International Journal for Research in Engineering Application & Management (IJREAM)

ISSN : 2454-9150 Vol-04, Issue-12, Mar 2019

Design & 3D Printing of 180cc Engine

Connecting Rod
Prof. Amit Dalvi1, Mr. Pravesh Shilotri2, Mr. Vaibhav Jadhav3, Mr. Girish Jadhav4
1
Professor, 2,3,4 B.E. Student, Dept. of Mechanical Engineering, VOG College of Engineering,
Atgaon, Maharashtra, India.

Abstract: Connecting rod interconnects piston to crankshaft and it is responsible for transferring power from piston to
the crankshaft and sending it to the transmission. Connecting rod are traditionally manufactured using mould casting
method which has high moulding cost and requires highly skilled designer to design the mould which is also more
costly. So there is a need to optimise the manufacturing process of connecting rod. In this project work, Objective is to
use advance manufacturing processes to produces complex Designs using 3d printing methods. Connecting rod of
Apache RTR 180cc engine is considered and will use 3D printing technique and different filament materials for
customized requirements. Theoretical designing of connecting rod is done as per standard connecting rod design
procedure and 3D modelling is done using Solidworks 2015 software. Finite Element analysis software ANSYS 15.0 is
used to study the load carrying capacity of connecting rod. Connecting rod is manufactured using 3D printing FDM
technique with three different filaments i.e. ABS, Nylon 66 and PC. Experimental testing will be done on the 3D printed
connecting Rod using UTM Machine.[1] The results of Finite element analysis shows that 3D Printed Connecting rod
made of Acrylonitrile Butadiene Styrene will carry 47 KN load compared with other 3D printed Connecting rod. These
types of connecting rod can be used for as per engine specifications and required load carrying capacity with short time
of production and complex designs.

Keywords — Acrylonitrile Butadiene Styrene, Connecting Rod, CAD Design, 3D Printing, Finite element analysis, NYL
66.

In this paper, an attempt is made to design a new concept

I. INTRODUCTION of manufacturing connecting rod using additive
3D printing creates solid parts by building up objects one manufacturing where there is a requirement for customized
layer at a time. Producing parts via this method offers order or single product without investing into mold
many advantages over traditional manufacturing manufacturing cost. Connecting rod is designed using 3
techniques. 3D printing is unlikely to replace many Different filaments i.e. ABS, PC and Nylon.
traditional manufacturing methods yet there are many It consist of three main parts
applications where a 3D printer is able to deliver a design
quickly, with high accuracy from a functional material. Pin End (Small End)
Understanding the advantages of 3D printing allows Shank Section (Middle)
designers to make better decisions when selecting a Crank end (Big End)
manufacturing technique that results delivery of the
optimal product. One of the main advantages of additive
manufacture is the speed at which parts can be produced
compared to traditional manufacturing methods. Complex
designs can be uploaded from a CAD model and printed in
a few hours. The advantage of this is the rapid verification
and development of design ideas. Where in the past it may
have taken days or even weeks to receive a prototype, Fig -1: Connecting Rod
additive manufacturing places a model in the hands of the
designer within a few hours.[3] While the more industrial Traditionally Connected rods are manufactured using Alloy
additive manufacturing machines take longer to print and steel, who’s manufacturing cost is high due to mold
post process a part, the ability to produce functional end casting, quenching processes etc. So there is a need to
parts at low to mid volumes offers a huge time saving design a 3D printed Connecting rod using advanced 3D
advantage when compared to traditional manufacturing printing methods & materials which can be made quickly
techniques. and easily, with high strength, durability and performance.
With following objective we overcome above problem.

479 | IJREAMV04I1248168 DOI : 10.18231/2454-9150.2019.0173 © 2019, IJREAM All Rights Reserved.

 International Journal for Research in Engineering Application & Management (IJREAM)
ISSN : 2454-9150 Vol-04, Issue-12, Mar 2019

1. To Design the 3D printed connecting rod with

different 3D printing materials and to study the
Table -1: Design Parameter & Calculation
behavior at actual loading conditions.
2. To find the stresses and deformation produced on
3D printed connecting rod.
3. To find the strongest 3D printing material to
manufacture a connecting rod.

CAD Model
Solid works currently markets several versions of the Solid
works CAD software in addition to e-drawings, a
collaboration tool and a draft sight a 2D CAD product. 3D
Modelling of Connecting rods as per Design Calculations
in Solidworks
Fig -2: CAD Model of Connecting Rod
Chart -1: Methodology

II. DESIGN CALCULATION OF ONNECTING

ROD SPECIFICATION OF ENGINE
Connecting rod can be used in large number of engine
capacities. In this project work, it is restricted to design of
two wheeler 180cc engine. Commonly used 180cc Apache
RTR Engine is considered whose specifications are as
follow
Consider an Apache RTR 180
Engine type =Single-
cylinder, 4-stroke air
cooled
Bore × Stroke (mm) =
63×56 Displacement = 3D Printing & Material Selection
177.4 cc Additive Manufacturing (AM) is a term to describe set of
Maximum Power = 17.3ps @ 8500 technologies that create 3D objects by adding layer-upon-
rpm Maximum Torque = 15.5nm @ layer of material. Materials can vary from technology to
6500 rpm Compression Ratio = technology. But there are some common features for all
9.35/1 Addictive Manufacturing, such as usage of computer
Design Parameter together with special 3D modeling software.
Thickness of flange & web of the
Selection of 3D Printing Method
section= t Gas force = Fg
Table -2: Selection of 3D Printing Methods
Thickness of the bush = tb = 2
Marginal thickness = tm = 5
Bearing Pressure = Pb = 15
Length of the piston pin = L1 = 1.5 x IDs
Length of the piston pin = L2 = 1 x IDs
Design Calculation

Fused deposition modeling (FDM) 3D printing method is

selected because its products have high strength and it is
most widely used method for 3D printing. It is compatible
with huge variety of filaments such as nylon, wood, carbon
fiber etc. FDM method is simple doesn’t require an expert

480 | IJREAMV04I1248168 DOI : 10.18231/2454-9150.2019.0173 © 2019, IJREAM All Rights Reserved.

 International Journal for Research in Engineering Application & Management (IJREAM)
ISSN : 2454-9150 Vol-04, Issue-12, Mar 2019

worker. This Method is used for manufacturing of

Connecting Rod.

Table -3: 3D Printing Materials

Fig 3: Geometry of connecting rod in ANSYS.

The following 3D printing materials have been shortlisted
because of their high tensile strength, durability,
availability and low cost which is required for the proper
functioning of connecting rod.
Table -4: Mechanical Properties of Material

Material Selection is done on the basis of Availability of

Fig -4: Boundary Condition
Printing Machine to print the Component, Cost, and
Weight Carrying Capacity and commonly preferred by the Analyze connecting rod for ABS, NYL 66 & PC Material
industry. for Stress and Deformation
Table -5: 3D Printing Product Cost Estimation

Printing cost for 3D printed parts in the market varies from

Rs. 15/gram to Rs. 35/gram depending upon the machine
used for printing and type of filament used. The above said Fig -4: Equivalent Stress & Deformation
cost is for ABS, it may vary slightly for other materials
also. This cost is inclusive of filament and machining cost.
IV. RESULTS
III. FEA SIMULATION Table -6: FEA Results
ANSYS Workbench 15.0 is used for FEA. Connecting rod
is assumed to be fixed at small end and subjected to
compressive bearing load at the Big end. Mesh size is 2
mm.[2] Patch confirming method with tetrahedron mesh is
done. ANSYS simulation is done for four materials.
Appling boundary conditions cylindrical support 0 and
bearing load 47000N.

A. FEA results shows that Acrylonitrile Butadiene

Styrene is strong when subjected to tensile or

481 | IJREAMV04I1248168 DOI : 10.18231/2454-9150.2019.0173 © 2019, IJREAM All Rights Reserved.

 International Journal for Research in Engineering Application & Management (IJREAM)
ISSN : 2454-9150 Vol-04, Issue-12, Mar 2019

compressive loading. These types of 3D printed [4] K. Sudershan Kumar, Dr. K. Tirupati Reddy, Syed
components can be used when there is customized Altaf Hussain, "Modeling And Analysis Of Two
requirement. Wheeler Connecting Rod", ―International Journal Of
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Biology where 3D printed body parts can significantly [6] Leela Krishna Vegi, Venu Gopal Vegi, "Design And
enhance learning. Feeling the texture of a brain is Analysis Of Connecting Rod Using Forged Steel",
different from seeing it in a book or on screen. ―International Journal Of Scientific & Engineering
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Rod’s Made From Ti-6al-4v, Steel And Al-Lm6 ",
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482 | IJREAMV04I1248168 DOI : 10.18231/2454-9150.2019.0173 © 2019, IJREAM All Rights Reserved.