Design of Connecting Rod for Weight Reduction using Alternativecomposite Material

There is demand of high speed and efficient vehicle. For high-speed vehicle, manufacturer has to design lighter, faster, and more efficient engines. Crankshaft assembly is among large volume production components in the internal combustion engine. Weight reduction of a connecting rod will increase the fuel efficiency of the engine. Therefore, it is necessary to find out alternate material for connecting rod. AluminiumSiC fly ash composite can be used as alternate material. It should give required strength and lightweight. From the given dimensions, CAD model of Connecting rod is generated. Aluminium composite is prepared by stir casting method and further tested for tensile stress and wear. Connecting rod cross section is modified for new material. FEA analysis by using Ansys workbench is carried to compare stress results of both materials. FEA result shows there is reduction in stress for composite connecting rod and these stress are within yield stress limit of material. There is61.42% percent weight reduction by using new connecting rod. It is found from literature survey that the addition of fly ash and silicon carbide in aluminium shows improvement in friction coefficient and friction force.