Numerical analysis of the application of different lattice designs and materials for reciprocating engine connecting rods

Nowadays, the use of lattice structure designs in metallic parts to produce lightweight systems has gained importance owing to advances in additive manufacturing technology. On the other hand, vehicle manufacturers are constantly looking for new ways to reduce weight due to the depletion of fossil fuels, the demand for vehicles having higher performance, global warming and increasingly stringent emission standards. In this study, in order to reduce the weight of the internal combustion engine, different lattice designs were made in the connecting rods. Four different 2.5D lattice designs, hexagonal, octagonal, square and triangular, were created in reference connecting rod body. The dimension of the lattice designs was 10x10x12 mm with the wall thickness of 1.5 mm. The fatigue behaviors of the connecting rods as well as mechanical properties under static conditions were analyzed using finite element approach. Three different materials were used in the analyzes: AISI 4140, Inconel 718 and Ti6Al4V. As a result, it was seen that weight reduction of up to 15.75% was possible in the connecting rod thanks to the lattice designs and the maximum stresses were below the yield stresses of the materials. Moreover, connecting rods with lattice design had satisfactory safety factor values.