Title: Manufacturing and Machining Effects on Recycled Composite Connecting Rods

Authors: Walter Oppelt, Eltahry Elghandour, Alan Zhang, Masoud Yekani Fard

DOI:

Abstract: Carbon fiber reinforced polymers (CFRPs) are widely valued in aerospace, automotive, and other industries for their high strength-to-weight ratio. However, producing virgin carbon fiber is energy-intensive, creating both economic and environmental challenges. Recycled carbon fiber offers a promising alternative by reducing manufacturing energy usage while maintaining many of the desirable properties of CFRPs. This study investigates the application of recycled CFRPs and woven prepreg carbon fiber in internal combustion engine connecting rods, assessing both structural performance and sustainability. Composite connecting rod specimens were fabricated using autoclave curing and CNC machining. Mechanical behavior was characterized through tensile and compression testing under load cases representative of engine operation. An Abaqus FEA model to simulate the rod performance was then validated with experimental results. The findings indicate that CFRPs can achieve mechanical properties comparable to those of aluminum, a material commonly used in connecting rods. Woven prepreg CFRPs displayed the highest strength and stiffness, but recycled CFRPs also demonstrated sufficient mechanical performance to be considered a feasible alternative. Importantly, the use of recycled carbon fiber materials presents a pathway to advance sustainable practices in composite engineering. Overall, this research highlights the potential for integrating recycled composites into demanding mechanical applications, balancing performance requirements with environmental and energysaving benefits.

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Conference: SAMPE 2026

Publication Date: 2026/04/27

SKU: 70

Pages: 12

Price: $24.00