CONNECTING ROD EDI JUNEDI

2613093051

WHAT IS CONNECTING ROD ?

• A rod in engine block that connecting piston to crankshaft

FUNCTION

• Transmitting the thrust of the piston to the crankshaft

TYPE OF CONNECTING ROD

• I-Beam Rods the most popular type of connecting rod cheap to make and very reliable.

• H-Beam Rods used in high hp and low rpm have more strenght in compression

• Alumunium Rods popular among high rpm race engines very light and strong but a short fatigue lift

• Titanium Rods highest strength to mass ratio of all materials

used to make connecting rods higher cost

MANUFACTURING PROCESS

• Conventional Forging

• Powder Forging

CHEMICAL COMPOSITION REQUIREMENT FOR POWDER FORGED PATRS

POWDER FABRICATIONSource : Randall M. German, Powder Metallurgy Science

• Electrolytic Fabrication Serbuk kemurnian tinggi, berpori,

bentuk dendrit Serbuk: Cu, Fe, Pd, Zn, Au, Ag Perlu dicuci, milling, annealing Parameter:

Jenis & konsentrasi elektrolit, Konsentrasi total logam dlm elktrolit, Anodic & cathodic current density, temp elektrolit, voltase, komposisi elektroda

• Chemical Fabrication :Decomposition of Solid by Gas

Reduksi oksida (FeO) oleh gas reduktor (CO, H2)

– T rendah: berpori – T tinggi: masif, poligonal

Oksida, pemurnian (magnetik), pelumatan, proses reduksi, pelumatan, annealing Termodinamika:

– Fe3O4 + 2H2 → 3Fe+4H2O

– K=pH2O/pH2

– FeO + CO → Fe + CO2

Kinetika:– J=Aexp(-Q/RT)– DH2 in, DH2O out, reaksi di interface

Contoh serbuk: Fe, Mo, W, Cu Kemurnian: 2N Parameter: ukuran dan bentuk oksida, komposisi gas, T, Kinetika, tebal muatan

• Atomization FabricationWater Atomization

Pembentukan serbuk dari cairan yang disemprot oleh air Serbuk: elemental, prealloyed, berbentuk ligamental, 5 s/d 100 m, laju

produksi tinggi 400kg/min, kemurnian rendah Parameter: Tm, Tpouring, laju - tekanan - kecepatan air, sudut tembak,

susunan nozel, diameter nozel, laju alir logam cair Contoh produksi Stainless Steel Tm=1365oC, Tpouring=1510oC, Dnozle= 6mm, laju logam= 22kg/min,

water jet= 8, Pair= 9 MPa, Sudut tembak= 8o, Kec. Air=110 m/s, laju air=200 l/min

Serbuk: ligamental, 60m

Gas Atomization Pembentukan serbuk dari cairan yang disemprot oleh Udara/Gas Serbuk: elemental, prealloyed, berbentuk bulat, 50 s/d 200 m, laju

produksi tinggi 200kg/min, kemurnian tinggi Parameter: Tm, Tpouring, jenis gas, laju - tekanan - kecepatan gas, sudut

tembak, susunan nozel, laju alir logam cair Contoh produksi Nickel Tm=1400oC, Tpouring=1550oC, Argon, laju logam= 20kg/min, water jet= 8,

Pair= 2 MPa, Sudut tembak=40o, Kec. gas=100m/s, laju air= 8 m3/min Serbuk: bulat, 120m

Centrifugal Atomization• Jenis: Rotating Electrode, Rotating Disk, Rotating Cup, Rotating Wheel,

Rotating Screen• Logam cair terlempar oleh gaya sentrifugal, saat membeku membentuk

serbuk• Produk: serbuk elemental, pre-alloyed, reactive materials (Zr, Ti, Ni-base

super alloys). 5 – 250m, berbentuk bulat.• Parameter: putaran (10.000 – 20.000 rpm), atmosfer (Ar, He, udara),

Chamber Size, Del,

• Ukuran Serbuk43.0

m64.0

12.0

d

MD m

but the most appropriate for iron and steel are the atomization methods. Water atomization is widely used for conventional iron and mass-produced low alloyed steels. The gas atomization process is used for special steels (such as high speed steels) and steels obtained by non conventional methods.

POWDER MIXING

COMPACTION

• Powder blank is pressed to a simple shape halfway• Powder are compacted on computer-numerical-controlled

(CNC) servohydraulic multiplaten powder press• Hydraulic press slowly than mechanical press in operation and

less economical• But Hydraulic press offer advantage : adjustable tonnage and

constant pressure can be maintained• Density product 6.4 to 6.6 g/cm3

SINTERING

Sintering is carried out at 1120 oC for 15 minutes

FORGINGDensification process in which an unsintered, presintered, or sintered preform made out of powders is forged to higher densities

• The specified densities of more than 7.6 or even 7.8 g/cm3 are achieved

• After ejection, the forged connecting rods will be cooled down to room temperature under controlled conditions in a protective atmosphere

• Shot peening is performed to remove the connecting rod forging pale

Advantage of Powder Forging : • Greater homogenity as regards composition• Finer microstructure• Dimensional consistency and accuracy• Minimum material waste• Consume less energy• Provides longer tool life• smoother running in the engine• reduced engine weight

Limitation :• Steels containing readily oxidisable elements such as

chromium and manganese cannot easily be used• Production costs in powder forging are generally

higher than in conventional casting or forging due mainly to the high price of the starting material and tooling

Comparative Study Forged Steel and PM Connecting Rods

• Chemical Composition

• Mechanical Properties

• Reversal to failure

• Fracture surface

• Cost Manufacturing Process

DAFTAR PUSTAKA

1. Agus Wahyudi dkk, Material Selection and Manufacturing Processes Connecting Rod in Diesel Engine Locomotive, 2003.

2. Connecting Rods from www.grapeaperacing.com.3. James R. Dale, Connecting Rod Evaluation, MPIF, 2005.4. P. Ramakrishnan, Residual Stresses in Powder-Metal Processing in Handbook of

Residual Stress, ASM Internastional, 2002.5. Randall M German, Powder Metallurgy Science, MPIF, 1984.6. Slameto Wiryolukito, Produksi Komponen Melalui Jalur Teknologi Logam Serbuk,

Teknik Material ITB7. G S Upadhyaya, Powder Metallurgy Technology, Cambridge International Science

Publishing8. www.circletrack.com9. Adila Afzal and Ali Fatemi , A Comparative Study of Fatigue Behavior and Life

Predictions of Forged Steel and PM Connecting Rods, SAE International, 2003