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Study of failure analysis and manufacturing processes improvement of cracking connecting rod

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Abstract

Herein, we provide a novel method of using finite element analysis to guide the improvement of manufacturing processes on the basis of physicochemical analysis. First, based on the theoretical analysis of the force of the connecting rod, the solid model of cracking connecting rod is established by SolidWorks. Then the static stress analysis, modal analysis and fatigue analysis are carried out by ANSYS, determining the location where the connecting rod is prone to failure. Second, the influence of processing technology and other factors on the failure of connecting rod is analyzed, and several improved schemes for the manufacturing process are proposed. Finally, the fatigue test of the connecting rod is performed to verify the effect. Compared with the unimproved connecting rod, the tension and pressure of the improved connecting rod increased to 92.34 KN and −425.7 KN, respectively. The safety factor under this load is 1.8, which has increased by 20 % compared to 1.5 before the improvement.

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Abbreviations

ω :

Angular velocity of crankshaft rotation

α :

Angular of crankshaft rotation

β :

Angular of connecting rod rotation

β′ :

Angular velocity of connecting rod

β″ :

Angular acceleration of connecting rod

L :

Length of the connecting rod

R :

Radius of the crankshaft

γ :

Crank and connecting rod ratio

M j :

Mass of the reciprocating part

m r :

Mass of rotation motion, and the direction of rotation

p :

Air pressure in the cylinder

p′ :

Air pressure in the crankcase

D :

Piston diameter

P :

Total acting force on the connecting rod

p j :

Reciprocating inertial force

p r :

Rotary inertial force

p g :

Algebraic sum of the acting force of air

P max :

Highest gas pressure in cylinder

m 11 :

Mass of piston assembly

m 21 :

Mass of piston pin

F press :

Maximum pressure of the connecting rod

F tensile :

Maximum tensile load of the connecting rod

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Author information

Authors and Affiliations

  1. School of Mechanical Engineering and Automation, University of Science and Technology Liaoning, Anshan, 114041, China

    Zhen Zhang & Haodong Ding

  2. School of Applied Technology, University of Science and Technology Liaoning, Anshan, 114041, China

    Anyuan Jiao

  3. Shandong Gold Phoenix Co., Ltd., Leling, 253600, China

    Xiwei Lv

Authors
  1. Zhen Zhang
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  2. Anyuan Jiao
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  3. Xiwei Lv
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  4. Haodong Ding
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Corresponding author

Correspondence to Anyuan Jiao.

Additional information

Zhen Zhang is an M.S. student and received his B.S. degree from the Department of Mechanical Engineering at Northeastern University in 2011. His research interests include fiber reinforced composite and engineering failure analysis.

An-yuan Jiao received his B.S. degree in Vehicle Engineering from the Northeast Forestry University in 2000. He obtained his M.S. degree from the Department of Mechanical Engineering at University of Science and Technology Liaoning in 2005. He received his Ph.D. degree from Northeastern University. He is currently a Professor at University of Science and Technology Liaoning. His research interests are magnetic abrasive finishing, precision milling and automation equipment development.

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Zhang, Z., Jiao, A., Lv, X. et al. Study of failure analysis and manufacturing processes improvement of cracking connecting rod. J Mech Sci Technol 36, 5445–5453 (2022). https://doi.org/10.1007/s12206-022-1010-0

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  • DOI: https://doi.org/10.1007/s12206-022-1010-0

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