Investigation of failure mechanism of a DCI engine connecting rod

In reciprocating engines, connecting rod cap and bolts are critical as they exposed to varying loads under different operating conditions. This paper focused on the failure of a 1.5 dci K9K diesel engine. As result engine for approximately 378400 km, was broken, reasons bolt were investigated. The designed in accordance with dimensions SolidWorks software then exported ANSYS stress fatigue analysis. Also, macrostructure broken We knew that mechanic who fixed about two years ago tightened without using torque meter. Therefore, analyzes performed determine effect tightening torques (ranging from 22.5 52.5 Nm) at 2000 rpm. According numerical analysis results, increasing torque, maximum equivalent alternating values increased significantly, while safety factor cyclic life decreased. First, fracture occurred right hand bolt. Immediately after, lower cup deformed crashed cylinder liner. brittle left shoulder shank. chevron markings clearly visible evidence fracture.