Connecting Rod Manufacturing PDF

CHAPTER-5
CONNECTING ROD- A FORGING COMPONENT

Chapter-5. Connecting Rod-A Forging Component 73
CHAPTER-5
CONNECTING ROD- A FORGING COMPONENT
5.1 SCOPE
Metal working is one of the three major technologies used to fabricate metal products.
The others are casting and powder metallurgy. However, the metal working is perhaps
the oldest and major out of three. This forming technology has developed slowly.
During industrial revolution the iron and steel age started with the larger need for
forging components. To satisfy these needs the fast track technologies are invented.
Now days the forging processes are approaching towards boom to satisfy the need of
quality forging of light metals and micro alloys for space, automotive vehicles and
industrial purposes [1].
The modified slab method is well applicable for the forging component having plane
strain and axisymmetric flow sections. The connecting rod is a perfect example of
combination of these two sections. Connecting rod is highly dynamically loaded
component used for power transmission in combustion engines. The flow sections are
shown in Fig 5.1. The flow pattern shows that the complete deformation of
connecting rod during forging process is a summation of axisymmetric flow at big
and small end and a plane strain flow at the shank.
Axisymmetric flow Plane strain flow

at both ends in center section
Fig-5.1- Modes of Metal Flow in Forging of Connecting Rod.
“Design And Development Of Expert System for Forging Process.”

(A Case Study on Forging of Connecting Rod and Allied Components)
The connecting rod is subjected to a complex state of loading. It undergoes high

cyclic loads of the order of 108 to 109 cycles, which range from high compressive
loads due to combustion, to high tensile loads due to inertia. Therefore, durability of
this component is of critical importance. Due to these factors, the connecting rod
design and its manufacturing process has been the topic of research for different
aspects such as production technology, materials, performance simulation, and
fatigue.
It can be produced either by casting, powder metallurgy or forging. Connecting rods

for automotive applications are typically manufactured by forging from either
wrought steel or powdered metal. It could also be cast. However, castings could have
blow-holes which are detrimental from durability and fatigue points of view. The fact
that forgings produce blow-hole-free and better rods gives them an advantage over
cast rods.
The connecting rod is divided into three major parts; Big end (Circular / modified),
Small end (circular), Middle I- section. Big end connected or fixed to the crankshaft
and it has to withstand against high compressive loads due to combustion and tensile
loads due to inertia at crank shaft end. Small end is connected to the piston pin and it
has to withstand against high compressive loads due to combustion and high tensile
loads due to inertia at piston end. Middle I section connects big end to small end. It
offers maximum rigidity with minimum weight.
The investigation of forging process is designed to perform such that the modified
analytical method is to implement to the standard component i.e connecting rod. It is
to validate experimentally and then obtained deviation is used to develop knowledge
base of the expert system.
5.2 PRODUCT INFORMATION
The connecting rod under investigation and its geometrical specification is given in
Fig 5.2. The material for the connecting rod is C70S6 (AISI standard) having

Chapter-5. Connecting R6d-A Forging Component 75
controlled cooling type heat treatment. The hardness range of the material is 286 BHN
to 321 BHN. The mechanical properties include ultimate tensile strength of 900-
lOOON/mm2; the yield strength is of 7.85 • 10'6 Kg/mm2 with the permissible
elongation of 10%. The chemical composition of the connecting rod to be forged is
consisting of alloying elements as carbon, Silicon, Manganese, Sulphur, Phosphorus,
Nickel, at a different percentage as given in Table 5.1 The configuration of
connecting rod which considered the net weight, length, width and thickness along
with the initial stock size required is registered in Table 5.2.
Table 5.1 Chemical composition of Connecting rod to be forged.
ALLOYING ELEMENTS PERCENTAGE (%)
Carbon 0.56
Silicon 0.26
Manganese 0.28
Sulphur 0.014
Phosphorus 0.313
Chromium 0.12
Nickel 0.09
Table 5.2 Configuration of the connecting rod
Net weight 2.54 Kg
Length of connecting rod 316.3 mm
Width of connecting rod 128.6 mm
Height/thickness of connecting rod 41.8 mm
Initial stock size 0 56 mm X 210 mm

Fig 5.2 Connectig Rod - component for forging
5.3 MANUFACTURING OF CONNECTING ROD
The manufacturing of connecting rod includes the series of manufacturing processes

consisting of stretch rolling, flattening, performing, final forging, flash removal and
hole punching. The sequence of manufacturing operation and the component shape is
shown in Fig. 5.3
The stretch rolling operation is performed for the production of preform [19]. The
stage 1-5 shows the progressive change of shape during stretch rolling process. The
resulting shape in stage 5 undergoes flattening operation performed between flat tools
for the objective of uniform mass distribution. The stage 7 and stage 8 are the main
stages of die forging. The stage 7 shows the blocker operation where the stroke marks
the initial impression of the shape. This stage involves the production of flash around
the periphery of blocker component. The stage 8 represents the finisher operation
where the press stroke giving rise the final impression on the component. After the die

forging operation the resulting output undergoes flash removal process and the
punching of holes at big end and small end.
The forged connecting rods are usually produced in several die-forging stages as
shown in Fig 5.4. The dies are constructed in two halves and are mounted as a one to
the platform and one to the punch. The flattening die, blocker die, and finisher die are
mounted on a die set over which the billet is to be placed and transferred in a
sequence. In many of the cases that is for small sized components, the flattening
operation is eliminated and the die consists of only blocker and fmisher.
Fig. 5.3. Workpieces after forming stages.[l-5: stretch-rolling, 6: flattening, 7,8: die-
forging, 9: flash removal and hole punching]
5.4 DIE DESIGN
The sources of inaccuracy introduced by the forging process are many: die mismatch,
uneven scaling of forged stock, uneven shrinkage, die wear, and uneven temperature
distribution in work piece. In order to prevent these factors, the forging process
tolerances are applied to dimension of forged part. The die design is based on the
proper consideration of these tolerances.

Fig. 5.4 Dieset -Flattening (left), Blocker (Middle), Finisher (right).
The design allowances are necessary material addition, included on the part design,
which accommodate the functional requirement of the forging process. These
allowances are mainly influenced by the choice of work piece material and includes,
finish allowance, draft angles, and comer and fillet radii. These tolerances are mainly
determined by the complexity of part’s shape and include the tolerances on length,
thickness or width to account for the effect of die wear, mismatch and straightness.
The first step in the forging die design is to establish the location and shape of the
parting line. The parting line is the plane of separation between upper and lower part
of closed die set. Generally the parting line is located after the weighing of
economical and technical considerations as it can measurably affect the initial cost,
ultimate wear of dies, grain flow, and machining requirement for finish parts. The
parting line for the connecting rod is through the largest cross section of the forging to
avoid narrow, deep die impression.
The die design progressed with the selection of draft angle [52], The draft angle is
refers to a taper given to internal and external sides of closed die forging to facilitates
its removal from the die cavity. It is expressed as an angle from the direction of ram
travel. It is not only ensures good forging with minimum of production difficulty but
also reduces die sinking expense. Among the standard draft angles of 1°, 3°, 5°, 7° and
10° the 3°- 5° is used for finisher and maximum of 7° is used for blocker.

The selection of fillet and comer radii is the most important factor in the design of
forging die. Metal flowing in the die containing cavities of various depths will not
undergo the abrupt changes in the flow direction and can lead the condition called
‘flow-through’. The comer radii is formed by the intersection of two surfaces with an
included angle (with in forging) of less than 180° or extruded angle (outside the
forging) of greater than 180°. During establishment of minimum dimensions of comer
radii, the two factors are considered, the radius as a stress concentrator in the die and
the pressure necessary to fill the die cavity.
The fillet radius is the intersection of two surfaces with an included angle (with in
forging) of greater than 180° or extruded angle (outside the forging) of less than 180°.
Liberal fillets on the forging permits the forging stock to follow the die contour more
easily during the forging forces.
The last step in the forging die design is to consider the finish allowances. The finish
allowances are the amount of additional material that is added to all surfaces of the
part which are to be machined. This material is added so that the part can machined to
desired tolerances with an acceptable surface finish. The surfaces parallel to the
parting line are affected by the die closure and straightness tolerances, surface
perpendicular to the parting line are affected by dimensional, straightness and material
tolerances. The adverse effect of these tolerances is considered and the minimum
machining allowances is considered to be 0.02 in (0.5mm). The above discussed
allowances are considered and the die design for finisher components and registered
inFig.5.5.
5.5 DIE MODELING BY CATIA V5 R15.
CATIA (Computer Aided three Dimensional Interactive Application) developed by

Dassault systems is one of the world leading CAD/CAM/CAE packages. Being a
solid modeling tool, it not only unites the 3D parametric features with 2D tools, but
also addresses every design through manufacturing process. In addition to creating

solid models and assemblies, 2D drawing views can also be generated in the drafting
workbench of the CATIA. The drawing views that can be generated include
orthographic, section, dimensions in the drawing views. The bidirectional associative
nature of this software ensures that the modification made in the model is reflected in
the drawing views and vice versa.
The CATIA serves the basic design tasks by providing different workbenches. A
workbench is defined as a specified environment consisting of a set of tools, which
allows the user to perform specific design task in a particular area The basic
workbenches are Part Design workbench. Wire frame and Surface Design workbench.
Assembly Design workbench, and Drafting workbench.
5.5.1 Part Design Workbench
The part design workbench is a parametric and feature based environment use to
create the solid model can be create. The basic requirement for this workbench is a
sketch. The sketch for this feature is drawn in sketcher workbench which is invoked
within the part design workbench. The various applicable constraints are
automatically applied to it while drawing the sketch. The features are also provided to
apply additional constraints and dimensions. The set of other tools are also provided
for the features like fillets, champers etc. The provision is also available to assign the
material to the model in the part design.
5.5.2 Wireframe and Surface Design Workbench
The Wireframe and the surface design workbench is a parametric and feature based
environment used to create wireframe or the solid model. The tools in this workbench
are similar to those in part design workbench. The only difference is that the tools in
this environment are used to create the basic and advanced surfaces. It is provided
with the surface editing tools which are used to manipulate the surfaces to obtain the
required shape.
‘Design And Development Of Expert System for Forging Process.”

Fig 5.5 Allowances on Finished Connecting Rod

5.5.3 Assembly Design Workbench
The Assembly design workbench is used to assemble the components using the
assembly constraints available in this workbench. There are two types of assembly
design approaches; Bottom-up and top-dawn. In the bottom-up approach of assembly
the previously created components are assembled together to maintain there design
inert. In the top-dawn approach, the components are created inside the assembly in the
assembly design workbench.
5.5.4 Drafting Workbench
The Drafting workbench is used for the documentation of the parts or assemblies
created earlier in the form of drawing views and their detailing. There are two types of
drafting techniques; Generative drafting and Interactive drafting. The generative
drafting technique is used to automatically generate the drawing views of the parts
and assemblies. The parametric dimensions added to the component in the part design
workbench during its creation can also be generated and displayed automatically in
the drawing views. The provision is also provided to generate the bill of material
(BOM).
In interactive drafting, it is required to create the drawing views by sketching them

using the normal sketching tools and then adding the dimensions.
The connecting rod under consideration is drafted using the CATIA and with the
addition of proper allowances it is removed from the block to generate its
corresponding die. The two dies are modeled on the single die block for blocker and
the finisher operation. The finisher die is provided with the provision for gutters so as
to ensure the excess material flow around its periphery as a flash. The drafted view of
the connecting rod die is shown in Fig.5.6 The die blocks are separated by parting line
and generate as a two halves. The assembly of the two dies is reported as a complete
die for the connecting rod under investigation in its mating state is registered in
Fig.5.7.

Chapter-5, Connecting Rod-A Forging Component 83
Blocker Die
Finisher Die
JBEDL
■JSRuEEZDEL.
Fig. 5.6 Connectin Rod Die Modelled by CATIA
Fig 5.7 Die Assembly
‘Design And Development Of Expert System for Forging Process.'

5.6 SIMPLIFICATION OF COMPLEX DEE SHAPE OF CONNECTING ROD
To implement the modified slab method, it is required to represent a complex forging

in to a simplified and equivalent forging. The plan projected area As and perimeter Ps
of a simplified geometry must be equal to the plan area of actual forging. The plan
area of connecting rod is shown in Fig 5.8. The Fig-5.9 represents the top view of
simplified die of connecting rod.
As=n L2+ 2LsL (5-1)
Ps=2ttL+2Ls (5-2)
Perimeter of
area
Fig 5.8- Plan area of connecting rod
Two half axisymmetric element
Pane strain element
Fig-5.9 Simplified equivalent forging (Top view)

During converting the complex die in to an simplified die, the parameter L and Ls are
correlate with the area and the perimeter of the connecting rod
The total load is to estimate by adding the load for two half axisymmetric elements of
radius ‘ L’ and the load for plane strain element of length ‘Ls’and width ‘ 2L’.The
relation are registered as,
Ls= (Ps-2 tt L)/2 (5.3)
L= (5.4)
2n
In general the L is taken as 0.2843 times the center distance of connecting rod.
5.7 EMPIRICAL ESTIMATIONS
The empirical set of relations from literature, forging practice handbook are studied
and implemented for estimation of fixed parameters of the process. The overall
approach is made to find the shape complexity factor, flash weight, flash dimensions
and selection of press capacity. The empirical relations are defined and applied to a
connecting rod under investigation.
5.7.1 Estimation of Shape Difficulty Factor
The overall design of forging process requires the prediction and estimation of Shape
complexity and volume of the forging, number and configuration of perform or
blocker, flash dimension in the dies and the additional flash volume required in the
stock for performing and finishing operation, forming load. The size of production lot
and the number of performing operation necessary and required tolerances are
determined essentially by the geometrical complexity of the forging for a given
material. It is therefore useful in planning the production of forging to define an
objective of reproducible quantity representing its geometrical complexity.

The shape difficulty factor is determined from the ration of finished component
weight to the envelope weight [49]. The density of material (alloy steel C7056) is,
p = 7.85 »10'6 Kg / mm3
The geometrical parameters as shown in Fig. 5.10 are,

Length of initial block Lb = 316.3 mm
Width of initial block Bb = 128.6 mm
Height of initial block Hb = 1.8 mm
2] 6
Lb= 316.3
Fig. 5.10: Major Dimensions for Calculations of Shape Difficulty Factor
Equation for the Enveloped weight is estimated as,

Wenvelope Lb *Bb • Hb * p (5.5]
= (316.3) . (128.6) *(41.8) .(7.85.10'6)
= 13.34 kg
The weight of forging component without flash weight i.e Net weight is,
Wfinish = 2.54 Kg
The shape difficulty factor is estimated as.
S = Wfinish / Wenvelope (^-6)

= 0.190

5.7.2 Estimation of Slug Weight
The sectional view of connecting rod die showing major dimensions is used in
calculations of slug weight of the forging component. The geometrical parameters
shown in the Fig.5.11 are,
Diameter of slug at the big end Dbe = 68.5 mm
Diameter of slug at the small end Dse = 34 mm
Thickness of slug at both ends T =9.1 mm
E>be= 68.5 mm DSE=34 Iam
The Big end slug weight is calculated as,

WBE = (ic) / 4} • (Dbe) 2 * (T) * p (5.7)
= 0.263 Kg
The small end slug weight is calculated as,

WSE = m / 4} . (Dse) 2 ♦ (T) * p (5.8)
= 0.065 Kg
The total slug weight is calculated as,

WsiUg = WBE + WSE (5.9)
= 0.328 Kg.

5.7.3 Estimation of Flash Weight
Total weight of component including sludge weight is given as,
Wfinish + Wslug = 2.868 Kg
The Fig 5.12 and 5.13 reported important considerations during flash weight and
design variables on connecting rod die.
Fig. 5.12 Important considerations for flash weight [59].
Section AA Section BB
Fig.5.13 Design variables to determine the flash weight of connecting rod

The geometrical parameters shown are registered as,
Final height of forging,
hf = 41.8 mm
Minimum distance between flat surfaces upon which stock is resting when dies are
closed is given as,

ho = 14 mm
Distance between internal and external parting lines with considering the symmetry
about its axis is,

Iia = 00 mm
Diameter of the initial round stock,
Do =56 mm
Final forging diameter Dj = 128.6 mm
The dimensionless parameter ‘V’, which represents height ratio, is calculated as, [60]
V = hf /(ho + hA) (5.10)
= 2.985
The dimensionless parameter ‘n’ is calculated as, -
n =S(Do/Di)2V2 (5.11)
= 0.321
The constants ki and k2 are defined by Altan etal [58] to estimate the flash load. The
terms are defined and evaluated as,
k! = 0.54 + [15.44 (Wflm+Wsiug) ('a2) (1 + 0.00757 * n)] (5.12)
= 13.08
k2 = 0.7026 + (1 + 0.01969 . n). 3.7 (5.13)
= 3.731
The flash weight is estimated as [50],

Wflash ~~ [ki * kj] * (Wfini + Wslug) / 100
= 1.199 Kg
s l-2Kg
5.7.4 Estimation of the Forging Component Weight
The estimation of forging component weight is comprised of consideration of sludge

weight and flash weight with weight of finished component Thus the forging
component weight is given as [51,52,57],
Wall = Wfinish + Wflash + Ws]ug P-O)

= 4.068
= 4.1 Kg
5.7,5 Estimation of Flash Thickness and Land Width
The shape difficulty factor is accounted for the estimation of flash dimensions. Hence
the equation (4.48) and (4.49) pertaining to case -1 from chapter-4 are employed for
this estimation.
t = -0.09 +2 (Wall)1/3- 0.01 Wall

t = 3.07 ram (5.16)
The flash land width is given as,
w = { [ 0.02 + (0.0038)(S)(Do/t) + [4.93/(Wall)0'2]} t

w= 11.48 mm (5.17)
The ratio of flash land width to flash thickness is given as,

w/t = [11.48/3.07]
= 3.73
‘Design And Development Of Expert System for Forging Process,”

5.7.6 Selection of Forging Press
The forging operation is performed as a series of edger, blocker and finisher stroke.
Most of the connecting rods involve the blocker and finisher operation. The selection
of forging press is depends on the load requirement for the blocker operation. The
empirical relations are employed to obtain the load required for blocker.
The die geometry for blocker operation is shown in Fig. 5.14.
Fig.5.14 Plan area of finished die with flash land width.
The various parameters required in load calculations are given as.
Component plan area using AutoCAD is obtained as A = 26406 mm2
Length of component including land width, L = 333.56 mm

Component diameter including land width, Ds = 145.86 mm
Yield strength y = 7.85 • 10'6 Kg/mm2
The overall component width is calculated as
26406
(5.18)
333.56
= 79.14 mm

Chapter-S. Connecting Rod-A Forging Component 92
The load required to forge the component in Blocker die is given by [54],
' 20
k Axy
P 4 x [l - (0.001 x .Ds)] x 1.2 + x 1 + 0.1 X
v Ds 1000
2
= 4 x[l-(0.00 lx 145.86)] x 1.2 +
, „ , /333.56 f 26406x7.85]
X 1 + 0.1./ X
L 1000 J
V 79.14
= 1039.26 Ton (5.19)
Thus for forging this component in blocker die the press capacity of 1600 Ton is
selected.
5.8 SUMMARY
The connecting rod is considered for forging process to which the modified slab
method equations are to be implementing to validate and to generate the knowledge
base for the forging process. The detail dimensional parameters with its material
properties are explained. The allowances are discussed for the design of die of the
component. The studied allowances are implemented and modeled by CATIA V5
R15. The modeling of two half dies as an assembly is reported for the further
investigation. The empirical equations are employed to the component to determine
the fixed parameters like flash dimensions, and flash weight. The press selection is
made for the blocker based on the empirical equation for the blocker operation.
The connecting rod is selected as a component for forging process and is designed to
analyze analytically by modified slab method. The validation of the results can be
remarked by performing experimentation for the same. Thus the experimentation for
the forging of connecting rod is designed and performed in the next chapter.


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CHAPTER-5

CONNECTING ROD- A FORGING COMPONENT

Axisymmetric flow Plane strain flow

Fig-5.1- Modes of Metal Flow in Forging of Connecting Rod.

“Design And Development Of Expert System for Forging Process.”

The connecting rod is subjected to a complex state of loading. It undergoes high

It can be produced either by casting, powder metallurgy or forging. Connecting rods

5.2 PRODUCT INFORMATION

“Design And Development Of Expert System for Forging Process.”

Table 5.1 Chemical composition of Connecting rod to be forged.

ALLOYING ELEMENTS PERCENTAGE (%)

Table 5.2 Configuration of the connecting rod

Net weight 2.54 Kg

Length of connecting rod 316.3 mm

Width of connecting rod 128.6 mm

Height/thickness of connecting rod 41.8 mm

Initial stock size 0 56 mm X 210 mm

“Design And Development Of Expert System for Forging Process.”

Fig 5.2 Connectig Rod - component for forging

5.3 MANUFACTURING OF CONNECTING ROD

The manufacturing of connecting rod includes the series of manufacturing processes

“Design And Development Of Expert System for Forging Process.”

5.4 DIE DESIGN

“Design And Development Of Expert System for Forging Process.”

Fig. 5.4 Dieset -Flattening (left), Blocker (Middle), Finisher (right).

“Design And Development Of Expert System for Forging Process.”

the pressure necessary to fill the die cavity.

5.5 DIE MODELING BY CATIA V5 R15.

CATIA (Computer Aided three Dimensional Interactive Application) developed by

“Design And Development Of Expert System for Forging Process.”

5.5.1 Part Design Workbench

5.5.2 Wireframe and Surface Design Workbench

‘Design And Development Of Expert System for Forging Process.”

Fig 5.5 Allowances on Finished Connecting Rod

“Design And Development Of Expert System for Forging Process.”

5.5.3 Assembly Design Workbench

5.5.4 Drafting Workbench

In interactive drafting, it is required to create the drawing views by sketching them

“Design And Development Of Expert System for Forging Process.”

Fig. 5.6 Connectin Rod Die Modelled by CATIA

Fig 5.7 Die Assembly

‘Design And Development Of Expert System for Forging Process.'

5.6 SIMPLIFICATION OF COMPLEX DEE SHAPE OF CONNECTING ROD

To implement the modified slab method, it is required to represent a complex forging

As=n L2+ 2LsL (5-1)

Fig 5.8- Plan area of connecting rod

Two half axisymmetric element

Pane strain element

Fig-5.9 Simplified equivalent forging (Top view)

“Design And Development Of Expert System for Forging Process.”

Ls= (Ps-2 tt L)/2 (5.3)

5.7 EMPIRICAL ESTIMATIONS

5.7.1 Estimation of Shape Difficulty Factor

“Design And Development Of Expert System for Forging Process.”

The geometrical parameters as shown in Fig. 5.10 are,

Fig. 5.10: Major Dimensions for Calculations of Shape Difficulty Factor

Equation for the Enveloped weight is estimated as,

The shape difficulty factor is estimated as.

S = Wfinish / Wenvelope (^-6)

“Design And Development Of Expert System for Forging Process.”

5.7.2 Estimation of Slug Weight

E>be= 68.5 mm DSE=34 Iam

The Big end slug weight is calculated as,