GROUP # 3

Muhammad waseemSaim khalidZafar 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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FORGING CASTING

MANUFACTURING PROCESS

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FORGING

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Forging Vs CastingForging Total processes approximate 16 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 36 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

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

MACHINING

DEBURRING

MACHINING OF TOP SURFACE

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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