The main objective of this study is focused on designing an optimized connecting rod for a 1957 Chevrolet V8 engine using Topology Optimization software, in which the primary goal was to achieve weight reduction without strength reduction. The connecting rod was designed for the process of Metal Additive Manufacturing. The strength of the original design was determined by Finite Element Analysis with calculated Boundary Conditions, using both engine specifications and important engine parameters from engine analyzer software.
The design space of the connecting rod was maximized based on the clearance inside the crankcase, and optimum density distribution was obtained by maximizing stiffness.
An optimized connecting rod was designed and modeled using Computed Aided Design software, based on Topology Optimization results and general metal Additive Manufacturing guidelines. In order to verify the strength of the optimized design, a Finite Element Analysis study was performed on the optimized connecting rod with the above-mentioned Boundary Conditions. The optimized connecting rod design resulted in an 8.13% mass reduction compared to the original design, without any significant strength reduction. In fact, the optimized design had an overall lower stress distribution.
The optimized connecting rod was compared to design trends among high-performance connecting rods in order to evaluate similarities in design trends.
Various metal Additive Manufacturing and Additive Manufacturing post-processing methods were discussed in terms of the possibility of manufacturing the optimized connecting rod, and to meet the strength and fatigue strength requirements for a connecting rod used in an internal combustion engine.
|Commitee:||Whisler, Daniel, Schmitz, Adeline|
|School:||California State University, Long Beach|
|Department:||Mechanical and Aerospace Engineering|
|School Location:||United States -- California|
|Source:||MAI 82/3(E), Masters Abstracts International|
|Subjects:||Mechanical engineering, Engineering, Automotive engineering|
|Keywords:||Additive manufacturing, Connecting rod, Topology optimization|
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