Design and Structural Analysis of a Connecting Rod Using Different Materials

Helal Uddin; Rasel Ahmed; Touhidur Rahman Sajib; Khalid Shaifullah Mahmud; Abdur Rahim Hera

doi:doi:10.11648/j.sdm.20260101.13

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Design and Structural Analysis of a Connecting Rod Using Different Materials

Helal Uddin^*

, Rasel Ahmed

, Touhidur Rahman Sajib

, Khalid Shaifullah Mahmud

, Abdur Rahim Hera

Published in Science Discovery Materials (Volume 1, Issue 1)

Received: 17 August 2025 Accepted: 27 January 2026 Published: 11 February 2026

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Abstract

A connecting rod or connective rod is a very important part of internal combustion engines that connect the piston to crankshaft, which enables conversion of the reciprocating motion to another rotary motion. Connecting rods have traditionally been constructed out of forged steel because of its fatigue strength, although its density adds weight and decreases efficiency to engines. As the requirements for lightweight and fuel-efficient engines increase, so too do the negative influences of the mass of forged steel connecting rods leading to easier induction of inertial forces and loss of performance. The purpose of the research is to design and analyze connecting rod materials alternative to reduce weight, increase stiffness and fatigue life compared to conventional forged steel connecting rods. A connecting-rod was modeled parametrically in SolidWorks and assessed using SolidWorks Workbench finite element analysis (FEA). The paper compared Forged Steel to Titanium Alloy, Beryllium Alloy-25, Magnesium Alloy and Aluminum 360 such in stress strain, deformation, safety factor and fatigue life. Out of the tested material, Aluminum 360 had the lowest deformation (1.950e-05 mm), least stress (2.992e+04 N/m 2), greatest margin of safety and substantial weight reduction compared to forged steel. The results encourage the use of Aluminum 360 in place of forged steel used in two-wheeler engines since it provides better performance, efficiency, and a longer life.

Published in	Science Discovery Materials (Volume 1, Issue 1)
DOI	10.11648/j.sdm.20260101.13
Page(s)	34-49
Creative Commons	This is an Open Access article, distributed under the terms of the Creative Commons Attribution 4.0 International License (http://creativecommons.org/licenses/by/4.0/), which permits unrestricted use, distribution and reproduction in any medium or format, provided the original work is properly cited.
Copyright	Copyright © The Author(s), 2026. Published by Science Publishing Group

Keywords

Connecting Rod, Aluminum Alloy, Forged Steel, Carbon Steel, SOLIDWORKS, Deformation, Stress Analysis, Structural Analysis, FEA

References

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[3]	Hussin, M. A., et al., Design and analysis of connecting rod using aluminium alloy 7068 T6, T6511. 2014. 5(10): p. 57-69.
[4]	Vegi, L. K., Design and analysis of connecting rod using forged steel. 2013.
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[6]	Chumbre, V., et al., Design and Comparative Analysis of Connecting Rod using Finite Element Analysis. 2018. 6: p. 765-773.
[7]	Premkumar, T. M., et al., Optimizing the Design and Material used for Connecting Rod through Finite Element Simulation. 2021. 13(5).
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[16]	Kathirselvam, M., et al., An Overview of the Advancements and Upgrades Made to the Connecting Rods in the Internal Combustion Engine. 224: p. 231.
[17]	Savaripour, H., et al., Finite element analysis of fatigue in the connecting rod of a spark ignition engine based on results of combustion tests. 2025: p. 09544070251320130.
[18]	Asrith, V. V., et al., Numerical and mathematical modelling of connecting rod of internal combustion engine. 2025: p. 1-9.
[19]	Naik, M.S.A.J.I.J.E.T.R., Design & shape optimization of connecting rod using FEA: a review. 2014. 2(8): p. 95-100.
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APA Style

Uddin, H., Ahmed, R., Sajib, T. R., Mahmud, K. S., Hera, A. R. (2026). Design and Structural Analysis of a Connecting Rod Using Different Materials. Science Discovery Materials, 1(1), 34-49. https://doi.org/10.11648/j.sdm.20260101.13

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ACS Style

Uddin, H.; Ahmed, R.; Sajib, T. R.; Mahmud, K. S.; Hera, A. R. Design and Structural Analysis of a Connecting Rod Using Different Materials. Sci. Discov. Mater. 2026, 1(1), 34-49. doi: 10.11648/j.sdm.20260101.13

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AMA Style

Uddin H, Ahmed R, Sajib TR, Mahmud KS, Hera AR. Design and Structural Analysis of a Connecting Rod Using Different Materials. Sci Discov Mater. 2026;1(1):34-49. doi: 10.11648/j.sdm.20260101.13

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@article{10.11648/j.sdm.20260101.13,
  author = {Helal Uddin and Rasel Ahmed and Touhidur Rahman Sajib and Khalid Shaifullah Mahmud and Abdur Rahim Hera},
  title = {Design and Structural Analysis of a Connecting Rod Using Different Materials},
  journal = {Science Discovery Materials},
  volume = {1},
  number = {1},
  pages = {34-49},
  doi = {10.11648/j.sdm.20260101.13},
  url = {https://doi.org/10.11648/j.sdm.20260101.13},
  eprint = {https://article.sciencepublishinggroup.com/pdf/10.11648.j.sdm.20260101.13},
  abstract = {A connecting rod or connective rod is a very important part of internal combustion engines that connect the piston to crankshaft, which enables conversion of the reciprocating motion to another rotary motion. Connecting rods have traditionally been constructed out of forged steel because of its fatigue strength, although its density adds weight and decreases efficiency to engines. As the requirements for lightweight and fuel-efficient engines increase, so too do the negative influences of the mass of forged steel connecting rods leading to easier induction of inertial forces and loss of performance. The purpose of the research is to design and analyze connecting rod materials alternative to reduce weight, increase stiffness and fatigue life compared to conventional forged steel connecting rods. A connecting-rod was modeled parametrically in SolidWorks and assessed using SolidWorks Workbench finite element analysis (FEA). The paper compared Forged Steel to Titanium Alloy, Beryllium Alloy-25, Magnesium Alloy and Aluminum 360 such in stress strain, deformation, safety factor and fatigue life. Out of the tested material, Aluminum 360 had the lowest deformation (1.950e-05 mm), least stress (2.992e+04 N/m 2), greatest margin of safety and substantial weight reduction compared to forged steel. The results encourage the use of Aluminum 360 in place of forged steel used in two-wheeler engines since it provides better performance, efficiency, and a longer life.},
 year = {2026}
}

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TY  - JOUR
T1  - Design and Structural Analysis of a Connecting Rod Using Different Materials
AU  - Helal Uddin
AU  - Rasel Ahmed
AU  - Touhidur Rahman Sajib
AU  - Khalid Shaifullah Mahmud
AU  - Abdur Rahim Hera
Y1  - 2026/02/11
PY  - 2026
N1  - https://doi.org/10.11648/j.sdm.20260101.13
DO  - 10.11648/j.sdm.20260101.13
T2  - Science Discovery Materials
JF  - Science Discovery Materials
JO  - Science Discovery Materials
SP  - 34
EP  - 49
PB  - Science Publishing Group
UR  - https://doi.org/10.11648/j.sdm.20260101.13
AB  - A connecting rod or connective rod is a very important part of internal combustion engines that connect the piston to crankshaft, which enables conversion of the reciprocating motion to another rotary motion. Connecting rods have traditionally been constructed out of forged steel because of its fatigue strength, although its density adds weight and decreases efficiency to engines. As the requirements for lightweight and fuel-efficient engines increase, so too do the negative influences of the mass of forged steel connecting rods leading to easier induction of inertial forces and loss of performance. The purpose of the research is to design and analyze connecting rod materials alternative to reduce weight, increase stiffness and fatigue life compared to conventional forged steel connecting rods. A connecting-rod was modeled parametrically in SolidWorks and assessed using SolidWorks Workbench finite element analysis (FEA). The paper compared Forged Steel to Titanium Alloy, Beryllium Alloy-25, Magnesium Alloy and Aluminum 360 such in stress strain, deformation, safety factor and fatigue life. Out of the tested material, Aluminum 360 had the lowest deformation (1.950e-05 mm), least stress (2.992e+04 N/m 2), greatest margin of safety and substantial weight reduction compared to forged steel. The results encourage the use of Aluminum 360 in place of forged steel used in two-wheeler engines since it provides better performance, efficiency, and a longer life.
VL  - 1
IS  - 1
ER  -

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Author Information

Helal Uddin

Department of Mechanical Engineering, Hajee Mohammad Danesh Science and Technology University, Dinajpur, Bangladesh

Contact Email

http://orcid.org/0009-0008-2765-8140
Rasel Ahmed

Department of Mechanical Engineering, Rajshahi University of Engineering & Technology, Rajshahi, Bangladesh

Contact Email

http://orcid.org/0000-0002-4633-6699
Touhidur Rahman Sajib

Department of Management, Multimedia University, Selangor, Malaysia

Contact Email

http://orcid.org/0009-0002-7675-3335
Khalid Shaifullah Mahmud

Department of Mechanical Engineering, Hajee Mohammad Danesh Science and Technology University, Dinajpur, Bangladesh

http://orcid.org/0009-0002-8668-6252
Abdur Rahim Hera

Department of Mechanical Engineering, Hajee Mohammad Danesh Science and Technology University, Dinajpur, Bangladesh

Contact Email

http://orcid.org/0009-0003-2728-7742

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APA Style

Uddin, H., Ahmed, R., Sajib, T. R., Mahmud, K. S., Hera, A. R. (2026). Design and Structural Analysis of a Connecting Rod Using Different Materials. Science Discovery Materials, 1(1), 34-49. https://doi.org/10.11648/j.sdm.20260101.13

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ACS Style

Uddin, H.; Ahmed, R.; Sajib, T. R.; Mahmud, K. S.; Hera, A. R. Design and Structural Analysis of a Connecting Rod Using Different Materials. Sci. Discov. Mater. 2026, 1(1), 34-49. doi: 10.11648/j.sdm.20260101.13

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AMA Style

Uddin H, Ahmed R, Sajib TR, Mahmud KS, Hera AR. Design and Structural Analysis of a Connecting Rod Using Different Materials. Sci Discov Mater. 2026;1(1):34-49. doi: 10.11648/j.sdm.20260101.13

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@article{10.11648/j.sdm.20260101.13,
  author = {Helal Uddin and Rasel Ahmed and Touhidur Rahman Sajib and Khalid Shaifullah Mahmud and Abdur Rahim Hera},
  title = {Design and Structural Analysis of a Connecting Rod Using Different Materials},
  journal = {Science Discovery Materials},
  volume = {1},
  number = {1},
  pages = {34-49},
  doi = {10.11648/j.sdm.20260101.13},
  url = {https://doi.org/10.11648/j.sdm.20260101.13},
  eprint = {https://article.sciencepublishinggroup.com/pdf/10.11648.j.sdm.20260101.13},
  abstract = {A connecting rod or connective rod is a very important part of internal combustion engines that connect the piston to crankshaft, which enables conversion of the reciprocating motion to another rotary motion. Connecting rods have traditionally been constructed out of forged steel because of its fatigue strength, although its density adds weight and decreases efficiency to engines. As the requirements for lightweight and fuel-efficient engines increase, so too do the negative influences of the mass of forged steel connecting rods leading to easier induction of inertial forces and loss of performance. The purpose of the research is to design and analyze connecting rod materials alternative to reduce weight, increase stiffness and fatigue life compared to conventional forged steel connecting rods. A connecting-rod was modeled parametrically in SolidWorks and assessed using SolidWorks Workbench finite element analysis (FEA). The paper compared Forged Steel to Titanium Alloy, Beryllium Alloy-25, Magnesium Alloy and Aluminum 360 such in stress strain, deformation, safety factor and fatigue life. Out of the tested material, Aluminum 360 had the lowest deformation (1.950e-05 mm), least stress (2.992e+04 N/m 2), greatest margin of safety and substantial weight reduction compared to forged steel. The results encourage the use of Aluminum 360 in place of forged steel used in two-wheeler engines since it provides better performance, efficiency, and a longer life.},
 year = {2026}
}

Copy | Download

TY  - JOUR
T1  - Design and Structural Analysis of a Connecting Rod Using Different Materials
AU  - Helal Uddin
AU  - Rasel Ahmed
AU  - Touhidur Rahman Sajib
AU  - Khalid Shaifullah Mahmud
AU  - Abdur Rahim Hera
Y1  - 2026/02/11
PY  - 2026
N1  - https://doi.org/10.11648/j.sdm.20260101.13
DO  - 10.11648/j.sdm.20260101.13
T2  - Science Discovery Materials
JF  - Science Discovery Materials
JO  - Science Discovery Materials
SP  - 34
EP  - 49
PB  - Science Publishing Group
UR  - https://doi.org/10.11648/j.sdm.20260101.13
AB  - A connecting rod or connective rod is a very important part of internal combustion engines that connect the piston to crankshaft, which enables conversion of the reciprocating motion to another rotary motion. Connecting rods have traditionally been constructed out of forged steel because of its fatigue strength, although its density adds weight and decreases efficiency to engines. As the requirements for lightweight and fuel-efficient engines increase, so too do the negative influences of the mass of forged steel connecting rods leading to easier induction of inertial forces and loss of performance. The purpose of the research is to design and analyze connecting rod materials alternative to reduce weight, increase stiffness and fatigue life compared to conventional forged steel connecting rods. A connecting-rod was modeled parametrically in SolidWorks and assessed using SolidWorks Workbench finite element analysis (FEA). The paper compared Forged Steel to Titanium Alloy, Beryllium Alloy-25, Magnesium Alloy and Aluminum 360 such in stress strain, deformation, safety factor and fatigue life. Out of the tested material, Aluminum 360 had the lowest deformation (1.950e-05 mm), least stress (2.992e+04 N/m 2), greatest margin of safety and substantial weight reduction compared to forged steel. The results encourage the use of Aluminum 360 in place of forged steel used in two-wheeler engines since it provides better performance, efficiency, and a longer life.
VL  - 1
IS  - 1
ER  -

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