This research was conducted to examine the design of the connecting rod and perform finite element analysis onto the design using ANSYS programme. ![]() Linear motion from the piston is transformed into rotational motion via the connecting rod. In an internal combustion engine, connecting rods are usually located in between a piston and a crankshaft. Consequently, the employment of ribs appears to be unjustified from a purely stress related viewpoint. The mechanical response of cap rectangular and ribbed cross sections is compared, and it is found that ribbed sections undesirably increase the cap bending stress. The normal stress within the cap is found to be considerably higher than its bending counterpart. This model indicates that the cap bending stress depends on the initial gap between the crankpin and the cap, and not on the applied load. A load parameter that accounts for the combined effects of several leading variables is analytically derived, on which the following variables depend: a) the contact angular extent between the crankpin and the cap b) the ratio between the normal and bending stress. ![]() This model accounts for the effect of the initial clearance between the crankpin surface and the cap intrados, and it realistically mimics the crankpin-cap progressive contact. An analytical model of the stresses within a connecting rod cap is developed and satisfactorily validated versus FE (Finite Elements). ![]() In this practically oriented paper, representative examples of cap failures in a connecting rod are discussed, and deeply dissimilar geometries of the cap cross section are presented.
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