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Connecting rod

technology Maturity 9-11 Next article →

A connecting rod, often called a "con rod," is a critical component in piston engines.

Drawing of a connecting rod in an automobile engine
Drawing of a connecting rod in an automobile engine

Its primary job is to connect the piston to the crankshaft. By doing this, the rod converts reciprocating motion into rotation. Reciprocating motion is the straight up-and-down movement of the piston. Rotation is the circular movement of the crankshaft. This conversion allows the energy from the piston to turn the wheels of a vehicle.

Piston and connecting rod
Piston and connecting rod

To perform this task, the rod must manage complex physical forces. It must transmit both compressive forces and tensile forces. Compression occurs when the piston is pushed downward. Tension occurs when the piston moves upward. During every single rotation of the crankshaft, the rod experiences these repetitive loads. These forces are actually proportional to the engine speed squared. This means as the engine spins faster, the stress on the rod grows very quickly. The rod also faces shear forces caused by the angle between the piston and the crankpin.

Biella rotta per fatica
Biella rotta per fatica

Most modern connecting rods consist of three distinct sections. The first part is the small end, which attaches to the gudgeon pin. This pin is also known as a piston pin or a wrist pin. The small end allows the rod to pivot so the angle can change during movement. The middle section is simply called the rod. The final part is the big end, which connects to the crankpin. Most engines use a plain bearing at the big end to reduce friction. Some smaller engines use a rolling-element bearing instead. Many rods also feature a small pinhole to let lubricating oil squirt onto the cylinder walls.

Engineers choose different materials based on how the engine will be used. Most mass-produced automotive engines use steel rods because they are reliable. High-performance engines often use "billet" rods. These are machined from a single solid piece of metal rather than being cast. Some designers use aluminum alloys, such as T6-2024 or T651-7075, to reduce weight. Aluminum can absorb high impacts, though it is less durable than steel. Titanium is another expensive option used to reduce weight. For cheaper, low-performance engines like motor scooters, manufacturers may use cast iron.

Mechanical linkages similar to the connecting rod have a long history. The predecessor to this design was used in Roman-era watermills. For example, sawmills in Hierapolis and Ephesus used these linkages. They converted the rotary motion of a waterwheel into the linear motion of saw blades.

Römische Sägemühle
Römische Sägemühle

Later, the inventor Al-Jazari documented a similar design between 1174 and 1206 AD. He described a machine that used a connecting rod and crankshaft to pump water. During the Renaissance, the artist Pisanello and the designer Taccola also sketched these mechanisms.

Sometimes, engineers must solve difficult space problems using special rod types. In radial engines, they use master-and-slave rods. One master rod connects directly to the crankshaft. The other pistons use slave rods that attach to rings on the master rod. This can cause vibration because the slave pistons may have different stroke lengths. Another solution is the fork-and-blade design. In this setup, one rod is split into a fork shape. A thinner "blade" rod fits into that gap.

Forked connecting rods (Autocar Handbook, 13th ed, 1935)
Forked connecting rods (Autocar Handbook, 13th ed, 1935)

This design is used in V-twin motorcycles and V12 aircraft engines.

If a connecting rod fails, the results can be catastrophic. This event is often called "throwing a rod." A broken rod can punch through the side of the engine crankcase. This usually makes the entire engine irreparable. Failure can happen due to high engine speeds or lubrication problems. It can also happen if a piston hits a valve. Additionally, the sideways force from the rod can wear cylinders into an oval shape. This happens because the rod pushes the piston against the cylinder wall. Longer rods can reduce this wear, but they must still fit within the engine block.

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File:Drawing of a connecting rod in an automobile engine.jpg
Drawing of a connecting rod in an...
File:Bielle.jpg
Bielle.jpg
File:Römische Sägemühle.svg
Römische Sägemühle.svg
File:Piston and connecting rod.jpg
Piston and connecting rod.jpg
File:Biella rotta per fatica.jpg
Biella rotta per fatica.jpg
File:Forked connecting rods (Autocar Handbook, 13th ed, 1935).jpg
Forked connecting rods (Autocar Handbook,...
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