A Comparative Study of Connecting Rod for Four Stroke Internal Combustion Engine: A Study Focused on Improving Structural Integrity and Weight Reduction

Internal combustion engines (ICE) are the primary power source in modern automobiles, converting the chemical energy of fuel into mechanical work. A connecting rod plays a crucial role in this process by transferring the linear motion of the piston into the rotational motion of the crankshaft. The structural integrity of the connecting rod is essential, as failure can lead to severe engine damage and costly repairs. Lightweight materials can improve engine efficiency by reducing inertial forces and fuel consumption, making material selection a key factor in optimizing performance. This study employs finite element analysis (FEA) in ANSYS to investigate the structural behavior of a General Motors Z19DTH engine connecting rod. The connecting rod was modeled and analyzed using structural steel and aluminum alloy, comparing their von Mises stress, deformation, and weight characteristics under operational loads. The results indicate that both materials remain within safe stress limits, but aluminum alloy offers a 64.7% weight reduction while maintaining structural integrity. This suggests that aluminum alloy is a viable alternative for lightweight engine applications, contributing to improved fuel efficiency and performance optimization. This research provides valuable insights into the structural performance of connecting rods by integrating accurate geometric modeling, material study, and real-world engine conditions.