Dimensional structural mass optimization of forged steel connecting rod for aircraft piston engine

Abstract

Abstract The connecting rod is an important component of the engine. It conveys the kinetic energy from the piston to the crankshaft. All cars and aircraft engines contain at least one connecting rod, which differs from one motor to another in terms of length, size and shape. Hence, it is subjected to massive alternating load. This research aims to improve the connecting rod design by reducing its mass without sacrificing durability and safety especially for aircraft applications. Therefore, a static stress analysis is carried out on forged steel connecting rod using ANSYS APDL. Geometric modelling of the connecting rod was created using ANSYS APDL. Additionally, von-Mises stress and strain, principal stresses and strains, shear stress and the deflation results of the connecting rod are investigated. The results showed a great opportunity for mass weight reduction. Thus, a dimensional structural mass optimization was performed. The optimization results were promising, which reduced the mass by 55.13% (in the tensile case) and 56.7% (in the compression case) from the initial design. Therefore, the efficiency of aircraft engine can be maximized.