Finite Element Analysis of Connecting Rod Materials for Internal Combustion Engines: A Comparative Study of Aluminum Alloys, Cast Carbon Steel, and Titanium

This study conducts a detailed finite element analysis (FEA) to evaluate the performance of different materials used in the manufacturing of connecting rods for internal combustion engines. The materials under investigation include aluminum alloys, cast carbon steel, and titanium. The primary objective is to compare these materials in terms of mechanical performance, stress distribution, and deformation characteristics under operational conditions. Using advanced simulation techniques, the study assesses the fatigue life, weight efficiency, and cost-effectiveness of each material. Aluminum alloys are known for their lightweight properties, which can significantly reduce the overall weight of the engine, leading to improved fuel efficiency. However, their lower strength compared to other materials necessitates a careful examination of their suitability for high-stress applications. Cast carbon steel, on the other hand, offers a good balance between strength and cost, making it a popular choice in the automotive industry. Despite its higher weight, its cost-effectiveness and adequate performance make it a viable option. Titanium, although more expensive, provides superior strength and fatigue resistance, making it ideal for high-performance engines where durability is critical. The FEA results indicate that titanium exhibits the highest strength and fatigue resistance, followed by cast carbon steel and aluminum alloys. However, aluminum alloys offer the most significant weight savings, which can be crucial for applications where reducing mass is a priority. Cast carbon steel remains a cost-effective option with satisfactory performance metrics. This comparative analysis aims to provide a comprehensive understanding of the trade-offs involved in selecting materials for connecting rods. The findings are intended to guide engineers and designers in making informed decisions to optimize the design and efficiency of internal combustion engine components.