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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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

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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

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