Enhancement in Performance of Connecting Rod Using Surface Treatment Process PDF

International Journal ofEngineering Science Invention (1JESI) ISSN (Online):2319 -6734, ISSN (Print):2319 -6726 org ||Volume 7Issue 5 Ver. TV|| May2018 || PP 65-73 www.ijesi. Enhancem...

International Journal ofEngineering Science Invention (1JESI) ISSN (Online):2319 -6734, ISSN (Print):2319 -6726 org ||Volume 7Issue 5 Ver. TV|| May2018 || PP 65-73 www.ijesi. Enhancementin Performance of Connecting Rod Using Surface Treatment Process Omkar Jamkhedkar, KetanMarathe, MayureshPawar, PrithvirajKhanvilkar SandeshGaonkar I.234(Student, Department,SITSNarhe, India) Mechanical (AssistantProfessor, Mechanical Department, SITS Narhe, India) Corresponding Auther: OmkarJamkhedkar Abstract: Connecting rods are used in every vehicle. A fracture ofthe connecting rod in the running engine leads to a failure of the engine Sogreat attention is paid to the connecting rods, eliminating stress risers by such technigues as grinding the edges of the rod to a smooth radius, shot peening to induce conmpressive sugface stresses(to prevent crack initiation), balancing all connecting rodpiston assemblies to the same weight and Magnaflxing to reveal otherwise invisible smallcracks which would cause the rod to fail under stress. But still there is need of enhancement of connecting rod. Therefore, in this paper surface treatment processes like Hardening and Tempering, Nitriding, Carburizing process were done on specimen to increase its performance. The processes and various testing are done on the sample specimens in furnace and lab respeclively. By various testingand processes, various parameter of connecting rod are measured like Tensile Strength, Hardness, Microstructure,and Corrosive Resistance, Toughness. Then paraneters of before heat treatment and after heat treatmentare shown. Keywords-20Mn Cr5,Connecting Rod, Heat treatmentprocess Date of Submission: 07-05-2018 Date of acceptance: 22-05-2018 I INTRODUCTION A connecting rod is a componcnt which is connected to piston by GudgeonPin and crank by Crank Pin in a reciprocating engine. Together with the crank, it forms a simple mechanism that converts reciprocating motion into rotating motion. A connecting rod also converts rotating motion into reciprocating motion. The body of the connecting rod is dominantly loaded against the pressure of the gas force and the tensile force due to incrtial forces. Both the maximum gas force and maximum value of the inertialforce occur in the expansion stroke. These forces generate the minimum and maximum normal stress within the cross-section of the body of the connectingrod. The connecting rod is an element of the internal combustion engine that transmits motion and forces amongst the piston and crankshaft. Due to the cyclical nature of internal combustion (1C) engine work process, all moving elements arce subjected to variable loads and change in the direction of motion. The body of the conecting rod is dominantly loaded against the pressure of the gas force and the tensile force due to the inertia of the components in motion, either alternative or rotational. Both the maximum gas force and maximum value of the inertial force occur in the expansion stroke. These forces generate the minimum and maximum normal stress within the cross-section of the body of the connecting rod. Figure no. 1- Failed Connecling tbd Connecting rods as well as other mechanical parts, which are exposed to variable load, are dimensioned to meet the durable dynamic strength. The dynamic strength is subject to the influence of several parameters.In www.ijesi.org 65 |Page  Enhancement in Performance of Connecting Rod Using Surface Treatment Process this case, the condition of the connecting rod surface and material properties are crucial. A fracture of the connecting rod in the running engine leads to a complete stop of the engine. The same occurrence can lead to catastrophic consequences in other engine designs. II. METHODOLOGY Method I Keep one heat treatment process constant. Then study change in strength of the component according to change in hardness. MethodII Change heat treatment processes. Then compare the strength of the component by keeping hardnesS nearly constant for various heat treatment processes. Study ofHeat Heat Selection of Treatment Treatonent Processes Specimen Processes Result Comparison Figure no.2 -Methodology III. EXPERIMENTAL WORK Material Selection Table 1 -Different Materials of connecting rod with Mechanical Properties Material Hardness Young's Yield strength Tensile strength Poisson's Density kg/m3 BHN Modulus of MPa MPa ratio elasticity % C-70 183 211.5 573.11 965.8 0.3 7850 AISI-4340 217 210 445 745 0.28 7800 35Mn5 167 200 450 765 0.33 7700 Al-360 217 71 363 422 0.33 2680 T-2024 125 80 370 495 0.33 2760 Al-7068 190 73.1 655 683 0.33 2850 20Mncr5 179 210 750 1100.83 0.28 7800 The Aluminum alloys are less expensive as well as less durable. The C-70 material cannot be heat treated. The AISI 4340 and 20MnCr5 are both alloy steels hence their properties are almost same. Therefore selected 20MnCr5because of its availability and material is durability. The20MnCr5 material is selected for the Hardness Test, Tensile Test, Impact Test, Salt Spray Test and Microstructurc. For thc casc of opcrations whilc tcsting, samplc bars arc takcn of the 20MnCr5 matcrial. www.ijesi.org 66 |Page  Enhancement in Performance of Connecting Rod Using Surface Treatment Process Figure no.3 -Unprocessed Component Composition of 20MnCr5 material is as follows Table 2--Composition Material C Si Mn P Cr 20CrMn5 0.2 0.2 1.09 0.021 0.019 1.19 Hardening and Tempering Set Up First Hardening process is in the temperature range of 920 °C for the duration of 2.5 hours carried out then oilcooling is done. Then in the stage of tempering the componentsare held in the first temperature range of 250'C for 2 hours and in second stage of tempering temperature range of 560 C for 3.25 hours. After this water cooling is done on the components. Figure no.4 -Hardening and Tempering Furnace Nitriding Set Up The Liquid Nitriding process is carried out in the temperature range of 550 "C for 4 to this water quenching is done in the components. 6 hours. After  Enhancementin Performance ofConnecting Rod Using Surface Treatment Process Carburizing Set Up In the Carburizing process, the components are held for 8 hours in the temperaturerange of 930 "C then for I hour in the temperature range of 830 "C. To achieve less hardness value, Tempering is carried out in the temperature range of 200 C for 2.5 Hours. After that oil quenching is done on the components. Figure no. 6- Carburizing Furnace Various Testing Set Up Hardness Testing Hardness is a measure of a material's resistance to localized plastic deformation Quantitative hardness developed over the years in which a small indenter is forcedinto the surface of a material techniques have becen to be tested, under controlled conditions of load and rate of application. The depth or size of the resulting indentation is measured, which in turn is related to a hardness number;the softer the material, the larger and deeper is the indentation, and the lower the hardness index number. Figure no. 7- Brinellhardness testing machine Tensile Test Set Up In the Universal Testing Machine, various parameters can be found such as Yield Strength, Ultimate Tensile Strength, % Reduction Area, % Elongation. The specimen is held by suitable means between the two heads of testing machines and subject to a progressively increasing tensile loaded until it fractures a record of load acing on the specimen with the progressive extension ofthe specimen in the obtained. www.ijesi.org 68|Page  Enhancementin Performance of Connecting Rod Using Surface Treatment Process Figure no. 8 - Universal Testing Machine Impact Test Set Up show identical properties when tested in tension can show pronounced difference in Materials which when tested in a notched Impact Test. In each case a certain mass is released from their properties some distance at the moment of the above the impact point which strikes the specimen. The kinetic encrgy of the tup or head (mgh). impact is (mv)/2which is the equal to the potential energy of the tup before its released Fromthis itwill be seen that the drop height determines the velocity and the drop height and mass jointly determine the energy. For different test and material different of kinetic energy and tangential levels velocity at the point of impact are required and hence this can be achieved by changing the mass of the head and the position of the pendulum are before release. Figure no. 9 - Charpy Impact Testing Machine Salt SpraySet Up The salt spray test is carried out for the determination of Rust. In this test, different components are placed in the chamber which is subjected toenvironment of 5% NaCl solution. Afer some time, Red Rust or White Rust or Black Spots are observed on the components depending on the material. CAMILQN Figure no. 10 - Salt Spray Testing Machine www.ijesi.org 69 | Page  Enhancementin Performanceof Connecting Rod Using Surface Treatment Process Microstructure The microstructure ofspecimen before heat treatmentand after heat treatment is studied with the heln of Optical Microscope. n this paper we determined microstrucure of unprocessed and hardening-tcmperin component because remarkable change is observed. But, since Nitriding and Carburizing processes are case hardening processes so no significant change will be observed. Figure no.11 - Optical Microscope IV. RESULT AND DISSUSION Hardness Test Result Hardness (BHN) 400 302 300 262 241 179 200 100 Unprocessed Hardning and Nitriding Carburising Component Tempering Hardness (BHN) Figure no. 12 -Hardness of Heat Treatment Processes Tensile Test Result Table 3 -Tensile Test Result Tensile Test Max. Test Y S. U.TS. Proccss Elongation Displaccment Specimen (KN/mm) (KN/mm) (mm) Original 358 588 25.88 15.29 Component 2 359 586 25.46 14.84 Hardening and 820 896 18.1 11.19 Tempering 803 858 17.46 IL41 759 818 17 12.89 Nitriding 2 755 815 17.7 12.37 1096 1103 1.34 5.85 Carburizing 2 1086 1091 1.78 6.21 Following graphs shows load (KN)variation with respect to displacement (mm).From this graph we can get yield load,ultimate load, maximum displacement, fracture point, etc. By dividing area to yield load and ultimateload,we can get yield stress and ultimate stress in KN/mm.  Enhancement in Performance of Connecting Rod Using Surface Treatment Process Graph LosdVe Dinpt 7000c 6300o 42 00O 140OO Figure no. 13 - Load vs Displacement Graph of Original Component Graph LOad Vs Displacement 45.00o 35 0oD 30 00o Load 25 0o0 20.0oo 150Oo 1000o S.00O YO=0D00 2.000 6.U0 Dispiscernert 10.000 1200 14.000 200 m Figure no. 14 –Load vs Displacement Graph of Hardening and Tempering Graph Load Vs Displacement 70.000 63000 49.00o 42 000 Load KN 35 000 28 00o 21.000 14000 7000 YO=0O00 2.000 6.000 10 000 12 000 14.000 16 000 18 000 20 000 Dspacement mn Graph Figure no. 15 Load Vs Displacement -Load Vs Displacement Graph of Nitriding 81.00o 72 000 54.000 Load 45 000 36 000 2700 18.000 9000 D700 X0-0.000 2 100 2800 1400 3500 4200 4.900 1isplacement mm 5 600 6300 7.000 Figure no. 16-Loadvs Displacement Graph of Carburizing www.ijesi.org 71|Page  Enhancement in Performance of Connecting Rod Using Surface Treatment Process Impact Test Result Energy Absorbed (U) 15 12 10 8 5 Unprocessed Hardning and Nitriding Carburising Component tempering Energy Absorbed (0) Figure no. 17– Energy Absorbed during Impact Test Salt Spray Test Result Red Rust Observed (Hrs) 80 72 72 60 48 40 20 Unprocessed Component Nitriding Carburising Red Rust Observed (Hrs) Figure no. 18- Result of Salt Spray Test Microstructure Result Figure no. 19- Microstructure of Original Specimen The microstructure reports states that before heat treatment the Uniform distribution of Pearlite and Ferrite structure was observed. Figure no. 20-Microstructureof Hardening-Tempering www.ijesi.oro | 72 Page  Enhancementin Performance ofConnecting Rod Using Surface Treatment Process Afer Hardening and Tempering the Tcmpered Martensite Structure was observed because when Martensite is reheated to temperature after quenching the tempering precipitates and the coaeultes subcritical carbides. Hence the microstructure consists ofcarbide particles.often spheroidal in shape, dispersed in ferdite niy The result is loss in Hardness but considerable improvement in Ductility and Toughnes8. 171 V. CONCLUSION Though carburized specimen has more strength, still we can't use it. Because the specimen has become e beeause it has high hardness valuc, so connccting rod will fail instantly without giving any idea before failure. tis important to increase hardness up to certain level; beyond that level toughness of that component will decrease. Ew above resull, due to Nitriding and Carburizing process, corrosion resistance had increased compare to of vehicle thcse connccting rod are more durable than that of original component i.e. in idle condition original one. which is useful Because of Nitriding and Carburizing process Wear Resistance of the componcnt increases, in case of 2-wheeler connecting rod where, there is continuous wear and tear of connectíng rod with crank shaft and no provision of cap. nearly same tensile strength and hardness Hardening and tempering process has optimum results. It shows as carburizing process and also it shows nearly same impact strength as original componcnt. REFERENCES. SLAVKORAKIc, UGLJESAEuGARIC, IGOR RADISAVLJEVIC, ZEUKOBULATOVICFATLURE ANALYsIs OF A SPECIAL VEHICLE ENGINE cONNECTING ROD, ENGINEERING FAILURE ANALYSIS, VOLUME 79, 2017. PAGES98-109, ISSN 1350-6307. 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VDKodegire,S.V.Kodegire, Material Science and Metalurgy Second Edition, (lndia,Everest Publishing House 2005) Chapter 3, Mechanical Testing and Evaluation of Properties, Page No 121-122 [71. Roger L. Brockenbrough, Frederick s. Merrit, Third Edition, Strucural Stel Designer's Handbook (England Butterworth Heinemann 2008)Section 1,Page No 1.31. V.D. Kodegire, S.V. Kodegire, Material Science and Mctallurgy Second Edition, Chapter 3, Mechanical Testing and Evaluation of Properties, Page No 61 [91. wiliam D. Callister, Jr., Materials Science and Engineering Seventh Edition, (United States of America John Wiley & Sons, Inc. 2007)Chapter 6Mechanical Propertics of Metals,6.10 Hardness, Page No 155 Omkar Jamkhedkar "Enhancement in Performance of Connecting Rod Using Surface Treatment Process "International Jounal of Engineering Science Invention(JESI), vol. 07, no. 05, 2018, pp 65-73