Fatigue Analysis and Weight Reduction of Connecting Rod Using FEM

Abstract

In this project, finite element analysis of four stroke single cylinder 100cc petrol Engine bike connecting rod is taken as a case study. Existing connecting rod was manufactured by using AISI 8620 steel. It is replaced by Aluminum alloy 7068 which has highest strength among group of aluminum alloys. Strength of new material is equivalent to that of steels and density is 2.75 times lesser than existing one. The Fatigue Strength is the most significant factor in the optimization of the connecting rod. So, Fatigue Analysis is done to verify new materials property to replace the existing one. According to results theoretical factor of safety and analytical factor of safety are equivalent. Also the fatigue life of existing and new material is equivalent in terms of 107 cycles. So, AISI 8620 steel can be replaced by Aluminum Alloy 7068. Shape Optimization gave the reduction in weight of nearly 22% in both the materials. So, it can be beneficial with a view to weight reduction also.

Keywords: Connecting Rod, Finite Element Analysis, Fatigue, Shape Optimization, ANSYS

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