The main objective of this work is to explore weight reduction possibilities, in the design and production of a connecting rod. This can be implemented by detailed load analysis. Therefore, this study has been dealt with two steps. The load and stress analysis of the connecting rod is done and then optimization is achieved by reducing the weight and cost. First part of the study analysis includes the determination of loads acting on the connecting rod as a function of time. This is done for finding out the minimum stress area and to remove the material in those areas.  The relationship between the load and acceleration of the connecting rod for a given constant speed of the crankshaft are also determined. Finite element analysis was done over several crank angles. The connecting rod can be designed and optimized under the loads ranging from tensile load, corresponding to 360 degree crank angle at the maximum engine speed as one extreme load and the compressive load proportionate to the peak gas pressure as the other extreme load. The fracture crack ability feature facilitates separation of cap from rod without additional machining of the mating surfaces. Yet, the same performance can be expected in terms of component durability. This aspect is considered in this work and the connecting rod is optimized by reducing the weight and cost.

Keywords : Connecting rod, Stress Analysis and Finite Element Analysis (FEA)