Sep 2026· International Journal of Automotive and Mechanical Engineering· Vol 23, pp. 13801-13815
Mechanical Failure Analysis and Simulation
Abstract
The present study investigated the impact of replacing gasoline with bioethanol on the high-cycle fatigue (HCF) life of an engine connecting rod. Finite element analysis (FEA) was performed using ANSYS software to determine the stress distribution. The nCode Design Life and the Goodman criterion were applied for HCF life prediction. The results indicated that the bioethanol increased the maximum connecting rod stress by about 3.46%. The minimum fracture cycles were predicted in the area between the shank and the small end as 2.744×109 and 2.356×109 cycles for gasoline and bioethanol, respectively, indicating a 14.14% reduction in HCF life with bioethanol. The safety factor indicated no critical area in the connecting rod. An 800-h durability test further confirmed the absence of connecting rod failure.
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