Large bore engine connecting rod fretting analysis

Abstract

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