GROUP # 3

Muhammad waseem
Saim khalid
Zafar iqbal
Muhammad imran

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 Agenda
• Manufacturing of connecting rod
• Forging Vs Casting
• Defects of forging
• Designing and manufacturing processes
• Limitation of forging
• Economics limitation

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 MANUFACTURING PROCESS

FORGING CASTING

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FORGING

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 Forging Vs Casting
Forging
 Total processes approximate
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 Dimensional consistency
and accuracy
 Reduce mass by 10%
 Consume less energy
 Provides longer tool life
 smoother running in the
engine
 Less cost for > 20,000 pieces
 High production rate
 Less time consumes
 Reduce cost about 25%
 It performed at low
temperature
Casting
 Total processes approximate
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 Less accuracy
 More time consuming
 Required high temperature for
melting
 Low production rate
 Defects such as pin
hole, shrinkage, porosity,
Rough surface etc.
 high cost for >20,000 pieces
 More waste of materials
 More labor cost
 Machining process
 Low strength
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Forging Defects

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Design of
connecting rod 7
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Manufacturing process
MATERIAL

CUTTING TO LENGTH OF MATERIAL

BILLETS HEATING

HOT FORGING

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 PLERCING

TRIMMING

SHOT BLASTING /SHOT PEENING

 DEBURRING
MACHINING OF TOP SURFACE
MACHINING
GRINDING THE SIDE FACES
DRILLING THE PISTON END
BROACHING OF CRANK AND
PISTON ROD
DRILLING OF BOLT HOLE
DRILLING OF HOLE
MACHINING OF BOLT HEAD
SEAT
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MACHINE FRACTURE SPLITTING GROOVE

FRACTURE SPLITTING

ASSEMBLY OF CONNECTING ROD

MACHINING FINISH GRINDING I=OF SIDE

FACES
FINAL DRILLING OF CRANK
AND PISTON
MILLING OF BEARING OF
POSITIONING GROOVE

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INSERTION OF CRANK END BEARING SHELLS

INSERTION OF SMALL END BEARING BUSH

INSPECTION

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 Selection of material
 the connecting rods are most usually made
of steel (for lightness and the ability to absorb high
impact at the expense of durability)
 titanium (for a combination of lightness with
strength, at higher cost) for high performance
engines, or of cast iron for applications such as
motor scooters.

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 Cutting of material
• Cut the material a little greater than the required due to
further process
heating billets
• Billet is heated in the furnace
at 500-600 ⁰C

Hot forging
• Hot forging is defined as working a metal above its
recrystallization temperature.
• The main advantage of hot forging is that as

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 the metal is deformed the strain-hardening effects are
negated by the recrystallization process.

piercing:

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Trimming:

Shot peening:

Machining:
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• Fracture splitting

• Assembly

• Insertion of bearing shell

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• Insertion of bering bushes

• Inspection

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 Limitation of forging
• It must be enviourment friendly
• It finished product cost must be moderate
• Limitation of the mass deviation along the
longitudinal axis
• materials are generally less expensive than the
materials required for casting. Limited scrap
and rework. Reduced labor costs and lower
tooling equipment expenses than casting

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Economic limitation

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