College of Engineering and Technology Mechanical and Manufacturing Engineering Page 1 of 6 Mechanical and Manufacturing Engineering Module Title: Advanced Mechanical Design and Manufacturing Engineering. Module Code: 7ME500 Module Leader: Dr Klaudio Bari Lecturers: Dr Klaudio Bari Coursework Assignment No: 1 Assignment Title: Fatigue in connecting rod of Yamaha motorcycle engine Weighting: 50% Issue Date: 25th January 2017 Submission Date: 22nd March 2017College of Engineering and Technology Mechanical and Manufacturing Engineering Page 2 of 6 Introduction The connecting rod in an internal combustion engine has the primary role of turning the vertical motion of the piston into rotational motion that the crankshaft can then output as work. The connecting rod is made of; the small end which connects to the piston head via a pin, the big end which connects to the crankshaft via a rod cap and slip bearing, and the shank or I-section that connects the two ends respectively as shown in Figure 1. Figure 1: A diagram of a connecting rod The connecting rod is a critical component of the engine that undergoes a variety of stresses including; cyclical tensile loading via the exhaust and compression strokes, coupled with compressive stress via expansion and intake strokes. The design of a connecting rod must be undertaken very carefully, while considering all factors. The connecting rod must be adequately hard, to endure the repeated tensile and compressive loads while also being light to reduce inertial forces created by its rotating motion. Fatigue in a connecting rod is not a common cause for engine failure, but it does occur occasionally. In this investigation, a 1998 Yamaha YZF-R1 inline 4-cylinder engine will be investigated. Learning Outcomes On successful completion of this assignment, the student should be able to: 1. Critically identify engineering problems at the design stage 2. Critically apply advanced engineering tools and present a clarification to an engineering problem Figure 2: Global Class Race CarCollege of Engineering and Technology Mechanical and Manufacturing Engineering Page 3 of 6 Analyses The Brief: Fatigue failure is an important problem in Engineering. The cyclic stress on the part below the yield strength can cause failure. The task is to optimise a suitable material for a connecting rod of Yamaha motorcycle 4 cylinders (980cc) engine. You are required to do the following:  Draw or scan the connection rod provided on SolidWorks software (10 Marks)  Use CES Edu Pack 2017 to select one suitable material that endures the load based on minimum cost and maximum Fatigue strength. (10 Marks)  Export that material file to perform simulation in SolidWorks. (10 Marks)  Numerical calculation of the cyclic of compressive and tension stresses that conrod endured during operation. Use the attached Yamaha Engine manual (20 Marks)  Use mesh adaptive OR refinement to compare the difference in the obtained results from the simulation (10 Marks)  Results in form of plot and tables based on one million fatigue cycle. (10 Marks)  Discussion and recommendations for source of error. (10 Marks)  Presentation of results (15minutes) (date will be confirmed later) (20 Marks) Results are presented in form of Report (~3000 word), Excludes references, list of figures and appendix. Reading Materials Read the case study attached to this assignment Please do look on the SolidWorks Simulation Tutorial under connection rod to give you an idea on how to conduct the simulation. Note: These sources are guides only to commonly available material. Students will also be expected to consult other relevant source material. Submission Requirements E-Submission In order to reduce unnecessary travel and queuing time for students, the University has moved to electronic submission (eSubmission) of all assignments where this is possible. Your tutor will advise you if this is not the case for the assignments of this module. Start by taking a look at the eSub website www.derby.ac.uk/esub as this is the main site supporting students with eSubmission and provides support documents and videos to talk you through the whole process.College of Engineering and Technology Mechanical and Manufacturing Engineering Page 4 of 6 You will also find a printable guide In the Assessments area of your module called Electronic Submission Guide for Students this will talk you through the submission process and guide you to further resources to help you submit your work. Your report must be submitted by uploading through the Report Assignment drop box for Turnitin before the date and time stated on the cover sheet. Your FEA files must be submitted through the FEA File Assessment drop box Remember to save all Files in one Directory and then add to a Zip file so all your work is compressed into one file. Submission Details Specific details for the submission of assignments will be provided with the assignment brief. There are no automatic right to late submission, with a capped mark of 40%. However, the University acknowledges that there may be circumstances, which prevent students from meeting deadlines and there are now three distinct processes in place to deal with differing student circumstances: Assessed Extended Deadline (AED) Students with disabilities or long-term health issues are entitled to a Support Plan. The Support Plan will outline any adjustments to assessments, which are required to accommodate an individual student’s needs. For further details refer to the link below: http://www.derby.ac.uk/studentatozHE/support-plans Exceptional Extenuating Circumstances (EEC) The EEC policy applies to situations where serious, unforeseen circumstances prevent the student from completing the assignment on time or to the normal standard. Students who submit a successful EEC claim will usually be required to complete a different assessment to that which was originally set. All EEC claims will be considered by Faculty/UDC panels, which will convene on a monthly basis. For further details refer to the link below: http://www.derby.ac.uk/eec Late Submission up to One Week Covering unexpected and severe disruption to study, where circumstances do not require the additional time allowed for by an EEC, the Late Submission process enables students to complete their existing assessment up to one week late, without a cap on the grade. Requests for late submission will be made to the relevant Subject Manager in the School who can authorise an extension of up to a maximum of one week. The Subject Manager will expect to see compelling evidence that such an extension is appropriate. RegulationCollege of Engineering and Technology Mechanical and Manufacturing Engineering Page 5 of 6 This module conforms fully to the UG regulatory framework as outlined in the student handbook. The grading scale applies to Levels 3, 4, 5 and 6 in the University Credit Framework. The descriptors are typical characteristics of the standard of work associated with each grade, and are given in details by level. Please refer to the 3Rs document - Section J - for a comprehensive view of this scale. http://www.derby.ac.uk/files/3rs_2011-12.pdf Study Ethics You are expected to abide by the rules and regulations of the University in all aspects of your conduct. Specifically, with regard to assessment, you should consider Sections J and Q of the “Rights, Responsibilities and Regulations” document available on the University web site. http://www.derby.ac.uk/files/3rs_2011-12.pdf Health and Safety The majority of the teaching and learning for this module will be classroom based. A classroom based Risk Assessment has been has been carried out by the University identifying significant hazards and risks within this environment. These will be communicated to you by the lecturer during the first lecture / session. Plagiarism An “academic offence” is committed when a student tries to gain improper advantage for her/himself, or not following the Academic Regulations, concerning any part of the assessment process. Please refer to the 3Rs statement on: http://www.derby.ac.uk/files/part_j_pdf.pdf (pages 57-58) THE POSTGRADUATE GRADING SCALE The grading scale applies to Levels 7 in the University Credit Framework. The descriptors are typical characteristics of the standard of work associated with each grade, and are given in details by level. Please refer to the 3Rs document for a comprehensive view of this scale on page 27-29. LECTURE/TUTORIAL /LABORATORIES GUIDANCE The module will be structured with lecturers and tutorials. You will be expected to attend all the lectures and those tutorial sessions indicated by the lecturer. The assessment may require students to perform ‘self directed study/activity’ and the lecturer may not necessarily be present at all of these sessions.College of Engineering and Technology Mechanical and Manufacturing Engineering Page 6 of 6 POSTGRADUATE MARKING SCALE This scale applies to Levels 3, 4, 5 and 6 in the University Credit Framework. The descriptors are typical characteristics of the standard of work associated with each range of marks. The descriptors are illustrative and for guidance only. They are not comprehensive. A mark of 40% is regarded as a minimum pass. ASSESSMENT CRITERIA All grades given for assignment work are provisional until confirmed or otherwise by the relevant examinations board.