COMPARISION OF BERYLLIUM AND CI CONNECTING ROD USING ANSYS
1R.Sabarish,
2C.M.Meenakshi,
1Asst.Professor, Department of Mechanical Engineering, 2Asst.Professor, Department of Mechanical Engineering,
BIST, BIHER, Bharath University, Chennai-73 [email protected], [email protected]
Abstract: Connecting rods widely used in many type
of engines such as in-line engines, V engines, opposed
cylinder engines, radial engines and oppose-piston
engines. The present work is aimed at replacing the
existing CI connecting rod with Beryllium, by doing a
comparative analysis in ANSYS.
Key Word: Connecting rod, Beryllium, ANSYS
1. Introduction
The higher finish of the rod is connected to the piston
by the piston pin. If the piston pin is barred within the
piston pin bosses or if it floats within the piston and
therefore the rod, the higher hole of the rod can have a
solid bearing (bushing) of bronze or the same material.
Because the lower finish of the rod revolves with the
shaft, the higher finish is forced to show back and forth
on the piston pin. [1-7]
Approximately 50 studies have been reviewed.
These studies are sorted by loading, stress analysis and
fatigue studies, optimization studies, manufacturing
process and economic studies, and other studies.
The maximum force is attained at 370o crank angle.
Inertia forces are composed of two parts. The first part
is inertia of reciprocating masses and acts on the pin
end and its direction changes with respect to the piston
acceleration. The second part includes centrifugal
forces, which act on the connecting rod in a distributed
manner. The centrifugal force is normal to the
longitudinal rod axis and produce bending stresses. The
maximum moment occurs when the crank is
perpendicular to the rod. The maximum tension and
compression forces occur at the top dead center point
during each cycle. It was observed that inertia load is
proportional to[9] the engine speed. Stress-time graphs
at different r.p.m. speeds were obtained. It was
concluded that the experimental methods restrict to
measure the dynamic stress on the connecting rod
because of the limited surface available for strain
gauges to stick on the connecting rod body, while FE
techniques were considered to be the best method to
find connecting rod stress distribution during operation.
2. Connecting Rod Materials
In this work the material selected for study and
analysis are carbon steel and beryllium.[10]
3. Model Creation
Carbon Steel
A model of the connecting rod is created and analyzed
for a pressure of 500 Mpausing ANSYS Workbench.
Figure 1. connecting rod model created using PRO-E
3.1 Model Analysis
Carbon Steel
Meshing of the created model is done using parameter:
solid 8node 183
International Journal of Pure and Applied MathematicsVolume 116 No. 17 2017, 127-133ISSN: 1311-8080 (printed version); ISSN: 1314-3395 (on-line version)url: http://www.ijpam.euSpecial Issue ijpam.eu
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Figure 2. meshing of carbon steel connecting rod
Table 1. Material Properties For Carbon Steel
Density
7.87e-6
Kg/cm3
Modulus of elasticity E
200GPA
Poisson’s ratio
0.28
Tensile Strength
745MPA
Yield strength
415MPA
Figure 3. Displacement of Carbon Steel
Compressive Load Diagram for CI
Von-Misses Stress And Strain for Compressive
Load
For the finite element analysis 500 Mpa of pressure is
used. The pressure is applied at the Big end of
connecting rod keeping Small end is fixed. [11]
Figure 4.Von-misses Stress of Carbon Steel
(Compressive Load)
From the fig..The maximum stress:314.154
Mpa and Minimum stress0.098965 Mpa. .
Figure 5. Von-misses Strain of Carbon Steel
(Compressive Load)
The maximum strain:0.157E-08MpaMinimum
strain:0.568E-12
Mpa.[12]
Tensile Load for Carbon Steel
Same model is analyzed for a pressure of 5Mpa applied
at the piston finish of the rod and stuck at the crank
finish of the rod. it's shown in Fig..
Figure 6. Tensile Load condition for Carbon Steel
(Tensile Load)
Von-Misses Stress And Strain for Tensile Load
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Figure 7. Von-misses Stress for Carbon Steel (Tensile
Load)
The maximum stress occurs at the piston end of the
connecting rod is 247.37 Mpa and minimum stress
occurs at the crank end of the connecting rod is
0.043209 Mpa. [13]
Figure 8. Von-misses Strain for Carbon Steel (Tensile
Load)
The Max strain occurs at the piston end of the
connecting rod is 0.167E-08Mpa and Min strain occurs
at the crank end .[14]
Von-Misses Stress And Strain for Compressive
Load:
For the finite element analysis 5 Mpa of pressure is
used. The pressure is applied at the Big end of
connecting rod keeping Small end fixed.
Figure 9. Von-misses Strain for Beryllium
(Compressive Load)
. The maximum stress is 326.816 Mpa and
minimum stress is 0.015687 Mpa.
Figure 10. Von-misses Stress for Beryllium
(Compressive Load)
The maximum strain :0.114E-08
Mpa and Minimum
strain: 0.979E-13Mpa.
Tensile Load Diagram for Beryllium Analysis is done with the pressure of 5Mpa.
Von-Misses Stress And Strain for Tensile Load
Figure 11.Von-misses Stress for Beryllium (Tensile
Load)
The maximum stress:255.595 Mpa and
Minimum stress :0.014743 Mpa.
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Figure 12. Von-misses Strain for Beryllium (Tensile Load)
. The maximum strain:0.940E-09
Mpa and Minimum strain :0.940E-09
Mpa
4. Comparison of Carbon Steel Vs Beryllium[16]
4.1 Tensile Strength for Carbon Steel
Table 2. Tensile analysis for Carbon steel
S.No
Name
Maximum (Mpa)
Minimum (Mpa)
1 Displacement 0.603E-06
2 Von-misses Stress 247.37 0.043209
3 Von-misses Strain 0.167E-08 0.324E-12
4 Factor of Safety 6 6
4.2 Compressive Strength for Carbon Steel
Table 3. Compressive analysis for Carbon steel
S.No
Name
Maximum (Mpa)
Minimum (Mpa)
1 Displacement 0.980E-07
2 Von-misses Stress 314.154 0.098965
3 Von-misses Strain 0.157E-08 0.568E-12
4 Factor of Safety 6 6
4.3 Tensile Strength for Beryllium Material
Table 4.Tensile analysis for Beryllium material
S.No
Name
Maximum (Mpa)
Minimum (Mpa)
1 Displacement 0.424E-06
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2 Von-misses Stress 255.595 0.014743
3 Von-misses Strain 0.940E-09 0.611E-13
4 Factor of Safety 4 4
4.4 Compressive Strength for Beryllium Material
Table 5. Compressive analysis for Beryllium material
S.No
Name
Maximum (Mpa)
Minimum (Mpa)
1 Displacement 0.695E-07
2 Von-misses Stress 326.814 0.015687
3 Von-misses Strain 0.114E-08 0.979E-13
4 Factor of Safety 4 4
4.5 ConnectingRod Weight (Carbon Steel)
Density of Carbon steel = 7.87e-6 Kg/mm3
Volume of connecting rod = 92419.78mm3 (Constant
value for carbon steel)
Weight of connecting rod = 0.727kg
Weight of connecting rod= 7.13 N
4.6 Connecting Rod Weight (Beryllium) Density of Beryllium = 1.844e-6 Kg/mm3
Volume of theconnecting rod = 256985.63mm3
(Constant value for Beryllium)
Weight of theconnecting rod = Density × Volume
=1.844e-6 ×256985.63
= 0.47488 kg
Weight of connecting rod = 4.6585N
4.7 Stiffness (Carbon Steel)
Weight of connecting rod =7.13N
Deformation =0.603E-06
Stiffness =Weight/Deformation
=7.13/0.603E-06
Stiffness = 11825N/m
4.8 Stiffness (Beryllium)
Weight of theconnecting rod =4.6585N
Deformation =0.695E-07
Stiffness =Weight/Deformation
=4.6585/0.695E-07
Stiffness=67029N/m.
5. Advantages
Light Weight –Beryllium material is used to reduce the
weight when compared to other material (up to 35
percent lighter) with suitable mechanical properties.
High Strength – Strength of the material is high when
compared to carbon steel,[17-20] carbon steel
connecting rod observe only a 3.73Mpa load for both
tensile and compression but Beryllium material observe
5Mpa load. Corrosion Resistance – Beryllium provide
good resistance to high temperature and chemical
environments. Beryllium is the material choice for
outdoor exposure, chemical handling as well as the
environment service.Durability –In this type of material
is with stand for different loading conditions and it can
be reused up to 2times.[21]
6. Disadvantages
Cost of the Beryllium material is moderate.
Beryllium materials have some non-visible
Damages. his type of Beryllium material connecting
rod is not readily available.
7. Conclusion
A rod of 150cc engine has been created in computer
code Pro/Engineer..The fabric used for the rod is steel
that is replaced with Be. By replacing with Be, the load
of the rod reduces regarding a pair of times than
exploitation steel since density of Be is extremely less
and young’s modulus of Be is high as compared with
steel. The analysis is carried out and Von-miss stress
values, Von-misses strain values and Deformations
obtained for each material. . The strain values and
strain values for each materials less for Be than steel.
By observation we are able to conclude that Be material
is healthier for rod
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131
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