international journal of pure and applied mathematics ... · is inertia of reciprocating masses and...

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

127

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

International Journal of Pure and Applied Mathematics Special Issue

128

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.


129

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)





4.3 Tensile Strength for Beryllium Material

Table 4.Tensile analysis for Beryllium material

S.No

Name

Maximum (Mpa)

Minimum (Mpa)



130




4.4 Compressive Strength for Beryllium Material

Table 5. Compressive analysis for Beryllium material

S.No

Name

Maximum (Mpa)

Minimum (Mpa)





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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