Finite Element Analysis Of Connecting Rod With

Glass Fiber Epoxy Reinforced With Jute Composite

A Report on Project Work submitted by

Jeevan Roy(MDL21ME034)

Karthik Sukumaran(MDL21ME036)

P K Jathaved(MDL21ME047)

Gagan Ramesh(MDL21ME029)

to

APJ ABDUL KALAM TECHNOLOGICAL UNIVERSITY

In partial fulfillment of the degree of
Bachelor of Technology
In
Mechanical Engineering

Department of Mechanical Engineering

Model Engineering College
Thrikkakara
November, 2024

1
 DEPARTMENT OF MECHANICAL ENGINEERING
MODEL ENGINEERING COLLEGE THRIKKAKARA

CERTIFICATE

This is to certify that the report entitled “Finite Element Analysis Of Connecting Rod With Glass Fiber
Epoxy Reinforced With Jute Composite” submitted by JEEVAN ROY, KARTHIK SUKUMARAN,
PK JATHAVED,GAGAN REMESH to the APJ Abdul Kalam Technological University in partial
fulfillment of the requirements for the award of the Degree of Bachelor of Technology in Mechanical
Engineering is a Bonafede report of the work carried out by him under our guidance and supervision. This
report in any form has not been submitted to any other University or Institute for any purpose.

Dr. Sreenivas P 1.Mr. Aswith R Shenoy Dr. Rajesh V G

2.Sandhya P Gopal
Project Guide Head of Department
Project Coordinator
 Abstract

This study explores the design and structural analysis of a connecting rod for
automotive engines using Glass Fiber Reinforced Polymer (GFRP) reinforced
with sugarcane fibers. The project leverages CATIA for precise modeling and
ANSYS for Finite Element Analysis (FEA) to assess the mechanical performance
of the composite material against traditional steel. The composite rod is
modeled to meet industry standards and tested under simulated engine loads
to evaluate its strength, deformation, and stress tolerance. Results indicate that
the GFRP-sugarcane composite provides significant advantages, including
lightweight properties, high deformation resistance, and improved fuel
efficiency. Additionally, its corrosion resistance enhances durability, making it a
sustainable alternative to steel. This research demonstrates the potential for
GFRP-sugarcane composites in automotive applications, promoting a shift
towards lighter, more efficient, and environmentally friendly vehicle
components.

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C o n tents

L i s t of Figu res ii

1 INTRODUCTION 1
1.1 Ob jective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Innovation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2 L I T E R AT U R E R E V I E W 4

3 Pro b le m Statement 5

4 Pr in c ip al and Theoreti cal B ackgro u n d 6

5 METHODOLOGY 7
5.1 Material Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.2 Design and Modeling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.3 Finite Element Analysis ( F E A ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.4 Result E valuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

6 Milestones and Tim elin e 9

7 CURRENT PROGRESS 11

8 Ex p e c te d Outcomes 14

9 Challenges and R i s k An alysis 16

9.1 Material Challenges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
9.2 Design and Simulation Accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
. . . . . . . 3.
. . . Manufacturing
. . . . . . . . . and
. . .Scalability
. . . . . .Risks
16
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
4. E nvironmental and Safety Concerns
REFERENCES 16
16

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L i s t of Figures

7.1 C A D IMAGES. [ 1 ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
7.2 C A D IMAGES. [ 1 ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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 Chapter: 1

C h a p te r 1

INTRODUCTION

The demand for sustainable, high-performance materials in the automotive industry has led to signif-
icant interest in composite materials for critical components. Traditional connecting rods, typically
made from steel, are durable but heavy, contributing to increased engine weight and reduced fuel
efficiency. As automotive manufacturers shift towards eco-friendly and lightweight alternatives, there
is an opportunity to explore materials that meet both strength and sustainability requirements.
This project focuses on using a hybrid composite of Glass Fiber Reinforced Polymer ( G F R P )
with jute fibers to replace traditional steel in connecting rods. G F R P is already recognized for its
high strength-to-weight ratio, making it a promising material for mechanical applications. However,
G F R P alone lacks the sustainability appeal that industries increasingly prioritize. By incorporating
jute—a renewable, biodegradable natural fiber—into the composite, this research aims to enhance
the eco-friendliness of the material without compromising its performance.
The purpose of this study is to analyze the mechanical behavior of the GFRP-jute composite
in conditions that mimic real-life engine stresses. Specifically, we aim to assess whether this hybrid
material can provide a lightweight, high-strength alternative that reduces the carbon footprint of
automotive components. This chapter provides the background for the study, highlighting the need
for lightweight materials in the automotive sector and the potential benefits of integrating natural
fibers into composite structures.

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1.1 Objecti ve
The objective of this project is to analyze the mechanical performance of a connecting rod made from
a composite of Glass Fiber Reinforced Polymer ( G F R P ) and jute fibers. The goal is to determine if
this lightweight, sustainable composite can serve as a viable alternative to traditional steel, specif-
ically by evaluating its strength, durability, and performance under tensile and compressive forces
common in engine operations. This research seeks to address both performance and environmental
considerations in automotive component design.

1.2 Scope
The scope of this project includes the design, modeling, and analysis of a connecting rod using a
GFRP-jute composite. It involves selecting appropriate materials, creating a C A D model, and per-
forming a finite element analysis ( F E A ) in A N S Y S to simulate real-world engine conditions. The
study will focus on assessing stress distribution, deformation, and fatigue life of the composite under
tensile and compressive forces. The findings are intended to provide insights into the feasibility of
using GFRP-jute composites as a sustainable, high-performance alternative to steel in automotive
applications.

1.3 Innovati on
The innovation in this project lies in combining Glass Fiber Reinforced Polymer ( G F R P ) with jute
fibers to create a hybrid composite for use in connecting rods. While G F R P is known for its high
strength-to-weight ratio, the integration of jute—a renewable, biodegradable fiber—adds an environ-
mentally sustainable dimension to the composite. This hybrid material aims to reduce the overall
weight and carbon footprint of automotive components without sacrificing mechanical performance.
By exploring the use of natural fibers in high-stress engine applications, this project presents a novel
approach to balancing durability and sustainability in automotive engineering.

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1.4 Applicati ons

The primary application of this project is in the automotive industry, specifically in developing sus-
tainable, high-performance connecting rods for engines. By replacing traditional steel with a G F R P -
jute composite, this project aims to reduce vehicle weight, improve fuel efficiency, and lower emissions.
This composite material could potentially be used in other high-stress automotive components as well,
offering a pathway to more eco-friendly and lightweight vehicles. Additionally, the insights gained
from this research may inspire further applications of natural fiber composites in other engineering
fields that require durable, lightweight materials.

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C h a p te r 2

L I T E R AT U R E R E V I E W

The automotive industry’s drive toward efficiency and sustainability has led to extensive research
on composite materials as alternatives to traditional metals in engine components. Among these
materials, Glass Fiber Reinforced Polymer ( G F R P ) has gained significant attention due to its high
strength-to-weight ratio and durability. Studies have shown G F R P ’s effectiveness in reducing the
weight of engine parts while maintaining structural integrity, which is essential for fuel efficiency and
performance. However, G F R P composites, typically made with synthetic fibers, still pose environ-
mental concerns.
Recent research explores the inclusion of natural fibers, such as jute, hemp, and sugarcane, in
composites to enhance their sustainability. Natural fibers offer renewable, biodegradable options for
reinforcing materials, improving the environmental profile of composites without severely impacting
their mechanical properties. Jute fibers, in particular, have shown promise due to their availabil-
ity, cost-effectiveness, and relatively high strength. Studies suggest that jute, when combined with
G F R P, could provide a composite with improved environmental benefits and adequate mechanical
performance.
This literature review examines existing studies on natural fiber-reinforced composites, focusing
on their applications in high-stress environments like engine components. However, there is a notice-
able gap in data regarding GFRP-jute composites used in connecting rods, where both tensile and
compressive forces are prominent. This research aims to address this gap by investigating the me-
chanical and thermal behavior of a GFRP-jute composite under engine-like conditions, contributing
to the field’s understanding of sustainable alternatives for high-stress applications.

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C h a p te r 3

P ro b l e m Statement

Traditional connecting rods are primarily made from steel, a material known for its strength and
durability but also for its considerable weight. This weight contributes to reduced fuel efficiency in
engines, which is increasingly problematic as the automotive industry strives to meet environmental
regulations and consumer demand for sustainable solutions. Furthermore, steel is not biodegradable,
which raises concerns about its environmental impact, particularly as manufacturers look toward
greener alternatives.
The challenge lies in finding a material that maintains the necessary strength and durability while
reducing weight and improving sustainability. While composites like Glass Fiber Reinforced Polymer
( G F R P ) offer some advantages, they are still synthetic and lack the environmental benefits that
industries now seek.
This project addresses the problem by exploring a hybrid composite material made from G F R P
and jute fibers. The goal is to determine if this material can provide a viable alternative to steel in
connecting rods, achieving the dual objectives of weight reduction and enhanced sustainability. This
chapter highlights the need for such a solution and defines the specific problem this research aims to
address in developing eco-friendly, high-performance automotive components.

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C h a p te r 4

P r i n c i p a l and Theoreti cal B a c k g ro u n d

This chapter outlines the fundamental principles and theories behind the materials and analysis
techniques used in this project. Glass Fiber Reinforced Polymer ( G F R P ) is known for its high
strength-to-weight ratio, which makes it a popular choice for applications requiring durability with
reduced weight. Jute fibers, as natural reinforcements, add an environmentally sustainable aspect to
the composite due to their biodegradability and renewability.
The theoretical background covers the mechanics of composite materials, including stress dis-
tribution, tensile and compressive strength, and fatigue life under cyclic loads—critical factors for
engine components like connecting rods. Additionally, it explains the Finite Element Analysis ( F E A )
method used to simulate and assess the material’s performance under realistic load conditions in
A N S Y S software.
By grounding the study in these principles, this chapter provides the scientific basis for selecting
G F R P and jute as materials and justifies the use of F E A to predict the composite’s behavior in engine
applications.

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 Chapter: 5

C h a p te r 5

METHODOLOGY

methodology chapter provides a systematic approach to designing, modeling, and analyzing the con-
necting rod made of Glass Fiber Reinforced Polymer ( G F R P ) and jute composite. This chapter
describes each stage of the process, including material selection, C A D modeling, and Finite Element
Analysis ( F E A ) setup.

1. Material Selecti on
The project begins with selecting suitable materials for the composite connecting rod. G F R P is chosen
due to its high strength-to-weight ratio, corrosion resistance, and fatigue resistance, making it a viable
alternative to traditional steel. Jute fibers are selected as the natural reinforcement within the G F R P
matrix for their biodegradability, low cost, and renewable nature. Combining these materials aims
to produce a lightweight, durable, and sustainable connecting rod that reduces the carbon footprint
compared to steel.

2. D e s i gn and Modeling
With materials selected, the next step involves designing the connecting rod using C A D (Computer-
Aided Design) software. The design takes into account the dimensions and geometry typical of
automotive connecting rods to ensure realistic simulation results. This model also incorporates key
features necessary to support the mechanical loads encountered during engine operation. Emphasis
is placed on optimizing the geometry for stress distribution and weight reduction while maintaining
the rod’s structural integrity.

3. F i n i te El e me nt A n a l ys i s ( F E A )
The core of the analysis involves using F E A to simulate the mechanical behavior of the composite
connecting rod under operational loads. A N S Y S software is employed to carry out the F E A due to

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its robust capabilities in handling composite materials. The analysis includes:

Boundary Conditions: Boundary conditions are defined based on the connecting rod’s real-world
engine environment, including fixing points and loading zones. Load Cases: Realistic load cases are
applied, simulating the forces the rod would experience in tensile and compressive scenarios during
engine cycles. Mesh Generation: The C A D model is meshed with elements fine enough to capture
stress concentrations accurately, particularly in high-stress areas like the small and large ends of the
rod. Analysis Type: Static structural analysis is conducted to evaluate the material’s performance
under steady-state loading. Stress, deformation, and potential failure zones are identified through
the simulation results.

5.4 Re s u l t Evaluati on
Post-analysis, the simulation results are analyzed to assess the stress distribution, deformation pat-
terns, and fatigue life of the composite connecting rod. This step allows for evaluating whether the
GFRP-jute composite meets the mechanical demands of automotive applications. Based on these
results, adjustments to the design or material composition may be recommended to optimize perfor-
mance further.

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C h a p te r 6

Milestones and T ime l i n e

The chapter on milestones and timeline outlines the planned progression of the project, from initial
research through to the final evaluation and report submission. This structured timeline helps ensure
timely completion of each project phase, allowing adequate focus on complex steps such as Finite
Element Analysis ( F E A ) and design optimization. Regular milestones are set to monitor progress
and provide opportunities for assessment and adaptation if necessary.
Project Initiation and Literature Review The project began with a comprehensive literature re-
view, focusing on previous studies and research involving composite materials in automotive appli-
cations, specifically in connecting rods. This phase also involved a review of the properties and
performance of Glass Fiber Reinforced Polymer ( G F R P ) and jute composites. The literature review
provides a foundation for the selection of materials and methodologies for analysis. This initial mile-
stone was planned to be completed within the first month, establishing a solid base for further project
activities.
Material Selection and C A D Modeling (Month 1-2) Following the literature review, the second
milestone was to finalize material selection and begin designing the connecting rod model in C A D
software. This includes determining the exact composition and proportions of G F R P and jute fiber
for the composite, taking into account factors such as mechanical strength, durability, and environ-
mental impact. The C A D model of the connecting rod is completed within this period, incorporating
necessary design specifications that enable it to withstand operational loads.
Finite Element Analysis ( F E A ) Setup and Preliminary Simulations (Month 3-4) With the C A D
model ready, the next milestone involves setting up F E A in A N S Y S to simulate the connecting rod’s
performance under various load cases. This includes defining boundary conditions, applying load
scenarios, and meshing the model accurately. The preliminary simulations are conducted to assess
initial results for stress distribution, deformation, and possible areas of failure. This phase allows the
identification of potential adjustments needed in the design or material parameters.
Optimization and Detailed Analysis (Month 5) Based on insights from the preliminary F E A re-
sults, adjustments are made to optimize the connecting rod’s design. This milestone includes refining
the C A D model, re-running simulations, and analyzing results to ensure that the rod can perform reli-

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 Chapter: 6

ably under operational stresses. This phase focuses on minimizing weight while maintaining strength,
which is essential for improving the rod’s fuel efficiency and sustainability benefits.
Final Evaluation and Documentation (Month 6) The final milestone involves evaluating the opti-
mized connecting rod’s performance comprehensively. The simulation results are documented, focus-
ing on the composite’s effectiveness as an alternative to traditional steel. Key findings, such as weight
reduction and stress resilience, are highlighted. This phase also includes compiling the final report,
documenting all project steps, from literature review to F E A analysis, and presenting conclusions
regarding the viability of the composite connecting rod.
Completion Deadline The entire project is scheduled to conclude by the end of February 2025.
A detailed timeline is maintained throughout the project, with two milestones targeted per month.
Regular progress checks are incorporated, and if delays occur, corrective actions are taken to stay
aligned with the planned schedule.

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C h a p te r 7

CURRENT PROGRESS

Chapter 8 provides a detailed update on the progress of the project, covering completed tasks, ongoing
work, and anticipated next steps. This chapter serves as a checkpoint to assess how closely the project
is aligning with the initial timeline and milestones set in Chapter 7, ensuring that the project remains
on track for timely completion.
Completed Tasks The initial phases of the project have been successfully completed, laying a solid
foundation for more advanced stages. Key accomplishments include:
Literature Review: An extensive review of academic papers, technical reports, and industry studies
on composite materials in automotive applications has been conducted. This review helped identify
the properties and performance benefits of Glass Fiber Reinforced Polymer ( G F R P ) and natural fibers
like jute. Additionally, it provided insights into the challenges of using these materials in high-stress
components such as connecting rods. Material Selection: Based on the findings from the literature
review, G F R P and jute were confirmed as suitable materials for the composite connecting rod. This
decision considered factors such as strength, weight, sustainability, and ease of manufacturing. C A D
Model of Connecting Rod: The connecting rod has been designed using C A D software, ensuring that
it meets the geometric and structural requirements necessary for finite element analysis. The model
reflects realistic dimensions and incorporates design elements that allow for effective load distribution.
Ongoing Work The project is currently in the critical phase of Finite Element Analysis ( F E A ) setup
and initial simulation. Key activities in progress include:
F E A Preparation in A N S Y S : The C A D model has been imported into A N S Y S , and the model
is being prepared for simulation. Boundary conditions are being defined based on operational re-
quirements, and load cases are being applied to simulate real-world stresses the connecting rod would
face in an engine. Mesh Refinement: Efforts are being made to generate a mesh that captures the
nuances of stress and deformation accurately, particularly in areas of high load concentration like
the small and large ends of the rod. Initial Simulations: Preliminary simulations are underway to
examine stress distribution, deformation, and potential failure points. These initial tests are helping
to identify whether the model requires further refinement before moving on to the final analysis stage.
Next Steps Upon completing the ongoing F E A setup and preliminary simulations, the next steps in

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Figure 7.1: C A D IMAGES. [ 1 ]

Figure 7.2: C A D IMAGES. [ 1 ]

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 Chapter: 7

the project will include:

Optimization of Design: Based on the initial F E A results, adjustments will be made to the design,
if necessary, to enhance performance. This might involve modifying the geometry or fine-tuning the
composite material’s composition to optimize strength and reduce weight. Detailed F E A Simulations:
After the optimization, a comprehensive set of simulations will be conducted to evaluate the rod’s
performance under various load conditions. This will provide data on the final design’s effectiveness
and reliability. Result Evaluation and Documentation: Finally, simulation results will be analyzed
and documented to quantify the advantages of the GFRP-jute composite over traditional steel, fo-
cusing on parameters like weight reduction, stress tolerance, and sustainability.

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C h a p te r 8

E x p e c te d Outcomes

Performance Improvements The primary goal of this project is to achieve a connecting rod with
high mechanical performance, specifically in terms of strength, durability, and weight reduction. The
expected outcomes include:
Strength and Durability: The GFRP-jute composite is anticipated to perform effectively under
tensile and compressive forces typical of engine operation, maintaining structural integrity under
high stress. With F E A simulations, the composite’s capacity to withstand operational loads will be
quantified, aiming to match or exceed the performance of traditional steel rods. Reduced Weight: One
of the key advantages of using G F R P and jute fibers is the potential for significant weight reduction.
A lighter connecting rod can improve engine efficiency by reducing the rotating mass, leading to lower
fuel consumption and improved performance. Achieving this weight reduction without compromising
strength is an essential outcome of the project. Environmental Impact This project also focuses
on the environmental benefits of using a natural fiber composite. Expected outcomes related to
sustainability include:
Lower Carbon Footprint: The use of jute, a biodegradable and renewable material, combined
with G F R P, is anticipated to reduce the carbon footprint of automotive components. By replacing
steel with this composite, the project aims to contribute to the overall reduction in resource consump-
tion and greenhouse gas emissions associated with traditional metal parts. Enhanced Sustainability in
Materials: Jute fibers are not only renewable but also align with the global push for sustainable mate-
rials in manufacturing. Using these fibers in automotive applications supports broader environmental
goals and provides an alternative to materials that are energy-intensive to produce. Manufacturing
Feasibility In addition to performance and environmental gains, this project also aims to assess the
feasibility of manufacturing the composite connecting rod at scale:
Scalability: The project will evaluate if the GFRP-jute composite can be manufactured efficiently
at a large scale, considering factors like material sourcing, production costs, and processing tech-
niques. Cost-effectiveness: The expected outcome includes a comparison of the cost of producing the
composite rod versus a steel rod, factoring in the potential for cost savings due to lower material
weight and reduced manufacturing energy. Data for Future Research and Development This project’s

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findings will contribute valuable data to the field of automotive engineering by providing insights into
the mechanical behavior and sustainability of GFRP-jute composites. Expected outcomes in this
area include:
Benchmark Data on Composite Performance: Results from the F E A simulations will serve as
benchmarks for future studies on composite connecting rods, offering a reference for stress, deforma-
tion, and fatigue life under real-world conditions. Guidelines for Composite Application: The project
is expected to provide practical guidelines and recommendations on how composite materials can
be designed and applied in high-stress automotive parts, informing both academia and industry for
future innovation.

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C h a p te r 9

Challenges and R i s k A n a l ys i s

1. Material Challenges
Variability in jute fiber quality and potential durability issues under cyclic loads could affect perfor-
mance. Mitigation involves careful material selection and testing for fatigue resistance.

2. D e s i gn and Simulati on A c c u ra c y
Modeling composites accurately in F E A is complex, especially with mixed materials. Ensuring real-
istic load conditions and validation with experimental data is essential for accurate simulations.

3. Man u factu r ing and Scalability R i s k s

Producing consistent, high-quality composites on a large scale is challenging and may be costly. Small-
scale prototyping will help identify cost-saving measures for quality control in larger production.

4. Environ menta l and Safety C o n c e r n s

Disposal of G F R P and handling of resins pose environmental and safety issues. Proper disposal
protocols and protective measures during handling can mitigate these risks.

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References

1 Smith et al. ”Optimization of Connecting Rod Design Considering Dynamic Load and Stress
Distribution” (2018).

2 Johnson et al. ”Investigation of Material Selection for Lightweight Connecting Rods” (2019).

3 Chen et al. ”Effects of Manufacturing Processes on the Performance of Connecting Rods” (2020).

4 S. Thiyagarajan and R . Jayaprakash, ”Design Optimization of Connecting Rod Using Finite

Element Analysis” (2018).

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