Fig. 2.

The three-dimensional model of the connecting rods cap

COMPUTER AIDED DESIGN OF THE CONNECTING ROD

Vasile George CIOAT Imre KISS Abstract: This study presents a method used to verify the connecting rods stress and deformation using the finite element method with Ansys v.11. The study only analyses a component of the connecting rod, and that is the connecting rods foot, and only for one challenge (request)-the extension-due to the maximum inertia force of the piston group at the end of the evacuation. The obtained results provided by this method are compared to the results obtained by classic calculation, in similar conditions of application, and afterwards conclusions are drawn. Keywords: connecting rod, stress and deformation, Ansys v.11, computer aided design Fig. 3. The three-dimensional models of the connecting rods screws and nut

1. INTRODUCTION
Based on the initial dates and relying on the recommendations from the specialized literature [1,2] the main dimensions of the connecting rods components have been established: the foot, the rod, the head of the connecting rod and the cap rod. For the three-dimensional model of the connecting rod based on the dimensions established in [2], the CAD Autodesk Inventor software, made by Autodesk, is used. Figure 1 presents the three-dimensional model of the connecting rod, Figure 2 the three-dimensional model of the connecting rods cap, and Figure 3 the threedimensional models of the connecting rods screws and nut. Fig. 4. The three-dimensional model of the connecting rods assembly The three-dimensional model of the connecting rods assembly is shown in Figure 4.

2. THE FINITE ELEMENTS ANALYSIS WITH ANSYS

In order to make the connecting rods verification with the computers help, the finite elements method is used, applied with CAE-Ansys v.11 systems help. Like many analysis programs with finite element, Ansys divides any analysis problem into three stages: preprocessing, solution and postprocessing. In the first stage, the user creates the model to be analyzed or imports it, defines the type of finite elements, establishes the materials and their properties, all these by easily activating the commands placed on the toolbar or in the contextual menu from the branches in the specification tree. In the second stage, the loads are implemented, the initial conditions and boundary conditions are defined, the model is discretized (the program also allows the automatically defining of the nodes and the finite elements for the piece exposed to the analysis) and the program is being asked to solve the problem. 83

Fig. 1. Three-dimensional model of the connecting rod

The last stage, postprocessing, allows the user to view the results obtained from the analysis. The program disposes of a big variety of facilities which will offer you the possibility of understanding the behavior of the model analyzed in reality. Animation can be used in order to test if the models form and operation fit with the practical final model.

The connecting rods foot is submitted to extension at the end of the evacuation by the maximum inertia force of the piston group, which has a value of Ft = 13562 [N].

3. MODEL DEVELOPMENT
The first step in order to start the analysis with the Ansys programs help is to choose the type of analysis. The type of analysis will decide which type of results will be obtained. For the case of the connecting rods analysis, a structural analysis will be performed. The connecting rods model is made in Autodesk Inventor and saved within this program in *.sat format. The model is imported in Ansys and then the mechanical characteristics of the connecting rod are established: density - 7850 kg/m3, Youngs modulus - 2.1.105 MPa, Poissons ratio - 0.3, elasticity limit - 320 MPa and tensile breaking strength - 610 MPa. The connecting rods analysis will be made in the linear static field, where small changes happen in rigidity, no change happens in the uploading direction, the materials stay in the linear elastic field and small deformations and efforts are generated. The finite elements network is made automatically, using the Mesh option from the specification tree. This procedures result is shown in Figure 5.

Fig. 6. The force distribution on the upper exterior cylindrical surface

Fig. 7. Bearing Load

Fig. 5. The finite elements results After the discretization, the loads and the constraints of the connecting rod are imposed. These are specific to every function phase of the connecting rod. One of the important factors for an accurate result is to apply correctly the loads and the constraints. There are many ways to apply different loads and constraints to the model: on nods, on edges, on surfaces or elements. The verification is made separately for the components of the connecting rod. This study presents the finite element analysis of the connecting rods foot, being loaded in tension. 84

Fig. 8. Embedding-Fixed Support It is considered that the force is distributed on the upper exterior cylindrical surface of the connecting rods foot, following a sinusoidal law (Figure 6), the resultant being equal to the concentrated force (Figure 7). Concerning the constraints applied to the piece, all the DOFs of A surfaces from Figure 8 (embedding-Fixed Support) and the DOFs tangent and radial of the inside cylindrical surfaces B from the same figure (Cylindrical Support) were bounded, the grade which allows the axial translation along the holes remaining free.

4. RESULTS
After performing the analysis, the results are obtained as stress fields and deformations. For the actual case, the stresses are obtained following the von Misses theory, the total deformations and deformations in X and Y direction. The equivalent stress fields calculated with the von Misses theory is shown in Figure 9, and the deformations in X and Y directions are shown in Figure 10 and Figure 11.

Fig. 11. The deformations in directions Y

5. CONCLUSIONS
In order to compare the equivalent stresses due to the challenge at traction of the connecting rods foot, obtained through the two methods, the representation in Figure 12 was made. Using the classic method, the maximum values of the equivalent stresses in the outer and inner fibers were obtained, considering that the embedded section corresponds to the 1300 angle. It can bee seen in Figure 12 that the equivalent stresses obtained with the finite element analysis in the interest zones, have approached values to those calculated with the classic method. Concomitantly, it can be observed that in the interest zones, the stress values are maximum, fact which confirms the theory.

Fig. 9. The equivalent stress fields calculated with the von Misses theory

Fig. 12. The equivalent stresses - the two methods The maximum deformation of the foot under the action of the extension force Ft, calculated with the classic method, has a value of 0.073 mm. In Figure 11 it can be observed that the maximum deformation obtained with the finite element method has a maximum value of 0.036 mm. This can be explained by the fact that many simplification hypotheses were considered for the classic calculation. 85

Fig. 10. The deformations in directions X

As a result of the connecting rods designing using the two methods: classic and computer aided, the next conclusions are made: From the constructive form designings point of view ,both of the methods require dates and informations which can be found in the specialized literature, some of them obtained through statistic ways, the experience of the designer being requested. After establishing the main dimensions of the connecting rod, in the case of classic designing, the execution drawing is made manually or with help from a drawing soft, composed of plane representations, which represents a disadvantage because it is necessary to compose the plane images in the mind to view its 3D model. Besides the fact that it allows the three-dimensional view of the designed model, a parametric threedimensional designing soft also allows the fast obtaining of execution drawings with the purpose of making its technical elaboration, and any modification on the three dimensional model is also made automatically on the execution drawings. From the verifications calculations point of view, it is obvious that using a finite element analysis soft (Ansys, in this case) for the stresses and deformations calculations, saves a lot of time, comparative to the classic methods calculation. Even more, results are obtained in all of the structures nodes, not only in certain sections. By using CAD and CAE software in the pieces designing activity, the designer has the possibility to analyze, in a short time, different constructive variants, making his designing work more effective. Concerning the obtained results through the two designing methods, it is observed that the values have the same size order (especially the equivalent stresses), which indicates the fact that the threedimensional model, the loads and the constraints were correctly prescribed.

REFERENCES
[1] PICOS, C., s.a, Tehnologia construciei de maini. Probleme, Editura didactic i pedagogic, Bucureti, 1976 [2] RAICA, T., Construcia i calculul motoarelor cu ardere intern, P. III, Lito IPTV Timioara, 1984 [3] CIOATA, V. G., MIKLOS I. Z., Proiectare asistat de calculator cu Autodesk Inventor, Ed. Mirton, Timioara, 2009 [4] CIOATA, V. G., Proiectare asistat de calculator cu Catia V5, Ed. Mirton, Timioara, 2008 [5] SHAM TICKOO, Autodesk Inventor 2008 for Designers, CADCIM Technologies, USA, 2008 [6] *** - Ansys Users Manual [7] STOLARSKI, T., & collective, Engineering analysis with ANSYS software, Butterworth-Heinemann, 2006

CORRESPONDENCE
Vasile George CIOAT, Lect. Dr.Eng. University Politehnica Timisoara Faculty of Engineering - Hunedoara 5, Revolutiei 331128 Hunedoara, Romania vasile.cioata@fih.upt.ro Imre KISS, Assoc. Prof. Dr., Eng. University Politehnica Timisoara Faculty of Engineering - Hunedoara 5, Revolutiei 331128 Hunedoara, Romania imre.kiss@fih.upt.ro

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