Figre 5 + 6ireframe $ie"
Figre 7+ Trans-arent $ie"
Res*%t an' Disc*ssion
The Ca$pro engine is the irst a*to$oti&e engine e&er 'e&e%ope' )# the
Ma%a#sian a*to$oti&e corporation, @roton! The na$e Ca$pro is short or Ca$
@roi%e! This engine po"ers the @roton Gen+., the @roton Satria Neo, the @roton
Fa?a Ca$pro as "e%% as @rotonGs *t*re $o'e%s! The Ca$pro engine is ai$e' to
sho" @rotonGs a)i%it# to $ake their o"n engines that pro'*ces goo' po"er o*tp*t
an' $eets ne"er e$ission stan'ar's!
:or o*r @ro?ect, "e ha' *sing a rea% connecting ro' ro$ Ca$ @ro engine!
The technica% speciication as pro&i'e' sho"s that a $a7i$*$ tor,*e is 20B N$ at
-/// rp$! :ro$ this inor$ation "e ca%c*%ate' the $a7i$*$ orce that app%ie' at the
top hea' "hen the engine "as operate! The &a%*e o $a7i$*$ orce is CBD1 N!
To *%i%% o*r o)?ecti&e o in'ing critica% point=stress at &a%&e "hen app%ie' so$e %oa',
this st*'# "i%% $ake s*re e" ass*$ption "hich inc%*'esA
a8 No co%%ision occ*rs )et"een the &a%&e an' piston!
)8 @o"er=orce pro'*ce' '*ring the co$)*stion process occ*r is i7e' at a%% ti$es!
c8 There are no oreign o)?ects in the co$)*stion cha$)er '*ring co$)*stion
process!
'8 A%% o the co$ponents insta%%e' c%ose to the engine an' operate proper%#!
O*r gro*p ha' *se' :EMA@ sot"are ana%#sis or the co$ponents o the connecting
ro'! The res*%ts o)taine' sho"e' that the $a7i$*$ stress )ase' on Hon Mises
Theor# at E%e$ent 6ID 1BD/8 is 2.!-//C N=$I an' the $ini$*$ stress at e%e$ent 6ID
1B-38 is /!/-2DD- N=$I,"hi%e the stress on the other parts is at a sae %e&e%! This
$eans ai%*re $ight happen i high orce app%ie'! The $a7i$*$ 'e%ection occ*rs at
no'e 6ID BDB8 is B!11D.CE+D $ an' the $ini$*$ 'e%ection happen at no'e 6ID 28
that the &a%*e is Jero 6Constraint8!