Static and Dynamic Analysis of Radial Engine Master Rod (PowerPoint Presentation Sample)

* Radial Engine is a reciprocating type IC Engine Configuration in which the pistons are connected to the crankshaft using master and articulating rod assembly. The small end of the master rod is connected to the piston end, and the big end is mounted on the crank pin of the crankshaft.
* The function of the master rod is to translate the alternating translating motion of piston into rotational motion of the crankshaft.
* The collapse of the master rod is among the most common radial engine failures. During the operation of the engine, the master rod is prone to tensile, compression, and buckling loading and fatigue loading.
* We will be doing failure analysis for master rod of 400cc 5- cylinder MOKI-S engines master rod.
8136975-91945LITERATURE SURVEY
Year

Author Name

Title

Highlights

2020

Sunil Kumar HE, Dr. Mohammed Imran, Sagar S R

Static and Dynamic Analysis of Radial Engine Master rod using ANSYS

The aim of the paper is to determine the stresses developed in the master rod due to static and dynamic loading conditions. Harmonic analysis is carried out to find out the various plots of frequency and amplitude against rotational velocities.

2016

C Juarez, F Rumiche, A Rozas, J Cuisano, P Lean

Failure Analysis of a diesel generator connecting rod

This paper presents the results of a failure analysis investigation conducted in a connecting rod from a diesel engine. Visual inspection, fractography, tensile and hardness testing, microanalysis was carried out at the fracture zone.

Year

Author Name

Title

Highlights

2017

K. Baria, A. Rolfea
, A. Christofia , C. Mazzucaa , K.V. Sudhakarb

Forensic investigation of a failed connecting rod from a motorcycle engine

A failed connecting rod was investigated for the root cause of failure. Scanning Electron Microscope was used to investigate mechanisms of fracture modes and to study microstructures. Results were validated using FEM analysis

2013

Priyank D. Toliya, Ravi C. Trivedi, Prof. Nikhil J. Chotai

Design And Finite Element Analysis Of Aluminium-6351 Connecting Rod

The objective of this research is to investigate the failure of the connecting rod experimentally and FEM Analysis. Static Analysis is done to determine the deformation, strain and stresses.

2017

Manish Kumar, Shiv N Prajapati

Design, Buckling and Fatigue Failure Analysis of Connecting Rod

In this paper various c/s of the rod like I Section, rectangular section, + section, circular section were studied using Fem analysis.

Year

Author Name

Title

Highlights

2015

Antonio Strozzi, Andrea Baldini, Enrico Bertocchi, Sara Mantovani

A Repertoire of failures in connecting rods for Internal Combustion Engines, and Indications on traditional and advanced design methods

The paper addresses various loading conditions and stress fields. Common and uncommon failure modes are discussed. The locations of the most critical con-rod sections are examined.

2019

Shailesh Govindbhai Goyani , Viraj Nileshkumar Kakadia

Design and Analysis of Radial Engine using Parametric Software

The aim of this paper to compare the stresses, strain , total deformation developed in the connecting rod of different materials with the help of ANSYS.

8136975-286139RESEARCH GAP
Ї Many existing literature surveys focus on the failure in the transition region between the piston end and the crank end of the master rod.
Ї Our project aims in determining how Euler type collapse, fretting fatigue and position of lubrication holes cause failure in the master rod.
OBJECTIVES
Ї To determine how fretting fatigue and position of lubrication holes contribute to failure.
Ї To determine the cause of failure in the shank region.
Ї To optimize the master rod in accordance with the results obtained from failure analysis and do failure analysis for the optimized master rod and compare results with existing master rod.
8136975-643OPTIMIZING THE MASTER RODMETHODOLOGY
DESIGN CALCULATIONS
DEVELOPMENT OF CAD MODEL
FAILURE ANALYSISMOKI-S ENGINE MASTER ROD
FAILURE ANALYSISOPTIMIZED MASTER ROD
COMPARING THE RESULTS
8323760-286397Design Calculations: Calculations are done to find out the axial forces and the bending moments which are acting on the master rod.
Development of CAED Model: The parts required for performing the failure analysis is taken from the standard Moki-s 400cc 5 cylinder engine specifications.
Modeling is done in SOLIDWORKS 2016 Software.
Failure Analysis of the Moki-S Engine Master rod: Failure Analysis on the existing Moki-S Engine Master Rod is done using ANSYS Workbench. The Master rod is tested for buckling, fatigue loading, fretting fatigue between reciprocating parts and how the position of lubrication holes contributes to stresses in the Master rod.
Optimizing the Master Rod: Depending on the results obtained from Failure Analysis, the master rod is optimized at the critical regions using Solidworks.
8136975-214096Failure Analysis of the Optimized Master Rod: After Optimizing the Master rod, the Solidworks model is incorporated into Ansys Workbench and is again tested for buckling, fatigue failure, fretting fatigue and the stresses developed near lubrication holes.
Comparing the Master Rods: The results from failure analysis of the existing master rod and the optimized master rod are compared between each other.
8136975-317889DESIGN CALCULATIONS
Analytical Design Calculations to determine the axial force on the master rod, buckling load ,bending moment are done by taking the dimensions from Moki-S 400cc 5 cylinder radial engine.
Max Power : 171 KW @ 6000 rpm
Stroke length(l) = 0.032m Crank radius(r) = 0.016m Master rod length = 0.25m
Thickness of the Master rod(t) = 0.005m Piston Weight – 13.73N (from research paper)
Weight of the master rod – 26.5N (from research paper)
14067788395888136975215137CAD Modelling
Master rod
Articulating rodMaster rod bearing
Piston ringsPiston Pin16
Piston
Piston Pin Plug
5500496200500
Link pin
Lower Rod BushUpper Rod bush
MODELLING
8136975-1069677Piston
Master rod
Piston pin plug
Articulating rod
Link pins
8136975-221549SIMULATION
The Analysis is done using ANSYS Workbench 19.2 The analyses done are as follows-
1 Transient Structural Analysis
1 to find the fretting fatigue between the Master rod-crankshaft end
2 to find Max. Principal stress and total deformation at the Master rod
2 Static Structural Analysis
3 to find optimum position for lubrication holes.
3 Eigen value Buckling & Fatigue Analysis
4 to determine different buckling modes of the Master rod.
5 to find Fatigue life and Safety factor.
819255630123Transient Structural Analysis
This analysis is done to determine the fretting fatigue for the master rod, in the region where the Master rod comes in contact with the crankshaft.
Boundary Conditions:
703376179400
803262250
Results :
1 Maximum Principle stress ( prime indicator of fatigue failure )
2868801859154641967102730
From the graph, max principal stress v/s step number
* The Maximum principal stress value over time at the Master rod is 332.75 Pa
* The Minimum principal stress value over time at the Master rod is -11.43 Pa
And the Maximum Fretting fatigue at the Master rod crankshaft end is 0.10326 Pa
Maximum principal stress over time in the Master rod23
2 Total Deformation
379831107738
From the graph, total deformation v/s step number
* The Max total deformation value over time at the Master rod is 0.17314 m
* The Min total deformation value over time at the Master rod is 0 m
Total deformation over time in the Master rod
* 8203517-5923Static Structural Analysis
Static Structural Analysis was done to find the optimum position of lubrication holes for the Master Rod. Three cases of lubrication holes were taken and maximum Principle stresses were found for each.