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The deformation and stress experienced by the Gudgeon pin of a reciprocating compressor used in air
brake system is scientifically predicted when the pin is fully floating with lubricating oil surrounding it
and when starved of oil. Both semi analytical approach in finite element method and simple bending
theory of beams are used. Inadequacy of the beam approach is highlighted. The results obtained by
both the approaches are compared. Role of clearance in piston bore and small end of connecting rod
and effectiveness of lubrication are examined. Factor of safety associated with the design of Gudgeon
pin is also looked into.
Key words: Gudgeon pin, semi and fully floating pin, semi analytic method, role of lubricant, factor of safety.
INTRODUCTION
Reciprocating air compressors in vehicles compress air modal superposition technique was reported by the
and supply it to the air brakes. Many of the components authors (Ramamurti et al., 2011). In the present
constituting the reciprocating air compressor are having investigation, the design considerations connected with
design features based more on standard practices rather the Gudgeon pin of reciprocating air compressors are
than on sound scientific analysis. One of the systematic presented. This is motivated by lack of scientific analysis
investigations reported recently is on the pressure in literature and the inadequacies in the design
variation inside the air compressor as a function of the procedure.
crank angle (Venkatesan et al., 2009). An experimental
investigation using optical probes was also reported
(Brun et al., 2005). The dynamic analysis of the response Relevance of investigation
of the inlet and discharge valves of the compressor using
Gudgeon pin (Figure 1) connects the small end of the
connecting rod with the piston providing a turning pair;
Gudgeon pin can either turn relative to the connecting rod
*Corresponding author. E-mail: ramamurti@hotmail.com. or relative to the piston bore or turn relative to
both(Ramamurti, 2009).
Nomenclature: C, Clearance in the piston bore; d, l ,D-Inner Prerequisite for this function is that the Gudgeon pin
diameter, one-third length and outer diameter of the Gudgeon has a sliding fit with the other two. Since the Gudgeon pin
pin; n, Fourier index; pr, p, radial and circumferential pressure transmits the load from the connecting rod to the piston,
on the pin; r1,r2, inner and outer radii of the pin; w, load per unit the deformation that it suffers during the operation must
length on the pin (F/ ); A1, A2, B1, B2, C, salient locations on be such that it does not have surface contact with both
the Gudgeon pin; E, Youngs modulus; F, force on the simultaneously. This will lead to seizure. Besides, the
connecting rod; F1, Reaction at the end of the Gudgeon pin; I, Gudgeon pin should not be stressed beyond its
second moment of area of the beam; M, Bending moment of the
beam; OX,OY,OZ, radial , axial, circumferential; coordinates in
endurance limit.
semi analytical approach; Z, Modulus of section of the pin; The Gudgeon pin is either a hollow or solid steel
,Semi contact angle (in radians); X, Y, Z, Stresses in cylinder of length roughly five times its outer diameter.
radial, axial and circumferential directions; , Angular position in This is subjected to lateral load from the connecting rod
the pin. (Figure 2). The load acts for the full width of the
76 J. Mech. Eng. Res.
connecting rod (for nearly one third of the axial length of other hand, assumed fixed, it ignores the fact that there is
the Gudgeon pin) acting over a substantial arc of the a radial clearance between the piston bore and the
outer cylindrical surface of the pin. A very simple method cylindrical surface of the Gudgeon pin. However, when
of analysis is to treat the pin as a simply supported beam assumed simply supported, beam approach is very easy
subjected to lateral load of uniform intensity from the to analyse since the structure is statically determinate.
connecting rod. This approach has two basic
deficiencies. (i) The Gudgeon pin does not qualify to be
treated as a beam since its length is much less than ten FORCE ANALYSIS OF GUDGEON PIN
times its outer diameter. (ii) Besides the beam, when
assumed as simply supported at the ends, ignores the The Gudgeon pin assembly is subjected to uniform
fact that its support is along an arc of a circle. If, on the intensity of pressure in the region of the connecting rod
Ramamurti et al. 77
due to air compressed on the top flat face of the piston. Analytical procedure
Besides it is prevented from moving axially by the circlips.
The deformation of the Gudgeon pin is to be within elastic Beam approach
limits under the action of the force along the width of the
connecting rod for various angular positions. The This corresponds to a problem ignoring the presence of
bending deformation of the Gudgeon pin is to be oil in the annular space and assuming direct contact
assessed to address the adequacy of clearance between between the piston bore and the Gudgeon pin and
the pin and the small end of the connecting rod and also between the Gudgeon pin and connecting rod. In this
between the Gudgeon pin and piston bore. approach, even though the beam length is only five times
The Gudgeon pin, in reality, is a cylinder of roughly the diameter, Euler beam theory is assumed to be valid.
length 5 times its diameter, supported by lubricating oil
present in the clearance on the piston bore for roughly
two thirds its length with the middle one third subjected to Case (i): Contacts at B1 and B2
lubricating oil pressure on the annular space of the small
end of connecting rod. The load that gets communicated Figure 3 shows the close up view of the Gudgeon pin.
to the Gudgeon pin from the connecting rod acts on the The length 3 of the pin is roughly divided into three parts,
outer circumference along the middle one third of its namely, one third from either end housed in the piston
length. The piston bore on both sides supports this pin bore and the middle one third inside the small end. When
through the lubricating oil. The pin oscillates through this is subjected to the bending load from the connecting
approximately 10 about its mean position. There are two rod, the middle one third can deform as shown in Figure
aspects to be considered for the load distribution, one 4. In Figure 3 the supports on either side are at the
along the length of the pin and other along its locations B1 and B2.The two parts of the deformed neutral
circumference. Along the circumference, due to the axis (Figure 4) A1 B1 and A2 B2 are assumed to be not
lubricating oil pressure, it is periodic with the resultant touching the piston bore. The deformed neutral axis B1C
along the line joining small end and the big end and along B2 is not also touching the small end bore of the
the width of the connecting rod, with uniform intensity. To connecting rod.
meet these two requirements, semi analytical approach This is possible, only when there is adequate clearance
can be used (Ramamurti, 2009; Ramamurti and Gupta, available in both the piston bore and the small end of the
1978; Ramamurti and Narayanan, 1989; Quing et al., connecting rod. The Gudgeon pin is treated as a beam
2006; Zienkiewicz, 1991). In this connection, the following carrying uniformly distributed load over one third of its
papers that have similar connected applications can be length as shown in Figure 3 and analysis carried out. For
cited. this first case, the beam is assumed to be simply
Ramamurti and Gupta (1978) have assumed the load supported in locations B1 and B2. Area moment method
of a kiln tyre supported by rollers to act over a small arc, (Papov, 1978) is used to compute the deflections and
whereas in another paper, Ramamurti and Narayanan axial stress at its salient locations. The beam deflects as
(1989) have assumed that the load is transferred along shown in Figure 4.
several short arcs for a roller clutch. Quing et al. (2006)
have determined the natural frequencies of a shell
system by semi analytical approach in finite element Case (ii): Contacts at A1, B1, B2 and A2
method. In this paper, both beam and semi analytical
approaches are attempted and results compared. In the second case (Figure 5), the free ends A1 and A2 of
78 J. Mech. Eng. Res.
Figure 4. Deformation of a Gudgeon pin when not touching the piston bore.
Figure 5. Deformation of the Gudgeon pin when it exceeds clearance in the piston bore.
the beam physically touch the piston bore. If the available the locations A1 and A2 .One can, then, calculate the
tolerance between the piston bore and the Gudgeon pin deflections and stresses on the pin.
is less than the difference in deflection between the ends
A1 & B1 or A2 & B2, the Gudgeon pin will touch the piston
bore. Semi analytical approach
Taking the tolerance available as input one can
compute the force F1 experienced by the Gudgeon pin at The beam approach overlooks the role of lubricating oil in
Ramamurti et al. 79
2
1
a0
2 f ( )d
0
being small
1
2
an
2 0 f ( ) cos n d
1
2
bn
2 0 f ( ) sin n d
Figure 6. Gudgeon pin surrounded by lubricating oil.
the annular space of the turning pair. This oil will itIf,
is on the other
written as: hand, if it is assured anti - symmetric, then
2
physically lift the pin and transfer the load from the
1
0
connecting rod to the two sides of the piston bore. This an f ( ) sin n d
corresponds to a dynamic problem of Gudgeon pin
supported by the lubricating oil and the load being
2
bn f ( ) cos nd
transferred from the connecting rod through the oil to the 1
piston bore. The connecting rod executes angular
oscillation up to 10 on either side of the mean position 0 (2)
around 3000 times a minute. One can examine its role by
using the semi analytical approach. In this finite element The resultant of the load must be along the line joining
approach, the axial section of the hollow cylinder is the small end and big end of the connecting rod (Figure
modelled as a rectangle, with the length equal to the 6). If the load is assumed to act over a semi contact
length of the pin and breadth as the difference between angle on either side of this line (=0) with uniform
the inner and outer radii of the pin. intensity f over this arc, then its components along the
Since the loading on the Gudgeon pin through the radial direction will be fcos and the tangential direction
surrounding oil is periodic, it may safely be assumed to fsin. Obviously fcos is a symmetric periodic function
be the sum of a finite number of harmonics. If the and f sin is an anti symmetric. When is extremely
pressure variation f() is symmetric Fourier series can be small, this can be treated as a starved Gudgeon pin and
written as: when is , fully lubricated.
2
1
a0
2 f ( )d For fcos (radial pressure, symmetric), using
0 Equation (1)
1
2
an
2 0 f ( ) cos n d 1
a0 f cos d sin
f
a0 2f cos
1 f
d sin
2
1 2 (3)
bn
2 0 f ( ) sin nd 1
an 1 f cos cos dn 1)
f sin( n 1) sin( n
(1) an f cos cos nd
f nsin( sin( n 1()n(n1)1)
(1)
(n
(n 1) (n 1)
f
If, on the other hand, if it is assured anti-symmetric, then
When
If, on the other hand, if it is assured anti - symmetric, then it can a1 as ( 2 sin 2 )
n be1,fwritten (4)
22 )
When n 1, a1 (2 sin
1
2
when , 2
an f ( ) sin nd when ,
0 a f
a 1 f
80 J. Mech. Eng. Res.
1 f
a0
a 0
1
2
2
ff cos d
cos d f sin
sin
Figure
7. Bending moment diagram when Contacts are at B1 and B2.
1 f sin( n 1) sin( n 1)
cos cos nd f sin( n 1) sin( n 1) ( n 1)
f
a 1 f
ann ( n 1) ( n 1)
( n 1) ( n 1)
cos cos n d ( n 1)
f simply supported only at B1 and B2 as shown in Figure 7.
When n 1, a1 f ( 2 sin 2 ) The bending moment diagram is shown along side.
When n 1, a1 2 ( 2 sin 2 ) (5)
when , 2 One can proceed to find out the deflection at C (mid
span), A1and A2 (overhanging ends) and the maximum
a f ,
when
1 stress experienced by the Gudgeon pin. Since the beam
a10 f n ( n 1) 0 is assumed to be symmetric, it is sufficient to calculate
a a
the deflections and stress at A1 and C alone.
a0 an ( n 1) 0 Deflection at C is obtained by computing the moment
about B1 of the bending moment diagram between B1 and
(6) C (6)
Area (1/ 24) * wl 3
For f sin, (for circumferential pressure, Distance of C.G of the shaded area from B1= (5/16)
antisymmetric) using Equation (2) Difference in the slope of the tangent between B1and C
when , B C
((11 // 24
24))3 wl
3
wl 3 *
* (5 // 16
16))ll // EI
EI
when , 1
B C (1 / 24) wl * (5 / 16)(l5/ EI
B1 C
1
1 (10)
f sin(n 1) sin(n 1)
a0 0, an (n 1) sin sin nd Sincethe
Since
Since the
the deflection
deflection
deflection at B1 at B1 is
is zero
is zero:
at B1 isatzero
B zero
1
1 (n 1) ) nn
f(fn sin(
1sin( 11))
Since
sin( the
n
sin( n 1)
deflection
1 ) 1
a00 0, ann (n 1) sin sin nd (n (7)
C (
(n5((/5 4
a 0 , a ( n 1) sin sin n d 5384
/)384
/ 384 4)) wl
wl 4 / EI
/ EI
When n 1, (n 1) 1 ) CC ( n 1) 1
) wl
/ EI
(11)
When n
f n 1, 1, Similarly
Similarly
Similarly the
thethe difference
difference in the
the deflection
deflection
in the deflection
difference in between
between A1 between
and C, A1 aa
A
aWhen
1 (f2 sin 2 ) 1
a1 2 f ( 2 sin 2 ) AACC
(1 /(1
(124//)24
24 (2133 /*16()21
wl 3)*wl
) wl * (21 // 16
l / EI 384) wl(21
16))(ll21// /EI
EI 3
(21/ EI// 384 wl 33 // EI
384))wl EI
a1 2 , (2 sin 2 )
1
A11 C (12)
when (8)
when2 ,
a1 f
,
Hence the deflection at A1:
when
1 f
a
a0 an (n 1) 0 A1 A C B C (1 / 24)wl / EI 4
(13)
a10
af n ( n 1 ) 0
1 1
a0 an (n 1) 0
Case (ii): Contacts at A1, B1, B2 and A2
(9)
The beam has contacts at A1, B1, B2 and A2 as shown in
Figures 5 and 8.The reaction forces at A1and A2 can be
DETAILS OF ANALYSIS computed by the difference in the displacement from the
clearance during manufacture
Beam approach The principle of superposition can then be used to
combine the effects of two discrete loadings, the first due
Case (i) Contacts at B1and B2 to uniform distributed load Case (i) and the second due to
a concentrated load F1 Case (ii) (Figure 9).
This is shown in Figures 4 and 7. The beam is assumed Considering the reaction forces F1 and using area
Ramamurti et al. 81
moment method on the bending moment diagram shown Similarly, the difference in the deflection between A1 and
in Figure 10 and Table 1, the difference in the deflection C:
between B1and C is:
A1C 1/ EI ( F1l * l / 2 * 5l / 4) ( F1l * l / 2 * 2 / 3l ) F1l 3 / EI (23 / 24)
(16)
B1 C F1l * l / 2 * l / 4 / EI
(14) Hence
Hence,
( F1l 3* l / 2 * 2 / 3l ) F1l 3 / EI
1 / EIA1 ( FA13lC * lB/C 2 * 5l 3/ 4)(14)
A1 C
Hence, C (1 / 8) F1l 3 / EI A(23C/ 24 * l (/FEI1l * (l1// 28)*F15*ll/ 4/ EI
1) F/1EI ) ( F(51l/ 6*)lF/1l2/*EI2 / 3l ) F1l 3 / EI (23 / 24)
Hence,
F1l * l / 2 * l / 4 / EI Hence A1 A(14)
1
Hence A C AC BBCC
1 (15)
Hence, C (1 / 8) F1l 3 / EI (23 / 24(23 / EI((11 //88) F
) F/ 124*) Fl 3*/l 3EI (5 /
) F*1l*3 /lEI3 /EI 6) F(5 6) F1l 3 / EI
l 3 // EI
(15) 1 1 1 (17)
(15)
82 J. Mech. Eng. Res.
Description A C
Loading due to UDL of connecting rod (1/24)*wl4/EI (5/384)*wl4/EI M/Z
3 3
Reaction force F1 at the ends (5/6)*F1l /EI (1/8)*F1l /EI M/Z
If the available clearance between the Gudgeon pin and Semi analytic approach
piston bore is c,
Using (Equation 17) one can write: ANSYS is used to handle this problem. Symmetric and
antisymmetric loading as presented in Equations (3) to
c (5 / 6) F1l 3 / EI (9) are taken as inputs. PLANE 25 (ANSYS) is used for
2-D modeling of axisymmetric (18) structures with
nonaxisymmetric loading. The element is defined by
/HenceF
c (5 Hence, 6cEI / 5l 3
6) F1l 3 /1 EI three or four nodes having three degrees of freedom per
node: translations in the radial, axial and circumferential
HenceF1 6cEI / 5l 3 (19)
directions as shown in Figure 11. The axial section is
arrested at the locations of the circlips. The radial
Ramamurti et al. 83
Values of coefficients
5
Plot area
15
30
90 180
45
displacements at the outer radius at locations of the in Figure 12 for various harmonics. It can be observed
circlips are also assumed to be zero. that convergence is achieved for semi contact angle
Load is uniformly distributed on the Gudgeon pin in the above 30. For angles less than 30 the number of terms
region of the connecting rod and with half its intensity on required increases rapidly. For angles less than 5 even
either side in the region of the piston bore (in opposite 100 terms are not sufficient. Hence the semi analytical
sense). approach become cumbersome for <30.
Sum of the deformations and stresses for semi contact
angles of 30, 45, 90 and 180 are calculated for
harmonics up to 15. NUMERICAL RESULTS
Gudgeon pin OD
Nominal Tolerance Min Max
13.997 0.002 13.995 13.999
S/No Description Value Manufacturable lower limit Manufacturable upper limit Comments
Case (i): Contacts at B1 and B2.
1 Deflection at C 0.0033 mm 0.004 mm 0.018 mm Acceptable
2 Deflection at A 0.0105 mm 0.004 mm 0.018 mm Exceeds lower limit
3 y at C 103MPa Endurance limit 200MPa (50% of yield)for Ni Cr steel Acceptable
Y of 80 MPa at the outer most fibers. This varies value exceeds 36 MPa. This is understandable since for
linearly across the depth of the beam. X and Z are not the same intensity of loading in case of semi analytic
present. approach the entire cross section participates in load
On the other hand in the case of semi analytic sharing. In beam theory the top and bottom fibers
approach, X, Y, and Z are present everywhere. ( X is experience maximum Y linearly varying across the depth
zero at the free surface of the outer radius).No individual with x and Z being zero everywhere.
86 J. Mech. Eng. Res.
Figure 16. Stress on Gudgeon pin for =45 degree semi analytic approach.
Lubricant oil
Figure 17. Gudgeon pin fully floating in the oil (semi analytic approach).
Figure 18. Stress distribution for beam approach and semi analytic approach.
Angle in degree
Figure 19. Von Mises Stress on Gudgeon pin for various semi contact angle.
MPa as shown in Figure 19. The material used for of safety around five. This implies that the Gudgeon pin is
Gudgeon pin is Nickel-chromium alloy steel whose basically an over designed member which is not
endurance limit is above 200 MPa. This provides a factor expected to fail during its operation. Likelihood of
88 J. Mech. Eng. Res.
ACKNOWLEDGEMENT