Design Optimization of an Automobile Connecting Rod Using FEM

Abstract In automotive engines, the connecting rod is subjected to high cyclic loads. These are represented by high compressive loads due to combustion, and high tensile loads due to the connecting rod mass of inertia. The main objective of this study is to optimize the shape of a connecting rod in an automobile engine. A model of the connecting rod has numerically been built and has been solved by the Finite Element Method (FEM) using the ANSYS package to determine the stresses distribution over the entire rod. In addition, the transition force analysis of the connecting rod and the verification of the analysis are shown. The aim of the optimization has been to minimize the respective Von Mises stresses which occur at connected rod in both cases, i. e. compressive loads coming from the gas pressure at maximum engine output and the bending loads resulting from the inertia force at the maximum engine power. The weight of the connecting rod should be maintained to prevent increasing of the inertia force. The results of this study indicate that the maximum compression stress occur at compressing loads at the small end section of the connecting rod. Optimizing the radius at the small end decreases such stresses. On the other hand, the inertia forces of the connecting rod mass cause a maximum bending stress at the large end section. By changing the shape and geometry of this section the maximum Von Mises stresses are reduced by 16.5 %, as compared to the original design. A buckling analysis has been carried out for the original and the optimized model and the results have been compared. The load factor (critical load / applied load) is increased by 7 % compared to the original design. Finally, a shape optimization for connecting rod reduces the stresses over the entire rod.