Design Optimization of an Automobile Connecting Rod Using

FEM
A Comparative Study of Optimal Shape with a Two- and Three-Dimensional Models
1

Hassan S. Hedia , Ismail M. R. Najjar and Saad M. Aldousari

1
King Abdulaziz University, Faculty of Eng., Prod. Eng. Dept., Jeddah, Saudi Arabia
Prof. Dr. Hassan S. Hedia, born 1959, is professor of Materials and Solid Mechanics. He is working at
the King Abdulaziz University, KSA. He received his BSc in 1981 from the Mechanical Engineering
Department of the Cairo University, Egypt, and his MSc in 1989 in Production Engineering, from the
Mansoura University, Egypt. 1996 he obtained his PhD from the Mechanical Engineering Department
at the Leeds University, UK, and the Mansoura University, Egypt under channel system. His field of
interests are advanced materials, fracture mechanics, stress analysis, and biomechanics.
Dr. I.M.R. Najjar, born 1966, is an assistant professor at the King Abdulaziz University, KSA. He
receiced his BSc and MSc in 1989 and 1993 from the Mechanical Engineering Department., Collage
of Engineering, King Abdulaziz University, KSA. His PhD he obtained in 2003 from the Warwick
University, United Kingdom. His field of interest is mechanical measurements.
Dr. S. M. Aldousari, born 1956, is an assistant professor at the King Abdulaziz University, KSA. 1980
he received his BSc from the Mechanical Engineering Department, Colleage of Engineering, King
Abdulaziz University, KSA, and his PhD and MSc in 1993 from the Bradford University, United
Kingdom. His field of interest is manufacturing technology.
Eng. Ghazi H Alsoruji received his BSc in Mechanical Engineering from the King Abdulaziz University
(KAU). Four years field experiences in one of the biggest desalination and power plant in Saudi
Arabia Shoiba Desalination and Power plants. Areas of interest are: modeling, design, optimization,
simulation, and manufacturing in mechanical engineering.

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.

Read More: http://www.hanser-elibrary.com/doi/abs/10.3139/120.110188