Fatigue Analysis Correlation and Failure Analysis of Optimized Connecting Rod

ABSTRACT The paper deals with the static and fatigue analysis of optimized design of automotive connecting rod. Optimized design is nothing but modification of existing design having initial weight 11.46kg. After modifying I-Section, there is about 17.37% weight reduction achieved. Fatigue analysis of modified design having weight of 9.47kg, shows fatigue life of 1.5E006. Experimental validation is done on optimized Connecting Rod design by testing the same on servo hydraulic testing machine which shows same fatigue life as given by FEA analysis. Then failure analysis has been carried out to check whether any other factor is responsible for this failure except design parameters or not. These checked parameters are chemical composition, surface finish at failure region and grain flow. These parameters are as per specifications. So we can say that failure is due to design only. But since fatigue life is sufficient, the modified design is optimized on.