Large bore engine connecting rod fretting analysis

Abstract

A detailed contact analysis of a large connecting rod was performed to evaluatethe fretting risk in the big end. Simulation was carried out in Abaqus considering all relevantboundary conditions, such as assembly loads, housing machining and dynamics from a exiblemultibody simulation with elastohydrodynamic bearings. Being one of the most importantvariables, the local coeffcient of friction (COF) and its evolution is calculated during the solutionby using a subroutine in Abaqus. The model is validated by strain gauge measurements in arunning engine. The resulted friction coefficient distribution matches well with the ndings froma laboratory engine. The described methodology increases the accuracy of the fretting damageprediction by using a more realistic friction coefficient denition.