Journal of Jilin University(Engineering and Technology Edition) ›› 2019, Vol. 49 ›› Issue (6): 1992-2001.doi: 10.13229/j.cnki.jdxbgxb20180816

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Performance analysis and lightweight design of 36MnVS4 fracture⁃splitting connecting rod

Zhou SHI1,2(),Shu-qing KOU1,2()   

  1. 1. College of Materials Science and Engineering, Jilin University, Changchun 130022, China
    2. Rolling Forging Institute, Jilin University, Changchun 130022, China
  • Received:2018-08-05 Online:2019-11-01 Published:2019-11-08
  • Contact: Shu-qing KOU E-mail:shizhou2023@163.com;Kousq@jlu.edu.cn

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Abstract:

Compared with the first-generation of fracture-splitting material C70S6, the tensile and yield strengths of the new material 36MnVS4 are significantly improved. In order to reduce the weight of the connecting rod to meet the requirements of the engine's low energy consumption and low vibration, the structure of the 36MnVS4 connecting rod is improved. Based on the design of the original C70S6 connecting rod structure, the high-strength steel 36MnVS4 is used instead. Three-dimensional inverse reconstruction of fracture surface of C70S6 and 36MnVS4 connecting rods are conducted, and an effective analysis model of connecting rods is established. The fatigue strength analysis by finite element simulation shows that the fatigue life and safety factor of the 36MnVS4 connecting rod are significantly higher than that of C70S6 connecting rod, and there is sufficient safety reserve for lightweight improvement. With the constraints of connecting rod strength and stiffness, the structural design of the 36MnVS4 connecting rod is improved that the mass of the connecting rod is reduced by 21%.

Key words: materials synthesis and processing technology, connecting rod fracture-splitting, 36MnVS4, reverse reconstruction, fatigue performance, lightweight design

CLC Number: 

  • TG406

Fig.1

Optical microstructure of the tested steels"

Fig.2

Material true stress and strain curves"

Fig.3

Connecting rod structure and dimension"

Fig.4

Fracture surface morphology"

Fig.5

Point cloud data"

Fig.6

Fracture surface after fitting"

Fig.7

Three dimensional model of connecting rod"

Fig.8

Load of connecting rod （a）最大拉伸工况 （b）最大压缩工况"

Fig.9

Fatigue life of connecting rods （a）C70S6 （b）36MnVS4"

Fig.10

Safety factor distribution of connecting rods （a）C70S6 （b）36MnVS4"

Table 1

Working condition and Optimization parts"

连杆区域 危险工况 潜在失效形式 优化措施
连杆小头 最大惯性力工况 疲劳失效、孔径变形 优化连杆小头截面的宽度及几何形状
连杆大头 最大惯性力工况 疲劳失效、大头孔变形 优化连杆大头截面的宽度、厚度及连杆螺栓孔周围加强筋的几何形状
连杆杆身 最大爆压力工况 杆身失稳 优化连杆杆身截面形状以及杆身与大、小头孔连接处结构
杆身与大、小头过渡处 最大爆压力工况 应力集中造成断裂 杆身与大、小头孔过渡区域圆弧

Fig.11

Small head structure （a）普通结构 （b）楔形结构"

Fig.12

Effects of α and X on the strength and stiffness"

Fig.13

Comparison of shaft structure before and after optimization"

Fig.14

Shaft deformation"

Fig.15

Size comparison of large head structure"

Fig.16

Deformation of big head hole"

Fig.17

Big end stress distribution"

Fig.18

Curve of stress change along the path"

Fig.19

Comparison of 36MnVS4 connecting rod structure before and after optimization"

Fig.20

Connecting rod fatigue life and safety factor distribution"

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