Analysis and optimization of connecting rod used in heavy. This process serves as the initial processing step for forging of parts such as connecting rod, crank shaft etc. The layout of this shop was designed and fitted for the furan sandmolding process, one of the most advanced molding processes. The biggest advantages of programmable forging hammer is that it can standardize the production process. Existing steel material connecting rod is manufactured by using forging process. Solution of manufacturing defects in connecting rod. Connecting rod hot forging simulation in qform youtube. We have also developed the fracture split crack connecting rods the latest high quality and high accuracy process for forging and casting. Comparision of manufacturing methods and analysis of. Concept and manufacture of a crankshaft production tool numerical and experimental analysis. The present work has been established to replace the existing connecting rod made of forged steel with the aluminium mmc connecting rod for weight optimization. Forged products ring forgings exporter from new delhi. Jun 20, 2015 an overview on different manufacturing processes of connecting rod.
Fem analysis of connecting rod of different materials. Us5878491a process for the manufacture of a forged. Forged connecting rods, forged conrods drop forging. Introduction connecting rods are widely used in variety of automobile engines. Selection of material, shape, and manufacturing process. Selection of material, shape, and manufacturing process for a. We could open the cover from connecting rod, thus manufacturing cost was saved. An overview of forging processes with their defects.
Therefore, choosing the appropriate forging materials, the reasonable forging process, play a crucial role on the performance of the connecting rod. Keywords crackable connecting rod, material selection, topsis method, ranking 1. And some oems may use forged rods only on higher performance versions of a given car or engine. Carbon steels or alloy steels are the most commonly used materials. Holes on both ends of a connecting rod are machined to perfectly connect to pistons and the crankshaft.
Jan 04, 2019 connecting rods are not universally made by forging. Alloy steels are used for manufacturing conrods for high performance engines as they provide the required cyclic strength without substantially increasing the dimensions of critical sections. In the above programmable output part of forging,estimated blow energy of 3 times straightening needs to be 16. The objective of this project is to make 3d model of connecting rod using pro. Here we explore competing processes for casting a small aluminum alloy connecting rod figure 14. Jan 11, 2018 a connecting rod is a shaft which connects a piston to a crank or crankshaft in a reciprocating engine. Engine connecting rod an overview sciencedirect topics.
Design and analysis of connecting rod using forged steel. Introduction forging is one of the past known metalworking process. With fatigue analysis we can determine the lifetime of the connecting rod. The connecting rod is modeled as plane stress problem using 25 quadrilateral pelements. Connecting rod hot forging simulation in qform is shown in this video. Analysis of finite volume of forging process of connecting rod. A connecting rod rough forging, free of lateral flash and including at least one bore initiator on the big end and on the small end, is manufactured by forging. The study includes material characterization, constitutive modeling, and numerical simulation of the forging process. Materials for connecting rods have included powder metallurgy steels, which are formed into an initial shape then forged to near final dimension, as well as medium carbon steels, which develop superior strength either through separate heat treating processes or by controlled cooling following the forging. Forged connecting rods with the development of automobile industry, the increase of the engine power, the requirement about the quality of the connecting rod is becoming more and more high. Usually, forging was done by a smith using hammer and anvil. Comparative study of the connecting rod manufactured.
Crackable connecting rod material selection by using. Connecting rods are available in a variety of sizes and materials ideal for certain situations. Comparative study of the connecting rod manufactured using forging and sintering. The connecting rod is the intermediate member between the piston and the crankshaft. Crane hook, connecting rod of ic engine, spanner, gear blanks etc.
To this end, it is necessary to finely control the volume and geometry of the preform in order to avoid both the flash. The properties and the damage behavior of pm connecting rod preform has a significant influence on its metal flow behavior during flashless forging. Connecting rods are not universally made by forging. Forging of connecting rods in the chines industry is illustrated in 1. Powdered metal pressed together and then put into an oven where it is sintered that means granuals are melted together and forms the rod. Connecting rods link oscillatory motion to rotary motion in ic engines, and rotary to oscillatory motion in pumps. Localization of the shear surface tracking of the initial billet of a connecting rod. The central composite design ccd was prepared with three. Then, the hot forging process of the connecting rod preforms was simulated using the material constitutive model based on finite element.
These ideas have been mainly related to machining sequence, machine tool and new technologies for machining. Parting edge where cap and the rod meet is fractured. Fortunately, further investigating the metal flow mechanisms of a porous pm connecting rod preform during the flashless forging process and properly designing the geometry of the preform before hot forging can offer the possibility to control the forming process such as to fabricate connecting rods with excellent mechanical properties. The purpose of this project is the analysis of a main component of internal combustion engines, the connecting rod, hereinafter conrod, focusing in particular on the bsegment small cars field. Manufacturer of connecting rod, connecting rod manufacturer. A new method of optimization on the hot forging tools for connecting rods was developed in this paper by combining response surface analysis. Abstract an integrated study of dynamic hot forging of sae 1151 steel connecting rod is presented. Supplier of connecting rods, exporter of connecting rod. Often, the cap part and lower rod part are forged separately, or forged slightly oblong and sawed in two pieces. Forging is often classified according to the temperature at which it is performed. This became one of the strengths of the powder forging. The metal flow behavior of a pm connecting rod preform during flashless forging were studied based on isothermal compression tests and fem. Many connecting rods today are manufactured using cheape.
In every combustion piston engine car, motorcycle, trucks. Connecting rods are practically generally used in all varieties of automobile engines. Comparative study of the connecting rod manufactured using. Pdf numerical optimization on hot forging process of. The changes of the temperature fields, stress fields of the billet. The shape of the connecting rod is to be determined to minimize its weight subject to a set of stress constraints. Analysis, connecting rod, fea, dynamic, optimization, etc.
After systematic inspections of connecting rod, we have found problem of cap tight and oversize of big end diameter of connecting rod. Energy savings is another advantage of the process when the forging step directly follows the sintering step, eliminating reheating. Agenda manufacturing of connecting rod forging vs casting defects of forging designing and manufacturing processes limitation of forging economics limitation 2. The powderforged connecting rod with a complex geometry shape is composed of the small end, the big end, and a beamlike shank.
This process generates a lot of heat, so the piston must be air cooled for one hour. Apr 16, 2014 in depth behind the scenes look at hot rods u. Powder forging is done at a lower forging temperature than conventional forging. Manufacturer of connecting rod, connecting rod manufacturer, manufacturer of connecting rods india power industries is a manufacturer, exporter of automobile, connecting rod from india, offers various types of connecting rods for caterpillar connecting rods, komatsu connecting rods, cummins connecting rods, john deere connecting rods, perkins connecting rods, mercedes connecting rods, cat. Pioneers in the industry, we offer ring forgings, forged bars, stainless steel flanges, connecting rods and cold forging from india. Pdf an integrated study of dynamic hot forging of sae 1151 steel connecting. A new method of optimization on the hot forging tools for connecting rods was developed in this paper by combining response surface analysis rsa with finite element method fem. In the late twentieth century, forging method developed into open forged steel connecting rods. Some examples of shapes obtained by forging process. Design, simulation and manufacturing of a connecting rod from.
Standardization can be repetitive operation,the repeatability is capable of producing consistent forged connecting rods,guarantee the. Connecting rods forged 4340 steel connecting rod material. Forging is a manufacturing technique in which metal is plastically deformed from a simple shape like billet, bar, ingot into the desired shape in one or more stages. Powder forging process powder forging consists of the rapid densification of a heated powderbased preform using a single forging strike.
The use of nearnet shape preforms results in less material flow resulting in longer tool life. We shall learn what types of stresses are present in each of the mechanical working process. The geometric model, finite element mesh, physical dimensions, and design variables are shown in figure 3. The slug is then removed from the oven, and placed into the punch.
Forging is the primary process which is used for manufacturing of connecting rod and after various machining process carried out for get desired dimension and surface finish. As tolerance chain analysis is an essential activity in process planning for geometry assurance, a tolerance chains study based on monte carlo simulations for the connecting rod line has been performed to develop. A process for manufacturing a forged connecting rod of the type including a big end, a shank and a small end. It is one of the oldest metalworking arts with its origin about some thousands of years back. The connecting rod pushes the piston up, and is helped back down by the pistons reciprocal motion. These blow energy can forge high deformation so that the resultant force is very low. Forging is a metal working process in which useful shape is obtained in solid state by hammering or pressing metal. We design and tailor our crankshaft forging process to each application. Together with the crank, it forms a simple mechanism that converts reciprocating motion into rotating motion it is the main function of a conne. Together with the crank, it forms a simple mechanism that converts reciprocating motion into rotating motion it is the main function of a connecting rod.
Abstract connecting rod is a major part inside of a internal combustion engine. His current research focuses on edm and severe plastic deformation processes. The function of the connecting rod is to transmit the thrust of the piston to the crankshaft and translate the transverse motion to rotational motion. Forging process produces parts of superior mechanical properties with minimum waste of material. It is authorized by the famous lr, gl, dnv, abs, bv, nk and kr as a manufacturer of steel castings and forgings for shipbuilding.
Forging steps for production of connection rods are briefly shown. Comparison of casting versus forging connecting rods in areas most. A read is counted each time someone views a publication summary such as the title, abstract, and list of authors, clicks on a figure, or views or downloads the fulltext. This thesis describes designing and analysis of connecting rod. The product thus obtained by forging is at good strength and free from any defects. Introduction the automobile engine connecting rod is a high volume production, critical component. Numerical optimization on hot forging process of connecting rods. Its manufacturing process involves the fabrication of a connecting rod preform by the conventional pm processing technique, followed by a forging process to its.
A crankshaft manufactured by the forging process typically imparts greater strength and density as compared to a casting or crankshaft machined from bar. Powertrain components forging custom forged powertrain. A comparison of manufacturing technologies in the connecting. Propeller and intermediate shafts, connecting rod, piston rod, guide rod, gear and pinion, crankshaft doosan is the largest maker of steel castings and forgings for shipbuilding in korea. A connecting rod is a shaft which connects a piston to a crank or crankshaft in a reciprocating engine. Modern manufacturing process of forged connecting rod.
Connecting rod inspection by jim gibson regardless of a connecting rod s application stock, performance or racing, prior to rebuilding or engine assembly, all rods must be inspected, measured and reconditioned before installation. Forging is a manufacturing process involving the shaping of metal using localized compressive forces. Connecting rods, forging, casting, powder metal based processes. In this process, the starting material has a relatively simple geometry. Metal flow behavior of pm connecting rod preform in. Deformation behavior of powder metallurgy connecting rod. Design, simulation and manufacturing of a connecting rod from ultra. A connecting rod is one of the most mechanically stressed components in internal combustion engines. Jun 16, 2018 hot forged connecting rods, in particular forged connecting rods for an internal combustion engine, especially when they are made of steel, are manufactured by a process which comprises hot forging of a connecting rod rough forging, a heat treatment and a machining operation. The casting shop has an annual production capability of 22,000 tons of various steel castings up to a unit weight of 350 tons. Concept and manufacture of a crankshaft production tool. Design, simulation and manufacturing of a connecting rod. Another advantage besides tolerance was that we could forge connecting rod cover together with the rod.
920 907 1245 672 959 366 1085 1418 103 1469 414 474 1477 609 1221 142 1369 1506 1415 973 171 1297 192 768 1406 1226 348 331 898 827 168 435 863 228 1441 1546 825 1300 1370 1231 189 994 1149 972 803 528 1279 450