FINITE ELEMENT STRUCTURAL ANALYSIS OF CONNECTING ROD OF AA7075-TIC COMPOSITE USING ANSYS

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1 International Journal of Mechanical Engineering and Technology (IJMET) Volume 8, Issue 7, July 2017, pp , Article ID: IJMET_08_07_119 Available online at ISSN Print: and ISSN Online: IAEME Publication Scopus Indexed FINITE ELEMENT STRUCTURAL ANALYSIS OF CONNECTING ROD OF AA7075-TIC COMPOSITE USING ANSYS Rajesh Prabha N Department of Mechanical Engineering, Noorul Islam University, Kumaracoil, Tamilnadu, India Edwin Raja Dhas J Department of Automobile Engineering, Noorul Islam University, Kumaracoil, Tamilnadu, India Ramanan G Department of Aerospace Engineering, Noorul Islam University, Kumaracoil, Tamilnadu, India ABSTRACT Connecting Rods are practically generally used in all varieties of automobile engines. Acting as an intermediate link between the piston and the crankshaft of an engine. It is responsible for transmission of the up and down motion of the piston to the crankshaft of the engine, by converting the reciprocating motion of the piston to the rotary motion of crankshaft. Thus, this study aims to carry out for the load, strain and stress analysis of the crank end of the connecting rod of different materials. The materials used here are stainless steel, aluminium7075 and its various compositions with titanium carbide. The results can be used for optimization for weight reduction and for design modification of the connecting rod. AUTODESK INVENTER2016 is used for modeling and analysis is carried out in ANSYS15.0 software. The results archived can also help us identify the spot or section where chances of failure are high due to stress induced. Also the results obtained can be used to modify the existing designs so that better performance and longer life cycle can be archived. Key words: Connecting Rod, Autodesk Inventer2016, FEM, Ansys15.0, Crank, Crankshaft, Piston, TiC, Aluminum7075. Cite this Article: Rajesh Prabha N, Edwin Raja Dhas J and Ramanan G, Finite Element Structural Analysis of Connecting Rod of Aa7075-Tic Composite Using ANSYS, International Journal of Mechanical Engineering and Technology 8(7), 2017, pp editor@iaeme.com

2 Finite Element Structural Analysis of Connecting Rod of Aa7075-Tic Composite Using ANSYS 1. INTRODUCTION Connecting Rods are used practically generally used in all varieties of automobile engines. Acting as an intermediate link between the piston and the crankshaft of an engine of an automobile. It is responsible for transmission the up and down motion of the piston to the crankshaft of the engine, by converting the reciprocating motion of the piston to the rotary motion of crankshaft. While the one end, small end the connecting rod is connecting to the piston of the engine by the means of piston pin, the other end, the bigger end being connected to the crankshaft with lower end big end bearing by generally two bolts. Generally connecting rods are being made up of stainless steel and aluminium alloy through the forging process, as this method provides high productivity and that too with a lower production cost. Forces generated on the connected rod are generally by weight and combustion of fuel inside cylinder acts upon piston and then on the connecting rod, which results in both the bending and axial stresses. Therefore it order to study the stress, strain and deformation in the crank end of the connection rod, firstly based on the working parameter and the vehicle chosen the design parameter or dimensions of the connecting rod is calculated, then the model of the connecting rod parts is prepared and finally it is analyzed using Finite Element Method and results thus achieved will provide us the required outcome of the work done here.also further study can also be carried out later on for the dynamic loading working conditions of the connecting rod and also improvement in design can also be made for operation condition and longer life cycle against failure. AUTODESK INVENTER 2016 software is used for modelling of the connecting rod model and analysis is carried out by ANSYS15.0. ANSYS being an analysis system which stands for Advanced Numerical System Simulation. It is an CAE software, which has many capabilities, ranging from simple static analysis to complex non-linear, dynamic analysis, thermal analysis, transient state analysis, etc. By solid modelling software, the geometric shape for the model is described, and then the ANSYS program is used for meshing the geometry for nodes and elements. In order to obtain the desirable results at each and every point of the model, the fine meshing is done which also results in accurate results output. In this study the elements formed after meshing are tetrahedral in shape. Loads and boundary constrains in the ANSYS can be applied on the surfaces and volume as required. Finally the results calculation is done by the ANSYS software and the desired output results can achieved. 2. FINITE ELEMENT METHOD The finite element method (FEM) is a numerical technique for solving problems to find out approximate solution of a problem which are described by the partial differential equations or can also be formulated as functional minimization. A principle of interest is to represented as an assembly of finite elements. Approximating functions in the finite elements are determined in the terms of the nodal values of a physical field which is sought. FEM subdivides a whole problem or entity into numbers of smaller simpler parts, called finite elements, and solve these parts for the problems. The main advantage of FEM is that it can handle complicated boundary and geometries with very ease. The main aim of the project is to determine the Von Misses stresses, Max Shear Stress, Total Deformation, Equivalent Elastic Strain and Max Shear Elastic Strain. Based on which the new material can be compared with the existing materials used for Connecting Rod. Analysis and modelling of the connecting rod has been done in the AUTODESK INVENTER 2016 software. The input parameters of FEM tool software ANSYS 15.0 is given to the model. To regulate the Von Misses stresses, Max Shear Stress, Total Deformation, Equivalent Elastic Strain and Max Shear Elastic Strain. To calculate stresses in critical areas and to identify the editor@iaeme.com

3 Rajesh Prabha N, Edwin Raja Dhas J and Ramanan G spots in the connecting rod where there are more chances of failure. To reduce weight of the existing connecting rod based on the magnitude of the output of analysis. MATERIAL SELECTED YOUNGS MODULUS POISSONS RATIO Table 1 Dimensions of connecting rod SL NO: PARAMETERS 1 THICKNESS OF CONNECTING ROD (t) = WIDTH OF THE SECTION (B = 4t) = HEIGHT OF THE SECTION (H = 5t) = HEIGHT AT BIG END = (1.1 TO 1.125)H = HEIGHT AT SMALL END =.9H to.75h = INNER DIAMETER OF SMALL END = 53 7 OUTER DIAMETER OF SMALL END = 61 8 INNER DIAMETRE OF BIG END = 65 9 OUTER DIAMETER OF BIG END = 87 STAINLESS STEEL Table 2 Material properties + 3%TIC + 7%TIC + 9%TIC MPa 71700MPa 76328MPa 78000MPa 78635MPa DENSITY 7750kg/M Kg/M Kg/M Kg/M Kg/M 3 BHN MODELING OF THE CONNECTING ROD USING AUTODESK INVENTER 3.1. FE model details The connecting rod is axi-symmetric and therefore axi-symmetric elements are chosen for making the FE model. Fig.8.l shows the FE model of the propellant tank FEM Analysis Total no. of elements in the FE model chosen for analysis is 1l36. The tetrahedral meshing approach is employed for the meshing of the solid region geometry. Tetrahedral meshing produces high quality meshing for boundary representation of solid structural model. Material properties play an important role in the result of the FE analysis. The material properties are one of the major inputs to perform the FEM. Figure 1 Finite element model (anti-symmetric) of the connecting rod editor@iaeme.com

4 Finite Element Structural Analysis of Connecting Rod of Aa7075-Tic Composite Using ANSYS 3.3. Boundary Conditions It is the mathematical procedure of defining the known values of loads, direction of constraints etc., on specific nodes or elements. Using these known values the software interprets the value of other modes/elementary by solving the matrix as explained before. In this FE model.the big end is made fixed and small end is made free. Figure 2 shows the boundary conditions applied. Figure 2 Constrains of Connecting Rod 3.4. Loading The loads are applied in the form of pressure at the internal surface area of the connecting rod is analyzed. In this axis-symmetric model the internal pressure is applied on the inner contour Of the FE model. During solution phase the pressure applied will be transferred to the FE model. 4. RESULTS OF FEM ANALYSIS Figure 3 Total deformation of connecting rod Figure 4 Shear stress of connecting rod editor@iaeme.com

5 Rajesh Prabha N, Edwin Raja Dhas J and Ramanan G Figure 5 Equivalent elastic strain of connecting rod 4.1. AL %TiC Figure 6 Maximum shear elastic strain of connecting rod Figure 7 Total deformation of connecting rod Figure 8 Von misses stress of connecting rod editor@iaeme.com

6 Finite Element Structural Analysis of Connecting Rod of Aa7075-Tic Composite Using ANSYS Figure 9 Shear stress of connecting rod Figure 10 Equivalent elastic strain of connecting rod 4.2. AL %TiC Figure 11 Maximum shear elastic strain of connecting rod Figure 12 Total deformation of connecting rod editor@iaeme.com

7 Rajesh Prabha N, Edwin Raja Dhas J and Ramanan G Figure 13 Von misses stress of connecting rod Figure 14 Shear stress of connecting rod Figure 15 Equivalent elastic strain of connecting rod Figure 16 Maximum shear stress of connecting rod editor@iaeme.com

8 Finite Element Structural Analysis of Connecting Rod of Aa7075-Tic Composite Using ANSYS Figure 18 Maximum shear elastic strain of connecting rod Table 3 Summary of Results ITEM Total Deformation(M) Equivalent Von mises Stress (Pa) Maximum Shear Stress(Pa) Equivalent Elastic Strain Maximum Shear Elastic Strain STAINLESS STEEL AL %TIC AL %TIC AL %TIC E E E E E E E E E E Figure 19 Shows variation of results from ANSYS 6. CONCLUSION In this analysis forces are applied on the piston head and effect of it on the connecting rod was studied. The connecting rod made of al 7075 has lower intensity of stress induced as compared to other materials. Thus AL7075 can be a good replacement. The areas where stresses and editor@iaeme.com

9 Rajesh Prabha N, Edwin Raja Dhas J and Ramanan G strains are higher can be minimized by adding material and in areas of less intensity the material can be removed. The stress is found maximum at the piston end so the material can be increased in the stressed portion to reduce stress. Stainless steel material poses minimum deformation and AL7075 poses maximum deformation. On adding TiC to AL7075, the deformation reduces. Von misses stresses are found to be minimum for AL7075 and maximum for AL % TiC. Maximum shear stresses are possessed by AL % TiC and minimum for AL7075. Stainless steel has greater von misses and shear stress than AL7075.on adding TiC to AL7075 as percentage increases, shear stresses are also increased. Stainless steel has minimum equivalent elastic strain and maximum for AL7075. On adding TiC, the strain also increases. Maximum shear elastic strain is obtained for AL7075 and minimum for stainless steel. On comparing with Al7075, on adding TiC there is no improvement in properties. Hence AL7075 can be used as connecting rod. REFERENCES [1] Hebeish P.X. Pham, D.Q. Vo, R.N. Jazar, Development of fuel metering techniques for spark ignition engines, Fuel, Volume 206, 2017, pp [2] Hwajin Kim, Jin Young Kim, J.S. Kim, Hyoun Cher Jin, Physicochemical and optical properties of combustion-generated particles from a coal-fired power plant, automobiles, ship engines, and charcoal kilns, Fuel, Volume 161, 2015, pp [3] R.J. Immanuel, S.K. Panigrahi, G. Racineux, S. Marya, Investigation on crashworthiness of ultrafine grained A356 sheets and validation of Hall-Petch relationship at high strain-rate deformation, Materials Science and Engineering: A, Volume 701, 2017, pp [4] Youping Zheng, Weidong Zeng, Yubo Wang, Dadi Zhou, Xiongxiong Gao, High strain rate compression behavior of a heavily stabilized beta titanium alloy: Kink deformation and adiabatic shearing, Journal of Alloys and Compounds, Volume 708, 2017, pp [5] Manish Agrawal, C.S. Jog, A quadratic time finite element method for nonlinear elastodynamics within the context of hybrid finite elements, Applied Mathematics and Computation, Volume 305, 2017, pp [6] Jan Jaśkowiec, Application of discontinuous Galerkin method to mechanical 2D problem with arbitrary polygonal and very high-order finite elements, Computer methods in Applied Mechanics and Engineering, Volume 323, 2017, pp [7] Ever J. Barbero, Mehdi Shahbazi, Determination of material properties for ANSYS progressive damage analysis of laminated composites, Composite Structures, Volume 176, 2017, pp [8] Ju Yi, Yingping Qian, Zhiqiang Shang, Zhihong Yan, Yang Jiao, Structure Analysis of Planetary Pipe Cutting Machine Based on ANSYS, Procedia Engineering, Volume 174, 2017, pp [9] Yi Pan, Guo Rui, Hongyi Li, Hongyuan Tang, Long Xu, Study on stress strain relation of concrete confined by CFRP under preload, Engineering Structures, Volume 143, 2017, pp [10] Anil Kumar Vishwakarma, Pawan Kumar Singh, Vicky Lad and Dr. L. P. Singh, Study and Analysis of Connecting Rod Parameters using Ansys. International Journal of Mechanical Engineering and Technology, 7(4), 2016, pp [11] Pawan Kumar Singh, Dr. L. P. Singh, Vicky Lad and Anil Kumar Vishwakarma, Modelling of Crankshaft by Cad Tool and Finite Element Analysis Using Ansys Software. International Journal of Mechanical Engineering and Technology, 7(4), 2016, pp [12] Hugh A. Carson, David L. Darmofal, Marshall C. Galbraith, Steven R. Allmaras, Analysis of output-based error estimation for finite element methods, Applied Numerical Mathematics, Volume 118, 2017, pp editor@iaeme.com