STRUCTURAL ANALYSIS AND COMPARISON OF GREY CAST IRON AND STEEL CONNECTING ROD FOR FOUR STROKE PETROL ENGINE

Abstract

The connecting rod is a crucial component in internal combustion engines, responsible for transmitting motion from the piston to the crankshaft. The choice of material significantly impacts the performance, durability, and efficiency of the engine. This study conducts a structural analysis and comparison of grey cast iron and steel (AISI 4140) connecting rods for a four-stroke petrol engine using Finite Element Analysis (FEA). A 3D CAD model of the connecting rod is developed, and static and dynamic analyses are performed to evaluate stress distribution, deformation, and fatigue life. The results indicate that steel exhibits superior mechanical properties, with higher tensile strength (450 MPa vs. 250 MPa) and significantly better fatigue resistance (1,000,000+ cycles vs. 200,000 cycles for grey cast iron). However, grey cast iron offers advantages in vibration damping and cost-effectiveness. The findings suggest that steel is preferable for high-performance engines, while grey cast iron may be suitable for low-cost applications with moderate stress conditions. This study provides valuable insights for material selection in connecting rod design, balancing strength, weight, and cost considerations.

Author

Mr. M.S.Mohamed Musthaq, Mr. P.Vignesh, V.Elangovan, C.Kalaiselvan, V.S.Srenivashan, M.Srithar