Assembly Analysis of Piston, Connecting Rod & Crankshaft

L. Karthik Chakravarthy, Dr. P. Srikanth

Abstract: The main function of the piston of an IC engine is to receive the impulse from the expanding gas and to transmit the energy to the crankshaft through the connecting rod. The piston must also disperse a large amount of heat from the combustion chamber to the cylinder walls. The aim of this Project is to Model & Assemble the Piston, Connecting Rod & Crankshaft for a 4-stoke air-cooled 150cc Engine by theoretical calculations & also to Compare the Structural Analysis & Modal Analysis on two different materials such as (Aluminum Alloy - Cast iron) for Piston, (Aluminum Alloy - Manganese steel) for Connecting Rod & (Nickel Chromium steel - High carbon steel) for Crankshaft. Modeling, Assembly of Piston, Connecting rod and Crankshaft is done in Pro/Engineering software & Analysis is done in ANSYS. Structural analysis is used to determine displacements & stresses under static & buckling loads. Modal Analysis is used to determine the Vibration characteristics (natural frequencies & mode shapes) of the three components. By comparing the displacement & stress results, using Cast Iron for Piston, Manganese Steel for Connecting rod and High Carbon Steel for crankshaft is best combination for assembly.

Keywords: Piston, Connecting Rod, Crankshaft, Pro/E, ANSYS, Structural Analysis & Modal Analysis