Advanced Connecting Rod Design for Mass Optimization
D i for Design f Light Li ht Weight W i ht Connecting C ti Rod R d
Alex Antoc MAHLE Industries Industries, Inc Inc.
2010-01-0420
MAHLE
Connecting Rod Weight Optimization
Contents
Connecting Rod Weight Optimization
Selection Criteria Critical Connecting Rod Zones Pin End Features Shank and I-beam Crank End Features Advanced Numerical Simulation Engine Validation Conclusions & Future Work
2010-01-0420
MAHLE
Connecting Rod Weight Optimization
Selection Criteria
Selection Criteria
Current Production Rod 36MnVS4BY Forged Steel Stepped Pin End Bushing-less Bushing less Pin End MJ8 vs. MJ9
Current Production
Optimized Design
2010-01-0420
MAHLE
Connecting Rod Weight Optimization
C iti l Zones Critical Z
Pin End
Strap Thickness Oil pockets Pin Bore Profile Surface Finish Coating & Clearance
Shank and I-beam
Web Thickness Cross Section Transition Shape
Crank End
Crank Bore Deformation Bolted Joint Optimization
2010-01-0420
MAHLE
Connecting Rod Weight Optimization
Pin End Features
DOE I & II
Pin Bore Profile Shape & Size Surface Finish Rough vs. Fine Finish Forged Oil Pockets Clearance g Pin Bore Coating
DOE 1&2 Matrix
2010-01-0420
MAHLE
Connecting Rod Weight Optimization
Shank and I-beam
Improved Transition Shape
Ogee-arc shape 10% Less Crank End Stress at Max. Speed 10 m Less Vertical Deformation 10 grams lighter Less Bearing Stress Improved Bearing Fatigue Limit
Minimum Cross Section
Corner Radii Web Thickness Numerical Simulation
2010-01-0420
MAHLE
Connecting Rod Weight Optimization
Crank End Features
Bolted Joint Friction
Tightening Method Clamp Load (Fatigue, Gap Opening) Bulging Bore Distortion Bolt Self Loosening Galling/Chatter
Minimum Thread Engagement
Material Selection, Thread Size Acceptable Limits (0.7-0.8 x Bolt Diameter)
Crank Bore Roundness
Increased Bearing Stress g & Wear Fatigue Roundness Planes Measurements
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2010-01-0420
MAHLE
Connecting Rod Weight Optimization
Advanced Numerical Simulation
Structural FEA
Fatigue F ti S Safety f t Factor F t Stress Results Criteria 95% Survival Rate 10 Million Cycle Pin Bore Profile
Piston pin p
Results
Pressure @ Beginning of Profile Too Aggressive Profile Safety Factors Above MAHLE Min. Standards
Connecting rod Bearings Bearing cap Bolt s
2010-01-0420
MAHLE
Connecting Rod Weight Optimization
Engine Validation
Tests
Successfully y Completed p 50 Hours Transient City y Cycle y Test Pin End Deformation Crank Bore Roundness Passed Buckling Bench Testing @ 1.4 x Max. Compression Load
2010-01-0420
MAHLE
Connecting Rod Weight Optimization
Buckling Limit Experimental Validation
Maximum Engine Loading
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2010-01-0420
MAHLE
Connecting Rod Weight Optimization
Conclusions
Results
27% Mass Reduction Meets MAHLE Min. Safety Factor Mass Production Valid Ideal for Range Extender/Hybrid Applications Light Weight Engine Applications
Future Work
Advanced Numerical Simulation Full Engine Dynamometer Durability Test
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2010-01-0420
MAHLE
