The challenge

The objective of the project was to redesign an existing connecting rod with the aim of reducing its weight while maintaining adequate mechanical strength and fatigue resistance under cyclic operating loads.
Using finite element analysis FEA, the component had to be evaluated under realistic operating conditions, including dynamic loads, bolt preload, and the contact interactions between the connecting rod, crankpin, and crankshaft.

Our contribution

SmartCAE developed a detailed finite element model of the connecting rod assembly to predict its structural response under representative service conditions.
The analysis accounted for dynamic operating loads, bolt preload, and nonlinear contact interactions, providing an accurate assessment of the stress distribution throughout the component.
Based on the simulation results, several design alternatives were developed, each targeting a different balance between lightweight design and mechanical performance. Depending on the selected solution, the optimized connecting rod achieved weight reductions ranging from 14% for the most conservative design to 28% for the most aggressive lightweight configuration, while satisfying the required structural performance criteria.