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CR-110 CONNECTING ROD — design comparison
3 runs against PCX-ENG-001 rev A · reference baseline
baseline · As released584.1 greferenceFail
V1 · Iteration 1575.7 g−8.4 g (−1.4%)Pass, with open items
V2 · Iteration 2568.6 g−15.5 g (−2.6%)Pass, with open items
What changed
| Variant | Dimension changes | Why |
|---|---|---|
| V1 | D2@SK-SMALL-END: 28.00 → 31.00 mm D1@SK-SHANK: 24.00 → 22.00 mm D1@BOLT-BOSSES: 20.00 → 18.00 mm | D2@SK-SMALL-END to 31 mm: SMALL-END-BORE reaches 395 MPa in LC2-inertia, 111% of the allowable stress. Add material here. D1@SK-SHANK to 22 mm: Its busiest feature, SHANK, works at 47% of the allowable stress. Material here is mostly idle. D1@BOLT-BOSSES to 18 mm: Its busiest feature, M8 CBORE, works at 22% of the allowable stress. Material here is mostly idle. |
| V2 | D2@SK-SMALL-END: 28.00 → 31.00 mm D1@SK-SHANK: 24.00 → 22.00 mm D1@BOLT-BOSSES: 20.00 → 17.00 mm | D1@BOLT-BOSSES to 17 mm: Its busiest feature, MIRROR M8 CBORE, works at 22% of the allowable stress. Material here is mostly idle. |
Results side by side
| Load case | Metric | baseline | V1 | V2 |
|---|---|---|---|---|
| Peak firing, 28 kN compression | Evaluated von Mises (MPa) | 268 | 279 (+4%) | 279 (+4%) |
| Peak firing, 28 kN compression | Yield factor of safety | 2.65 | 2.55 (−4%) | 2.54 (−4%) |
| Peak firing, 28 kN compression | Max displacement (mm) | 0.0536 | 0.0880 (+64%) | 0.0881 (+64%) |
| Peak inertia at overrun, 14 kN tension | Evaluated von Mises (MPa) | 395 | 307 (−22%) | 304 (−23%) |
| Peak inertia at overrun, 14 kN tension | Yield factor of safety | 1.80 | 2.31 (+29%) | 2.34 (+30%) |
| Peak inertia at overrun, 14 kN tension | Max displacement (mm) | 0.0807 | 0.0764 (−5%) | 0.0766 (−5%) |
Standard verdicts
| Criterion | Load case | baseline | V1 | V2 |
|---|---|---|---|---|
| S1 Factor of safety on yield | LC1-firing | Pass 2.65 | Pass 2.55 | Pass 2.54 |
| S1 Factor of safety on yield | LC2-inertia | Fail 1.80 | Pass 2.31 | Pass 2.34 |
| S2 Factor of safety on ultimate strength | LC1-firing | Pass 4.14 | Pass 3.99 | Pass 3.97 |
| S2 Factor of safety on ultimate strength | LC2-inertia | Fail 2.81 | Pass 3.61 | Pass 3.65 |
| S3 Maximum deflection | LC1-firing | Pass 0.0536 | Pass 0.0880 | Pass 0.0881 |
| S3 Maximum deflection | LC2-inertia | Pass 0.0806 | Pass 0.0764 | Pass 0.0766 |
| S4 Buckling load factor | LC1-buckling | Not assessed | Not assessed | Not assessed |
| M1 Mesh: elements through the thinnest wall | LC1-firing | Pass 2.50 | Pass 2.50 | Pass 2.50 |
| M1 Mesh: elements through the thinnest wall | LC2-inertia | Pass 2.50 | Pass 2.50 | Pass 2.50 |
| F1 Fatigue under cyclic loading | Not assessed | Not assessed | Not assessed |
Governing load case
0.1395.4 MPa
0.1316.1 MPa
0.2309.0 MPa
Assumptions and limitations
- Design loads are assumed for a single-cylinder engine with a Ø38 crankpin and Ø18 gudgeon pin: 28 kN peak firing compression, 14 kN peak inertia tension at overrun. Replace them with measured engine data before relying on the result.
- Pin loads are bearing loads with a sinusoidal distribution over the loaded half of each bore.
- The rod half of the big-end bore is fixed for the firing case. The two bolt-head seats are fixed for the inertia case. Rigid fixtures raise stress next to them, so stress is evaluated outside a 3 mm zone and the unfiltered peak is reported separately.
- Linear elastic, small displacement, room temperature, no bolt preload, no press-fit of the small-end bush.
- Material properties are read from the SOLIDWORKS material library entry assigned to the part.
- Each variant was rebuilt from the same source part with only the listed dimensions changed, then re-meshed and re-solved with the same loads, fixtures and mesh settings.
Rod body only. The bearing cap is removed on the derived copy: it is outside the load path in compression, and in tension the bolt-head seats carry the load into the bolts.
Open items
- S4 Buckling load factor: The solver refused this study type (swsRunAnalysisErrorAuthorizationFailed). Buckling needs a SOLIDWORKS Simulation Professional or Premium licence.
- F1 Fatigue under cyclic loading: Required for cyclically loaded parts. Not assessed by a linear static run: needs a fatigue study (S-N data, load spectrum, surface finish) and engineering sign-off.