Analysis and Simulation Optimization of Connecting Rod Cap Failure in Compressor

The connecting rod cap is one of the key components for the reciprocating motion of compressors and internal combustion engines, and it works in conjunction with the connecting rod to convert power.Regarding the fracture problem of the connecting rod cap of a certain compressor, the initial cause of the fracture was preliminarily determined through physical and chemical analysis to be the excessively small fillet radius at the bolt installation plane.A finite element model was established to verify the cause of the fracture, and based on this as a comparison benchmark, the model structure was optimized.It was found that increasing the fillet radius could indeed improve the performance of the connecting rod cap, but it is not the case that the larger the fillet radius, the better.In the simulation, it was discovered that the performance of the fillet with a radius of 4.5 mm was significantly worse than that of the fillet with a radius of 3.5 mm.Therefore, in the design of the connecting rod cap, an appropriate fillet radius should be selected to ensure its good performance.Additionally, a design combining the fillet with a chamfer can also be considered.