DEGIGN OF CONNECTING ROD

Where,

l  length of connecting rod

r  radius of the crank

t  thickness of the flange or web of the section

dp  diameter of the piston pin

dc  diameter of the crank pin

db  diameter of the bolt

B  Width of the web or flange

H  high or depth of the flange

H1  depth near the big end or crank end

H2  depth near the small end or piston end

1. Dimension of cross-section of the connecting rod

Buckling Load (WB)

WB = Max. gas force x Factor of safety
WB about X- axis = σc . A
1 + a (l/ Kxx )2
WB about Y- axis = σc . A
1 + a (l/ 2Kyy )2
a = Constant
= 1/7500, for mild steel
= 1/9000, for wrought iron
= 1/1600 , for cast iron
F.o.S = 5 to 6
Ixx = 4 Iyy Ixx  Moment of inertia about X - axis
2
A = 11 t Iyy  Moment of inertia about Y - axis
4
Ixx = (419/12) t A Cross – Sectional Area of connecting Rod
Iyy= (131/12) t 4
kxx= √( Ixx/A)

Empirical Relations:
B =4t
H =5t
H1 = 1.1 H to 1.25 H
H2 = 0.75 H to 0.9 H

2. Dimension of the crankpin at the big end and the piston pin at the small end
Maximum gas force(FL) = (П D2/ 4) x p
= dc . lc . pbc
= dp . lp . pbp
 Where,
D  Cylinder bore or piston diameter
P  Maximum gas pressure
dc  diameter of the crank pin
lc  length of the crank pin
lp  length of the piston pin
pbc  allowable bearing pressure in crank pin
pbp  allowable bearing pressure in piston pin

Empirical Relations:
lc = 1.25 dc to 1.5 dc
lp = 1.5 dp to 2 dp

3. Size of bolts for securing the big end cap

Inertia of reciprocating parts (F I )
FI = mR . ω2. r. [ cos Ө +( cos 2Ө . r / l )]
Ө=0
FI = mR . ω2. r. [ 1 +( r / l )]
= (П/ 4) dcb 2 σ t . nb
db = dcb / 0.84
Where,
mR  mass of the reciprocating parts in kg
ω angular speed of the engine in rad/s
dcb  Core diameter of the bolt in mm
σt  allowable tensile stress for the material of the bolt in MPa
nb  Number of bolts. Generally 2 bolts are used.
4. Thickness of the big end cap (tc)
Maximum bending moment (Mc) = FI x X / 6
X = dc + (2 x 3 ) + db + 3
Section modulus (Zc) = bc (tc)/6
bc = lc
Bending stress (σb) = Mc / Zc
σb max = Mmax / Zxx
Mmax = m1 . ω2 . r (l/9√3)
m1 = area x length x density
= 11t2 . l . ρ
Zxx = Ixx/ (5 t / 2)

Table 1

S.No Parts Bearing Pressure (N/mm2)

1. Crank pin 7 - 12.5

2. Piston pin 10.5 - 15

Table 2

S.No Material Crushing Stress (σc) N/mm2

1. Wrought Iron 250

2. Mild Steel 330

3. Cast Iron 550

Table 3

S.No Parts Tensile stress σt (N/mm2)

1. Bolt 60