DESIGN OF CONNECTING ROD OF INTERNAL COMBUSTION ENGINE:
A TOPOLOGY OPTIMIZATION APPROACH


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ABSTRACT

This paper presents the design connecting rod of internal combustion engine using the
topology optimization. The objectives of this paper are to develop structural modeling,
finite element analyze and the optimization of the connecting rod for robust design. The
structure of connecting rod was modeled utilized SOLIDWORKS software. Finite
element modeling and analysis were performed using MSC/PATRAN and
MSC/NASTRAN software. Linear static analysis was carried out to obtain the
stress/strain state results.

INTRODUCTION

Connecting rods are highly dynamically loaded components used for power
transmission in combustion engines. The optimization of connecting rod had already
started as early year 1983 by Webster and his team. However, each day consumers are
looking for the best from the best. That’s why the optimization is really important
especially in automotive industry. Optimization of the component is to make the less
time to produce the product that is stronger, lighter and less cost. The design and weight
of the connecting rod influence on car performance. Hence, it is effect on the car
manufacture credibility. Change in the structural design and also material will be
significant increments in weight and performance of the engine. Mirehei et al. (2008)
were performed the study regarding the fatigue of connecting rod on universal tractor
(U650) by using ANSYS software application and the lifespan was estimated.

OPTIMIZATION APPROACH

The objective of optimization technique is to minimize the mass of the connecting rod
and reduce the cost of production. The connecting rod subjected to tensile load at crank
end, while using factor of safety 3 as recommended by Shenoy (2004). The maximum
stress of the connecting rod monitored and make sure it is not over the allowable stress.
The load of the connecting rod optimized is comprised of the tensile load of 26.7 kN at
crank end. Linear buckling analysis was performed on the connecting is 26.7 kN. The
buckling load factor is considered also 3. The optimization technique methodology
flowchart is shown in Figure 1.

RESULTS AND DISCUSSION

This section presents the details results of FE Analysis, selection of the mesh type and
influence of mesh type, identification of mesh convergence and optimization of the
connecting rod.

CONCLUSION

The modeling of connecting rod and FE Analysis has been presented. Topology
optimization were analyzed to the connecting rod and according to the results, it can be
concluded that the weight of optimized design is 11.7% lighter and maximum stress
also predicted lower than the initial design of connecting rod. The results clearly
indicate that the new design much lighter and has more strength than initial design of
connecting rod. Material optimization approach will be considered for future research.