In the present work, a generic procedure for generating machining process sequence through spatial visualization is proposed and specifically applied onto a case study of connecting rod manufacturing. Automotive connecting rod, motorcylce connecting rod. Since 1962, air engineering has been supporting major manufacturing facilities around the world. Modern manufacturing process of forged connecting rod. Crackable connecting rod material selection by using. A connecting rod, also called a con rod, is the part of a piston engine which connects the piston to the crankshaft. The average life of a malleable iron connecting rod was 764,962 cycles at a 50% survival rate or 347,734 cycles at a 90%. Study of connecting rod cracking production line layout. Boostline introduces a new, revolutionary connecting rod design that is targeted towards boosted and nitrous application engines. A cap, that bolts to the main beam around the crankshaft. Enter ansys in the working directory specif ied by your instruct or using. Select xz plane and create the sketch as shown use symmetric protrude, depth 33mm 4hareesha n g, dept of ae, dsce 4. Fracture splitting method is an innovative processing technique in the field of automobile engine connecting rod conrod manufacturing.
The current situation of the connecting rod cracking technology development is introduced. Fatigue analysis of connecting rod using finite element. Solution of manufacturing defects in connecting rod. To offer a technically correct and dimensionally accurate representation of an automotive type connecting rod, i think three things need to be addressed. The connecting rod is used to convert the reciprocating motion of the piston to oscillatory motion of itself which is finally converts to rotary motion of the crank shaft 4. Connecting rod manufacturers, connecting rod suppliers. 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. Fracture splitting technology of automobile engine. Standardization can be repetitive operation,the repeatability is capable of producing consistent forged connecting rods,guarantee the. Design, simulation and manufacturing of a connecting rod. Manufacturing procedures, equipment and tools investment can be decreased and energy consumption reduced remarkably in this method. However, the cost of the blank is high due to the high material cost and.
In this project the material forged steel of connecting rod replaced with aluminium alloy. A connecting rod is subjected to a cyclic load during its service. Design and analysis of connecting rod using forged steel. The ductile iron connecting rod experienced an average life of 1,605,902 cycles at a 50% survival rate or 635,811 cycles at a 90% survival rate. Current automotive ic engines connecting rods are made of steel. The biggest advantages of programmable forging hammer is that it can standardize the production process. A study on process capability on connecting rod in assembly line 9 cpkl lower specification limit is calculated by formula x bar lsl 3s cpk value is taken as min. The basic design taken from chevrolet v8 big block engine, calculations and material selection. The lubrication channel exhibited an area containing an embedded wbased material. The task of this project was to describe a manufacturing process for selected part, connecting rod. The beam also has a machined oil squirt hole on the upper cap mounting face. These fatigue tests were performed to directly mimic the stresses a connecting rod undergoes in an engine. In this project cpk value plays an very important role in. A connecting rod is the link between the reciprocating piston and rotating crank shaft.
A connecting rod connrod mechanism converts rotating motion to reciprocating motion or vice versa. Our engineering team created this new, patentpending 3pocket design specifically for demanding turbocharged, supercharged and big nitrous applications. Under drop forging process, it is able to withstand much greater loads and faster engine revolutions than a cast rod. We can develop and manufacture of any type of connecting rod as per drawing or sample. Due to cap tight problem in the connecting rod, there will be loss of time for separate the cap and due to oversize of big end diameter of connecting rod there will be both wastage of time and material. The fracture splitting method is an innovative processing technique in the field of the automobile engine connecting rod conrod manufacturing. Maschinenfabrik alfing kessler gmbh in motion for more than 100 years 20 duration. The use of finite element modelling is not only related to the process design but to the study of the material behaviour as is the case of the research work by chen et al. Steel materials are used to design the connecting rod. As tolerance chain analysis is an essential activity in process planning for geometry assurance, a tolerance chains study based on monte carlo simulations for the connecting rod line has been performed to develop. Small end of the connecting rod is connected to the piston by means of gudgeon pin. 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.
This shows the assembly drawing of a connecting rod end. Our manufacturing product are all type of connecting rod suitable for cars, truck, tractors, jeep, compressor, marine compressor etc. Finite element modelling of crackable connecting rods at fracture splitting process. The function of the connecting rod is to transmit the thrust of the piston to the crankshaft and translate the transverse motion to rotational motion. Abstract connecting rod is a major part inside of a internal combustion engine. Together with the crank, the connecting rod converts the reciprocating motion of the piston into the rotation of the crankshaft. The objective of the present work is to design and analyses of connecting rod made of aluminium alloy. Forging creates much more ideal grainflow than a machined billet rod cut from sheet due to grain end exposure but i have to wonder how much it would matter in this type of.
A connecting rod is one of the most mechanically stressed components in internal combustion engines. A connecting rod rough forging, free of lateral flash and including at least one bore initiator on the big end and on the small end, is manufactured by forging. You can choose from a wide array of connecting rods including compressor connecting rod, forged connecting rod, engine connecting rod, cone connecting rods etc. The big end of the connecting rod is connected to the crankshaft.
This thesis has been focused on the study of the connecting rod manufacturing process. The typical aluminum rod is forged from 7075 and heat treated to t6 specifications. Cap alingment method, bearing inset crush and or machined grooves for bearing tabs and finally, piston pin hole diameter press fit pin or sized for a bushing and floating pin in which case the little end needs a hole for some lubrication. Process tolerancing based on the process capability studies is the optimistic and pragmatic approach of determining the manufacturing process tolerances.
Compared with traditional method, the technique has remarkable advantages. It can decrease manufacturing procedures, reduce equipment and tools investment and save energy. Given steps are useful to create 3d model of connecting rod using cad software. The connecting rod cracking production line was established on the basis of the actual connecting rod cracking production data. The connecting rod is required to transmit the compressive and tensile forces from the piston, and rotate at both ends. Design of a fixture of connecting rod for boring operation. Comparative study of the connecting rod manufactured using forging and sintering. The analysis of the scania line together with a benchmark among different leading companies on the connecting rod manufacturing has been undertaken. Agenda manufacturing of connecting rod forging vs casting defects of forging designing and manufacturing processes limitation of forging economics limitation 2 3. Parting edge where cap and the rod meet is fractured. Comparative study of the connecting rod manufactured.
Its light and has the ability to absorb high impact, but it comes a. The connecting rod rough forging is sized, contentwise, by plating the connecting rod rough forging between two inserts. Connecting rod made by steel forging will greatly achieve high performance applications. Connecting rod definition of connecting rod by the free. Stress analysis of connecting rod for weight reduction a. After perform analysis on steel material connecting rod and s. Wbased material acted as nucleation site for cracks that propagated by. Materialized optimization of connecting rod for four stroke. On adopting the definemeasureanalyzeimprovecontrol approach, the process potential capability index c p and the process performance capability index c pk values of identified process characteristics of connecting.
Materialized optimization of connecting rod for four. A process for manufacturing a forged connecting rod of the type including a big end, a shank and a small end. Introduction connecting rods are widely used in variety of automobile engines. Pdf processbased tolerance assessment of connecting rod. The threedimensional modeling, logistics analysis and witness simulation analysis are. Failure analysis of a diesel generator connecting rod.
Assembly of ic engine connecting rod linkedin slideshare. Introduction connecting rod is an important component of the engine which mainly bears the gas pressure, bolt preload and tensile, compression, bending. The origin of the fracture was located at the conrod lubrication channel. Hence the total production cost is greatly reduced. First of all need to choose reference plane and set dimension in mm and then need to go in the sketcher and then extrude these entities to design both ends of connecting rod. Study of strength and shear behavior of fracture splitting. Powdered metal pressed together and then put into an oven where it is sintered that means granuals are melted together and forms the rod.
Powder metal manufactured blanks have the advantage of being near net shape, reducing material waste. So we do some study on the design and manufacturing process of connecting rod to understand the reason of this two problem. A study on process capability on connecting rod i n. A failure analysis investigation of a connecting rod was conducted. The equipments were selected by the ahp, and production layout is realized by the slp. Manufacturer of connecting rod exporter of connecting rod. Material design for advanced connecting rod for mass.
Piston manufacturing process the pistons are usually manufactured by means of 1 casting an object made by pouring molten metal or other material into a mould 2 forging forging is the operation. Processbased tolerance assessment of connecting rod. Forces due to the cylinder pressure as well as the mass of the connecting rod and the piston assembly are illustrated in figure 2. The lv45 series is available with optional mounting flanges, rod eye ends. Compared with traditional methods, this technique has remarkable advantages. 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. Introduction he connecting rod is the connection between the piston and the crankshaft. Index terms connecting rod, weight reduction, fatigue strength, better machinability i. Keywords crackable connecting rod, material selection, topsis method, ranking 1. Us5878491a process for the manufacture of a forged. Comparision of manufacturing methods and analysis of.
The function of the connecting rod is to convert the reciprocating motion of the piston into the rotary. Selection of material, shape, and manufacturing process. The small end which connect the connecting rod to the piston through the piston pin. Twoshell type bearings placed between the crankshaft and connecting rod provide the proper oils clearance when. The average life of a malleable iron connecting rod was 764,962 cycles at a 50% survival rate or 347,734 cycles at a 90% survival rate.
754 826 1548 840 1037 1499 148 267 1015 346 1103 1373 18 789 857 13 575 1048 495 485 1448 698 1542 172 640 1349 95 1209 16 92 753 1316 758 951 823 120 1144 1368 1552 291 868 942 1437 355 1406 1160 374 224 506 1083