Process planning, tolerance chain, monte carlo, connecting rods. Pdf design and analysis of connecting rod with modified. The product thus obtained by forging is at good strength and free from any defects. The design was modified slightly from the existing forging. Evaluation of crankshaft manufacturing methods an overview. The crankshaft main journals rotate in a set of supporting bearings causing the offset rod journals to rotate in a circular path around the main journal centers. Fatigue analysis of connecting rod using finite element analysis 789 the stress at any point on the connecting rod at this axial load can be interpolated from the axial stress analysis results.
One end of a connecting rod is follows the circular path whereas the other end follows a path along with a straight line of big radius. Files are available under licenses specified on their description page. Connecting rod rectangular and ibeam crosssections with the assumed shape of the cross section for the connecting rod as shown in figure 2b, the cross sectional area of the ibeam section is 11 t 2. The video shows chk hammer is used to produce connecting rods. Now that we have seen the principle of working of the reciprocating compressor, let us see the various parts of the compressor. Youngs modulus e 210 gpa, yield strength s y 210 mpa, poissons ratio. Selection of material, shape and manufacturing process for a connecting rod abstract this activity centers on the courses of strength of materials and production design offered at a sophomore level mechanical engineering curriculum. Abstract connecting rod is a major part inside of a internal combustion engine. A comparison of manufacturing technologies in the connecting rod industry. Carbon steels or alloy steels are the most commonly used materials.
All structured data from the file and property namespaces is available under the creative commons cc0 license. The analysis of the scania line together with a benchmark among different leading companies on the connecting rod manufacturing has been undertaken. Pdf selection of connecting rod for good performance of engine is very difficult. The fourth part provides force calculations of a forged steel connecting rod. Materials science and engineering, volume 149, conference 1. After systematic inspections of connecting rod, we have found problem of cap tight and oversize of big end diameter of connecting rod. Implementation of this project increases the production of connecting rods by 200% in less than previous cycle time. The position of the central looseness of a crankshaft has been tracked during the complete forging process and is represented in the final shape. This thesis has been focused on the study of the connecting rod manufacturing process. Forged connecting rods creates a link between various mechanisms. Engine connecting rod an overview sciencedirect topics. A comparison of manufacturing technologies in the connecting.
Usually, forging was done by a smith using hammer and anvil. In fact, forging is often the optimum process, in terms of both part quality and cost, especially for applications that require maximum part strength, custom sizes or critical performance specifications. The major stress induced in the connecting rod is a combination of axial and bending stresses in operation. Crane hook, connecting rod of ic engine, spanner, gear blanks etc. Aljazaris fourth machine utilizing a connecting rod2. Aluminium piston connecting rod assembly interchangeable, find complete details about aluminium piston connecting rod assembly interchangeable, aluminum connecting rods, forging connecting rods, shaft assembly seal ningbo. One historian says this lack of technology had considerably limited the applications of mechanization4. It is one of the oldest metalworking arts with its origin about some thousands of years back. Connecting rod made by steel forging will greatly achieve high performance applications. Under drop forging process, it is able to withstand much greater loads and faster engine revolutions than a cast rod. Forged steel is currently eco boost mustang material. Through the suction valve the low pressure refrigerant is sucked inside the cylinder and through the discharge valve the compressed high pressure refrigerant is discharged to the discharge line, from where the refrigerant goes to the condenser.
The connecting rods being used in this build also came from our previous race engine and were prepped. Comparative study of the connecting rod manufactured. Ilia et al 2005 provide the minimum ibeam area for the connecting rod for the 1. The connecting rod is a high volume production from automobile side. Published under licence by iop publishing ltd iop conference series. Here we explore competing processes for casting a small aluminum alloy connecting rod figure 14. These connecting rods are available with customization as per. Design and analysis of connecting rod using forged steel.
A connecting rod may also convert rotating motion into reciprocating motion, its. Selection of material, shape, and manufacturing process for a. These blow energy can forge high deformation so that the resultant force is very low. Connecting rod is subjected to more stress than other engine components. After analysis a comparison is made between existing steel connecting rod viz. Coupling to the crankshaft is achieved through solid journal bearing half shells inserted on both sides of the split. The automobile engine connecting rod is a high volume production, critical component. These ideas have been mainly related to machining sequence, machine tool and new technologies for machining. Introduction forging is one of the past known metalworking process.
If you blast them or touch them with a file, or drop the rod onto the floor, you ruin the mirrorimage mating surfaces, and the rod becomes worthless. Analysis of finite volume of forging process of connecting rod. Aluminium piston connecting rod assembly interchangeable, find complete details about aluminium piston connecting rod assembly interchangeable, aluminum connecting rods, forging connecting rods, shaft assembly seal ningbo yinzhou fuchun precision casting co. Fraunhofer institute for structural durability and system reliability lbf, darmstadt, deutschland. Fatigue analysis of connecting rod using finite element. Enter ansys in the working directory specif ied by your instruct or using. 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. Jun 12, 2014 we design this line for one japanese company to forge the connecting rods for honda auto. A connecting rod is one of the most mechanically stressed components in internal combustion engines. 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. Forging is a metal working process in which useful shape is obtained in solid state by hammering or pressing metal.
About 200 companies in china forge connecting rods. Many connecting rods today are manufactured using cheape. The study includes material characterization, constitutive modeling, and numerical simulation of the. This type of connecting rod is created by drop forging the heated metal bar into net shape, then just do less machining to finished product. The connecting rod provides the mechanical linkage between piston and crankshaft and must exhibit properties of high strength, low inertial mass, and uniformity of mass with the other connecting rods attached to the crankshaft. 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.
Comparative study of the connecting rod manufactured using forging and sintering. Introduction a metal is shaped by compressive forces oldest metal working process 4000bc can be performed with a hammer and anvil typical forged products. Solution of manufacturing defects in connecting rod. Every vehicle that uses an internal combustion engine requires at least one connecting rod. Abstract connecting rod is a major part inside of an internal combustion engine. This customer has a beche hammer first, and then buy a baixie hammer. Dynamic load analysis and optimization of connecting rod. Comparison of casting versus forging connecting rods in areas most influenced by casting requirements10. Paper also describes the main achievements in precision forging in china with focus on quality of forged products. Connecting rods are not universally made by forging.
In europe, the invention of the crankconnecting rod system was unknown before the early fifteenth century. A connecting rod is a shaft which connects a piston to a crank or crankshaft in a reciprocating engine. Shear surface tracking of the initial billet up to the final geometry. Forging is often classified according to the temperature at which it is performed.
Forging shop forging is a manufacturing process involving the shaping of metal using localized compressive forces. An integrated study of dynamic hot forging of sae 1151 steel connecting rod is presented. Jun 16, 2018 manufacturing connecting rod in hot forging. 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. R k engineering works, pune manufacturer of forging reduce. Connecting rods forged 4340 steel connecting rod material. R k engineering works, pune manufacturer of forging.
Us5878491a process for the manufacture of a forged. Modern manufacturing process of forged connecting rod. Connecting rods link oscillatory motion to rotary motion in ic engines, and rotary to oscillatory motion in pumps. More product details about connecting rodforging from taiwan connecting rodforging suppliersprogress machinery co. Fatigue behavior and life predictions of forged steel and powder. The connecting rod is usually made up of carbon steel forging. The important parts of the reciprocating compressor are. The connecting rod pushes the piston up, and is helped back down by the pistons reciprocal motion.
Having in mind that conrod is a massproduct, choice of optimal way to manufacture these components is of vital technoeconomical importance. Together with the crank, it forms a simple mechanism that converts reciprocating motion into rotating motion. Comparative study of the connecting rod manufactured using. A process for manufacturing a forged connecting rod of the type including a big end, a shank and a small end. Aluminium piston connecting rod assembly interchangeable. In the above programmable output part of forging,estimated blow energy of 3 times straightening needs to be 16. This page was last edited on 7 january 2019, at 17. All these parts have been described in details below. Pdf design and analysis of a connecting rod for the 117kw six. Localization of the shear surface tracking of the initial billet of a connecting rod. The forged steel rod is fabricated by starting with a wrought steel billet, heating the billet and forging it in the materials plastic temperature range, fracturing or cutting the rod cap end, and then machining portions of the product to realize the final dimensional characteristics of the component.
We manufacture these products using high quality raw material and advanced technology in complete compliance with the defined. Some examples of shapes obtained by forging process. These connecting rods are available with customization as per the specification detailed by the clients. We manufacture these products using high quality raw material and advanced technology in complete.
Jul 11, 2014 powder forging, alloy steel forging and nonferrous metal forging. A backup file containing the connecting rod was provided with the. Powder forging, alloy steel forging and nonferrous metal forging. Pdf analysis and optimization of connecting rod with different. Selection of material, shape, and manufacturing process. The profile of these mating surfaces on rod saddle and cap must remain absolutely intact and undisturbed. In a 1993 study comparing cast malleable iron connecting rods and ductile iron connecting rods, ductile iron connecting rods outperformed the malleable iron connecting rods in pushpull fatigue tests.
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