“Finite Element Analysis of Connecting Rod Stresses, Deformation, and Material Optimization”

Abstract: The connecting rod is a vital component that converts reciprocating motion into rotary motion, enduring extreme compressive and tensile loads (Khudhair et al., 2024; Uddin et al., 2026). This study employs Finite Element Analysis to evaluate the structural integrity and performance of connecting rods under various material configurations, including forged steel, Aluminum 360, and advanced composites like Al-MWCNT (Chumbre, 2018; Uddin et al., 2026). Utilizing simulation software such as ANSYS and SolidWorks, the analysis focuses on minimizing mass while maintaining a high factor of safety to improve engine efficiency (Mishra et al., 2023; Muhammad et al., 2020). Results indicate that while forged steel provides high fatigue strength, Aluminum 360 exhibits significantly lower total deformation and a substantial mass reduction (Uddin et al., 2026). Furthermore, optimization techniques demonstrate that material substitution can lead to a weight reduction of up to 43.48% without exceeding material yield strength (Mishra et al., 2023). This research concludes that FEA is an essential tool for identifying critical stress concentrations and optimizing the geometric design of connecting rods for modern high-performance engines (Mihalache et al., 2014; Sun, 2006).

Keywords: Connecting rod, Finite Element Analysis, Stress analysis, Material optimization, Aluminum 360, Weight reduction, ANSYS, Von-Mises stress.