When we change the material of connecting rod from Steel to light weight alloys such as aluminium and titanium, what are all the factors we should consider in the DoE? . I am considering the change in the process guidelines suitable to material rest maintaining the same dimension ?
Is the design change of connecting rod a necessary and important factor to meet the benchmark property?
When changing the material from Steel to aluminum or titan, the design of the connecting rod has to be modified because of the different material characteristics. When doing some research of existing solutions, you will see, that the light weight material parts show some increased wall thicknesses and eventuelly stiffener at the side walls. In addition, the screw design must be changed, too. I recommend the application of light weight material screws because of the different thermal extension characteristics of steel. Eventually, the area of the conrod bearings has to be increased too, because of the reduced capability of light weight materials.
As Vinh Duy Nguyen has written, there are several solutions availabel for small capacity engines and motorcycle engines. e.g. from Honda or Ducati. A manufacturer for light weight material conrods for racing engines is Pankl Racing (http://www.pankl.com/). Pankl shows some examples on the homepage.
Best regards,
Mario
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