Proceedings of the NCNTE-2012, Third Biennial National Conference on Nascent Technologies Fr. C.

Rodrigues Institute of Technology, Vashi, Navi Mumbai, Feb 24-25, 2012 Department of Mechanical Engineering

DESIGN THROUGH ENGINEERING INTEGRATION OF CONNECTING ROD

Aqleem Siddiqui1, Nitin Gurav2, Ketan Patil3, Nachiket Gokhale4, Mangesh Daberao5, Saurabh Srivastava6
1

Professor, 2Assistant Professor, 3, 4, 5, 6 Students, Mechanical Engineering Department, Fr. C. Rodrigues Institute of Technology, Vashi, Navi Mumbai, Maharashtra

Email address: aqleems@yahoo.com, 2ni3gurav@gmail.com, 3kpatil19@yahoo.co.in, 4gokhale.nachiket@gmail.com,

5

daberao7@gmail.com, 6saurabh.jets@gmail.com

Abstract:
This paper deals with the need to develop and maintain complex design procedures by integrating MathCAD with ProEngineer . The objectives of this study are to develop a structural model and develop design calculations. The structure of connecting rod is modelled in Pro-Engineer software. Design calculations are entered into MathCAD. Integration of MathCAD with ProEngineer will be carried out to reach desired objective. By integrating MathCAD with Pro-Engineer we can work simultaneously with 3-D Model as well as manufacturing drawing of the product. MathCAD is a standardized & right tool for engineering calculations. MathCAD uses ultimate results in faster time to market. Pro-Engineer is a parametric, integrated 3D CAD/CAM/CAE solution. Ideal designing, suitable material properties and proper manufacturing processes are very important for developing successful component.

1.0 INTRODUCTION The integration between PRO-ENGINEER and MATHCAD is a bi-directional link between the two applications. A MATHCAD file can be easily associated with a PRO-ENGINEER part or assembly using the Analysis feature in PRO-ENGINEER . Critical values calculated in MATHCAD can be mapped to parameters and dimensions in the CAD model to drive the geometric design [1]. The integration offers dynamic updates to calculations and the CAD drawing when parameters are changed. MATHCAD can be used to apply scientific and mathematical principles to engineering design problems at the beginning of the design process
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. By calculating the parameters

required and predicting the performance of the design up front, instead of guessing key dimensions and parameters, product designers can produce an optimized design more rapidly and with less iteration than the traditional methods used today. 1.1 An Example for MATHCAD: A sample equation in Excel in which the logic is invisible because of the linear expression buried in the cell. Pinertia=((m*(^2)*r))*(cos(theta) + (cos(2*theta)/n)) (1.1)

The same equation can be represented in MATHCAD using standard math notation as below [2]:

Pinertia := m r co s +
2

cos2 n

(1.2)

The Design of a Connecting rod for a 1200cc displacement internal combustion petrol engine has been referred as far as the design purpose is concerned. Thickness of an I-Section of the connecting rod can be designed by using

Proceedings of the NCNTE-2012, Third Biennial National Conference on Nascent Technologies Fr. C. Rodrigues Institute of Technology, Vashi, Navi Mumbai, Feb 24-25, 2012 Department of Mechanical Engineering

same principle of integration. This integration can create impact on technology through Predictive engineering provides customers with a way to predict the behaviour of their models, Productivity and product quality improvements and audit capabilities - enhances the ability to verify, validate and audit engineering work and design results by providing clear documentation of design calculations which are directly linked to CAD model throughout the product development process. Connecting rods are highly dynamically loaded components used for power transmission in combustion engines. The optimization of connecting rod had started as early as 1983 by Webster and his team. However, each day consumers are looking for something better. Thats why optimization is really important especially in the automotive industry [3]. Optimization of a component is to reduce the time required to produce the product that is stronger, lighter and is cost effective. The design and weight of the connecting rod have a big influence on the performance of the car. Change in the structural design and material has a significant effect on weight and performance of the engine.Hence, the automotive system selected here is internal combustion engine and the sub system chosen for discussion is the connecting rod, which connects the piston and crankshaft in the engine assembly. 2.0 PRODUCT DESIGN APPROACH MATERIAL SELECTION

DESIGN OF CONNECTING ROD

INPUT OF PARAMETERS IN MATHCAD

CAD MODELLING IN PRO-E

LINKING MATHCAD AND PRO-E 3.0 MATERIAL STUDY Connecting rods operate under high loads needs high strength in both tension and compression and high fatigue strength [4]. For fulfilling that need here we have selected typical forged steel or ultra-high strength steel. This steel has strength level above 900MPa and this steel generally have carbon content ranging from 0.01-0.45%.This steel has good fabric ability, good weldability and good fracture toughness. It is well known that, as strength increases, toughness reduces. So toughness of ultra-high strength steel is an important consideration. As strength increases, critical length/size of defect decreases. Once the critical length of the defect is reached during processing or application, the material fails catastrophically without any prior warning. Therefore it is necessary to minimize the presence of defects such as, inclusions, cracks etc. during production, processing of the steel and fabrication of the components. Ultra high strength steels are classified according to their composition microstructure. The steel C-70 has been introduced from Europe as crackable forging steel. Alloying elements in the material enables hardening of forged connecting rods when they undergo controlled cooling after forging. This material fractures in a similar fashion to powder forged materials [5].

Proceedings of the NCNTE-2012, Third Biennial National Conference on Nascent Technologies Fr. C. Rodrigues Institute of Technology, Vashi, Navi Mumbai, Feb 24-25, 2012 Department of Mechanical Engineering

Recently American Iron and Steel Institute Bar and Rod market development group has promoted C-70 as an improved material over some other materials used for manufacturing the connecting rods in the market today. Table 3.1 Mechanical properties of C-70 steel [6] Symbol Properties Value UTS Tensile strength 990 MPa Yield strength (0.2% offset) Youngs modulus Percent elongation Percent reduction in area 4.0 DESIGN DATA For the design of the connecting rod, it is required to enter the input parameters to determine the corresponding desired unknown output. The following actual input parameters from automotive industry are considered for our design procedure. Table 4.1 Input parameters for connecting rod design [7]
Parameter Displacement Bore Stroke Compression ratio Maximum RPM Maximum Explosion Pressure Length of Connecting Rod Weight of reciprocating parts Notation Vs D L C.R. N Pmax LC.R. M Value 1242cc 73.00 mm 74.20 mm 10.00:1 6000 rpm 1.193 MPa 129.85 mm 1.82 kg
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YS E %EL %RA

580 MPa 210 GPa 27% 25%

The output parameters of a connecting rod are calculated using the standard design procedure evaluated in the following table. Table 4.2 Output parameters for Connecting Rod Design
Parameter I-Section Thickness Crank End Thickness Piston End Thickness Inner diameter of small end Outer diameter of small end Outer diameter of crank end Value 2.15 mm 12.90 mm 8.6 mm 16.8 mm 20.4 mm 43.8 mm

and the results are

Proceedings of the NCNTE-2012, Third Biennial National Conference on Nascent Technologies Fr. C. Rodrigues Institute of Technology, Vashi, Navi Mumbai, Feb 24-25, 2012 Department of Mechanical Engineering

Bolt Size Thickness of Cap

M18 x 1.5 mm 25.47 mm

4.0 LINKING PROCEDURE The link between the two softwares is completed using the following steps:-

Tagging of the input and output variables in MATHCAD Assigning of parameters in Pro Engineer in order to capture the values sent from MATHCAD Linking the variables sent from Pro Engineer to the ones in MATHCAD and vice versa Computing the result, Generating an analysis feature

5.0 CONCLUSION In the current practice of manufacturing the connecting rod, the connecting rod is manufactured in a single piece that offers high production rates and after that it under goes a few machining processes which increases labour cost. Nowadays mostly one piece forging is used for production by using crackable forged steels. The material C-70 crackable forged steel is one of them. It has got good factorability, which reduces its machining cost. The high production rates can be reduced by making the CAD model and then linking it with engineering calculations software that can automatically change the parameters of the connecting rod. Thus this technology overall reduces manufacturing lead time, ensures technical aspects behind designing, better product quality & customer order fulfillment within time. Same Parametric Modeling Approach can be applied to all Standard manufacturing products & results will be verified through this Linking / Integration.

References:
[3] [5] [6] [1] Brent Maxfield, Engineering with Mathcad Using Mathcad to create and organize your Engineering Calculations [2] Web link: http://www.ptc.com Mohd.Shamil Bin Shaari, Design optimization of connecting rod for internal combustion engine, Faculty of Mechanical Engineering, University of Malaysia, Pahang, 2010 [4] James Dale, Connecting Rod Evaluation in Journal of Metal Powder Industry Federation, 2005 Manas Shirgaokar, Forging Processes: Variables and Descriptions, 2005 M.M. Rahman, M.Y. Taib, A.R. Ismail, A.R. Yusoff, M.A.M. Romlay, Design of connecting rod of internal combustion engine: A topology optimization approach, in National Conference in Mechanical Engineering Research and Postgraduate Studies (2nd NCMER 2010), Faculty of Mechanical Engineering, UMP Pekan, Kuantan, Pahang, Malaysia; pp. 155-166 [7] Web link: http://www.carfolio.com C.S Sharma and Kamlesh Purohit,Design of Machine Elements,2005

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