Modeling and static analysis of a connecting rod in range extender engine

This paper discusses design and static analysis of a connecting rod which is one of the essential components of an internal combustion engine. In this study, connecting rod design is used to construct range extender engine. Range extender engine is one of the important components used to improve the shortcomings of electric vehicles which in this study is of 999 cc capacity. Finite element method was used to analyze the stress, deformation and strain on the connecting rod as a result of the pressure that occurs during combustion. The material used in this research is AISI 4340 steel. Design and analysis were done using SolidWorks software and Ansys Workbench. The pressure contained in the combustion chamber was 5.5 MPa, cylinder bore and stroke was 86 mm x 86 mm. The forces acting on the connecting rod due to pressure of combustion was 32157 N. The maximum value of stress, deformation and strain occurred in the connection between the rod connecting rod big end. Von Mises stress maximum is 423.95 MPa. The maximum deformation value of the connecting rod is 0,125 mm. The maximum principal elastic strain value is 0.0012 mm/mm. The maximum shear stress value of connecting rod is 218.38 MPa. Moreover, stress, deformation and strain evaluations of connecting rod were also done and the results obtained are used as valuable reference in the optimization and improvement to the connecting rod design.