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CR-110 CONNECTING ROD — structural check
Revision B · variant V2 · CR-110 connecting rod: firing and inertia load cases
Verdict · PCX-ENG-001 rev APass, with open itemsStatic strength and stiffness of machined steel parts
Part mass568.6 gAISI 4340 Steel, normalized
Governing resultFoS 2.34Peak inertia at overrun, 14 kN tension
VariantV2Iteration 2
Verdict against PCX-ENG-001
| Ref | Criterion | Load case | Result | Limit | Margin | Verdict |
|---|---|---|---|---|---|---|
| S1 | Factor of safety on yield | LC1-firing | 2.54 | ≥ 2.00 | +27% | Pass |
| S1 | Factor of safety on yield | LC2-inertia | 2.34 | ≥ 2.00 | +17% | Pass |
| S2 | Factor of safety on ultimate strength | LC1-firing | 3.97 | ≥ 3.00 | +32% | Pass |
| S2 | Factor of safety on ultimate strength | LC2-inertia | 3.65 | ≥ 3.00 | +22% | Pass |
| S3 | Maximum deflection | LC1-firing | 0.0881 mm | ≤ 0.10 mm | +12% | Pass |
| S3 | Maximum deflection | LC2-inertia | 0.0766 mm | ≤ 0.10 mm | +23% | Pass |
| S4 | Buckling load factor The solver refused this study type (swsRunAnalysisErrorAuthorizationFailed). Buckling needs a SOLIDWORKS Simulation Professional or Premium licence. | LC1-buckling | — | ≥ 3.00 | Not assessed | |
| M1 | Mesh: elements through the thinnest wall | LC1-firing | 2.50 | ≥ 2.00 | +25% | Pass |
| M1 | Mesh: elements through the thinnest wall | LC2-inertia | 2.50 | ≥ 2.00 | +25% | Pass |
| 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. | — | Not assessed |
Design changes in this variant
| Dimension | From (mm) | To (mm) |
|---|---|---|
| D2@SK-SMALL-END | 28.00 | 31.00 |
| D1@SK-SHANK | 24.00 | 22.00 |
| D1@BOLT-BOSSES | 20.00 | 17.00 |
D1@BOLT-BOSSES to 17 mm: Its busiest feature, MIRROR M8 CBORE, works at 22% of the allowable stress. Material here is mostly idle.
Load cases and results
Peak firing, 28 kN compression
- Crankpin seat: fixed fixture on 1 face (1,307 mm²)
- Gudgeon pin, firing: bearing load [0,-28000] N on 1 face (1,011 mm²)
Evaluated von Mises279 MPaat (-7.0, 43.1, -9.0) mm
Yield factor of safety2.54710 MPa yield
Peak incl. fixture zone279 MPa3.0 mm zone, 7,247 nodes
Max displacement0.0881 mmreaction 28,003 N
0.0279.3 MPa
0.0279.3 MPa
0.00000.0881 mm
0.00000.0881 mm
| Feature | Evaluated MPa | Peak MPa | Of allowable | Utilisation |
|---|---|---|---|---|
| POCKETS | 279 | 279 | 79% | |
| SMALL-END | 279 | 279 | 79% | |
| POCKET-CORNERS | 279 | 279 | 79% | |
| POCKET-FLOORS | 272 | 272 | 77% | |
| WEB | 254 | 254 | 71% | |
| OIL-HOLE | 229 | 229 | 65% | |
| SHANK | 185 | 185 | 52% | |
| BLEND-BIG-END | 172 | 172 | 48% |
Allowable 355 MPa = yield ÷ minimum factor of safety. “Evaluated” leaves out the fixture zone; “peak” includes it.
Peak inertia at overrun, 14 kN tension
- Bolt-head seats: fixed fixture on 2 faces (226 mm²)
- Gudgeon pin, inertia: bearing load [0,14000] N on 1 face (1,011 mm²)
Evaluated von Mises304 MPaat (0.0, 111.0, 1.5) mm
Yield factor of safety2.34710 MPa yield
Peak incl. fixture zone309 MPa3.0 mm zone, 3,778 nodes
Max displacement0.0766 mmreaction 14,000 N
0.2309.0 MPa
0.2309.0 MPa
0.00000.0766 mm
0.00000.0766 mm
| Feature | Evaluated MPa | Peak MPa | Of allowable | Utilisation |
|---|---|---|---|---|
| SMALL-END-BORE | 304 | 304 | 86% | |
| OIL-HOLE | 304 | 304 | 86% | |
| SMALL-END | 269 | 269 | 76% | |
| BLEND-SMALL-END | 205 | 205 | 58% | |
| POCKETS | 141 | 141 | 40% | |
| POCKET-CORNERS | 141 | 141 | 40% | |
| SHANK | 138 | 138 | 39% | |
| POCKET-FLOORS | 123 | 123 | 35% |
Allowable 355 MPa = yield ÷ minimum factor of safety. “Evaluated” leaves out the fixture zone; “peak” includes it.
Buckling under peak firing load
- Crankpin seat: fixed fixture on 1 face (1,307 mm²)
- Gudgeon pin, firing: bearing load [0,-28000] N on 1 face (1,011 mm²)
Not assessed The solver refused this study type (swsRunAnalysisErrorAuthorizationFailed). Buckling needs a SOLIDWORKS Simulation Professional or Premium licence.
Model
| Material | AISI 4340 Steel, normalized · E 205,000 MPa · ν 0.32 · yield 710 MPa · ultimate 1,110 MPa · 7,850 kg/m³ (from SOLIDWORKS Materials) |
|---|---|
| Mesh | second (high quality) tetrahedra, 2.00 mm global size, 89,986 nodes, 58,778 elements |
| Analysed | 376.4 g of 568.6 g; thinnest wall 5.00 mm |
Key dimensions
| Dimension | mm |
|---|---|
| CC@SK-SMALL-END | 120.00 |
| D2@SK-SMALL-END | 31.00 |
| D1@SK-SHANK | 22.00 |
| D1@SHANK | 18.00 |
| D1@WEB | 5.00 |
| D1@BOLT-BOSSES | 17.00 |
| D1@SK-BIG-END | 60.00 |
| D1@BIG-END | 22.00 |
| D1@SMALL-END | 18.00 |
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.
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.
Provenance
| Source part | D:\ParaCrux-ModelTest\ConRod\ConRod-110.SLDPRT SHA-256 6e0d10c9eccc627468ded9ecbe20a92b9efb0efa6f907a0dc91522520d1c24ee |
|---|---|
| Analysed copy | ConRod-110-V2.SLDPRT (derived copy; the source was not saved) |
| Software | SOLIDWORKS 34.4.1 · Simulation 891107 · paracrux swsim |
| Run | 2026-09-29T21:41:47Z · 218 s · spec D:\ParaCrux\.claude\worktrees\solidworks-simulation-api-fa7b65\paracrux\connectors\solidworks\simulation-mcp\cases\CR-110.json |