Inverse Reconstruction of Fracture Splitting Connecting Rod and its Strength and Fatigue Life
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TECHNICAL ARTICLE—PEER-REVIEWED
Inverse Reconstruction of Fracture Splitting Connecting Rod and its Strength and Fatigue Life Zhou Shi . Shuqing Kou
Submitted: 28 October 2017 / in revised form: 15 January 2018 Ó ASM International 2018
Abstract To investigate the strength and fatigue life of a fracture-split connecting rod, this study combines experiments on connecting rod fracture splitting, threedimensional reconstruction technology and the finite element technique. An actual fracture joint surface of a connecting rod is obtained by fracture-splitting experiment, and its mode is reconstructed by reverse engineering. Subsequently, the reconstructed fracture plane is imported into CAD to establish the actual three-dimensional model of the fracture-split connecting rod. The fatigue characteristics parameters of the fracture-split connecting rod material, namely C70S6, are obtained by a rotating bending fatigue test. Finally, by comparing to a traditional machining connecting rod, the inspection of the fatigue life of the fracture-splitting connecting rod is performed using the finite element method and the fatigue analysis theory. The results show that the fracture-split connecting rod meets the strength and fatigue life requirements. Keywords Fracture splitting connecting rod Joint surface Reverse engineering Strength analysis Fatigue life
Introduction As a new processing technique, the fracture splitting of connecting rod has taken the place of the traditional process with machining rod/cap joint surface using the splitting principle, which has many incomparable Z. Shi (&) S. Kou Roll Forging Research Institute, Jilin University, Changchun 130025, China e-mail: [email protected]
advantages. This technique can reduce the processing procedure, effectively decrease production costs, and provide highly accurate position between the cap and rod [1]. Most of all, the fracture-split connecting rod remarkably increases the contact area of the fracture surface, which significantly improves bearing capacity of the connecting rod [2]. The high-carbon micro-alloy non-tempered steel C70S6 is the first internationally mature steel for fracturesplit connecting rods. Currently, the C70S6 is the main material used for fracture-split connecting rods and has gained acceptance, for its characteristics high strength, good material purity and excellent cracking performance [3, 4]. The main difference between a fracture-split connecting rod and a conventionally machined connecting rod is the morphological features of the joint surface of the rod and cap. The connecting rod material and structure also change due to the change of the machining mode, which affects the strength and fatigue property of the connecting rod. However, the fracture surface of a fracture-split connecting rod exhibits its natural form, which has complex three-dimensional bump characteristics. It is difficult to quantify the fracture surface, thus modeling becomes a problem. At the present stage, the fracture surfaces of the connecting rod model use
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