A slip yoke is an integral component of a drive shaft assembly. Crankshaft design, materials, loads and manufacturing, by epi. Agenda manufacturing of connecting rod forging vs casting defects of forging. Highly motivated engineers and technical experts with many years of experience and a trained eye monitor the quality of our products throughout the entire production process. So we do some study on the design and manufacturing process of connecting rod to. 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. Con rod machining technology leader in fracture splitting since the beginning of the nineties, the first fracture splitting tests of con rods were realized and the technology was implemented into the production equipment. Crackable connecting rod material selection by using topsis. The holes created for the wrist pin are then put through a machine which smooths them, allowing the wrist pin to fit comfortably. The analysis of the scania line together with a benchmark among different leading companies on the connecting rod manufacturing has been undertaken. Forging is a manufacturing technique in which metal is plastically deformed from a simple shape like billet, bar, ingot into the desired shape in one or more stages. While using metal billet metal rod, the profile of cam is obtained by removing excess material which from metal billet.
Fatigue analysis of connecting rod using finite element. This paper will discuss a brief history of the connecting rod and then discuss the various. Con rod machining technology leader in fracture splitting since the beginning of the nineties, the first fracture splitting tests of con rods were realized and the technology was implemented into the. Manufacturing metal mold is much more expensive than manufacturing sand molds or investment casting process mold. Study of connecting rod cracking production line layout. 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. Pdf processbased tolerance assessment of connecting rod. 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. A further requirement is that the connecting rod should not buckle during operation. In this process only machining is required to manufacture cam.
Sqc uses process monitoring charts for recording the critical to quality ctq. The equipments were selected by the ahp, and production layout is realized by the slp. The manufacturing process of claim 7, wherein the transition metal is selected from the group consisting of titanium, vanadium, chromium, manganese, iron, cobalt, nickel, zirconium and niobium. A connecting rod is one of the most mechanically stressed components in internal combustion engines. The connecting rod pushes the piston up, and is helped back down by the pistons reciprocal motion. Spc uses process monitoring charts to record the key quality characteristics kqcs of the component in manufacture. In this process, two notches are made on the split line for the rod and cap 180 o opposite from. Design, simulation and manufacturing of a connecting rod. Development of fracture splitting method for case hardened. Manufacturer of connecting rod, connecting rod manufacturer. A piston is a component of reciprocating engines, reciprocating pumps, gas compressors, and pneumatic cylinders among other similar mechanisms.
This paper elaborates on one such kqc of the manufacturing of a connecting rod of an internal combustion engine. Ganga forgings provides yoke forgings in a vast variety of dimensions as these components. Us5878491a process for the manufacture of a forged. The task of this project was to describe a manufacturing process for selected part, connecting rod. Apr 16, 2014 in depth behind the scenes look at hot rods u.
Manufacturer of connecting rod exporter of connecting rod. A connecting rod is a shaft which connects a piston to a crank or crankshaft in a reciprocating engine. Manufacturing process material cutting to length of material. Jul 12, 2005 the connecting rod manufacturing art is constantly looking for ways to make the manufacture of connecting rods faster, cheaper, and easier. A sintered connecting rod assembly produced by the manufacturing process of claim 1. Jan 11, 2018 a connecting rod is a shaft which connects a piston to a crank or crankshaft in a reciprocating engine. While integral connecting rod is refers to the connecting rods that the body and cover is forged in a whole and then seperated by subsequent processing. The invention of the crank connecting rod system has enabled the invention of numerous machines the most notable of which is the internal combustion engine.
Comparative study of the connecting rod manufactured. These constraints are used to select an appropriate cross section and material for construction. The component is also used to allow ujoints to rotate smoothly and properly with the drive shaft. Jun 24, 2017 crankshafts are generally used to convert reciprocating linear motion to rotary motion or viceversa. A detailed description of the processes for mass manufacturing is as follows. 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. It is a deepnitriding alloy containing 300 points of chrome, developed in the midnineties specifically for aerospace bearing applications.
The remaining portion of the connecting rod market segment is produced by use of either conventional steel forging, or to a lesser extent, casting manufacturing processes. Crackable connecting rod material selection by using. A saw then cuts the rod into smaller pieces at varied lengths called slugs. Crankshafts are generally used to convert reciprocating linear motion to rotary motion or viceversa. Comparative study of the connecting rod manufactured using forging and sintering. Last month, we looked further into the use of titanium for con rods and this month we look briefly into the use of steel, which remains in many cases the material of choice for con rods. The basic design taken from chevrolet v8 big block engine, calculations and material selection. In 2 authors elaborate advanced manufacturing systems for forging products. Process planning, tolerance chain, monte carlo, connecting rods. Power industries has been a specialist for manufacturing connecting rods for diesel petrol engine over 30 years and offers an extensive range. A human worker then smooths out the sharp edges of the piston created during production. Finally, the pistons sprayed by hot, deionized water, removing any lubricant or oil gathered through the manufacturing process.
As tolerance chain analysis is an essential activity in process planning for geometry assurance, a tolerance chains study based. This improvement consists in an increase of 20% in the hardness of the final connecting rod which also possesses a microstructure grain size of 500 nm. To come to these conclusions, the results obtained with the connecting rods manufactured by isothermal forging from previously ecapprocessed material are compared with those conventionally. A process for manufacturing a forged connecting rod of the type including a big end, a shank and a small end. 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. The connecting rod cracking production line was established on the basis of the actual connecting rod cracking production data. The permanent mold casting is similar to the sand casting process in distinction from sand molds which are broken after each casting a permanent mold may be used for pouring of at least one thousand and up to 100,000 casting cycles. They have concentrated on the precision forging and its modified requirements on the process design and production control. Crankshaft design, materials, loads and manufacturing, by. 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. Connecting rods, forging, casting, powder metal based processes. Forged connecting rods with the development of automobile industry, the increase of the engine power, the requirement about the quality of the connecting rod is becoming more and more high.
Modern manufacturing process of forged connecting rod. In comparison with other severe plastic deformation processes, this process is the one which introduces the most homogeneous strain values and allows parts with. Because large numbers of parts are manufactured each year according to the aboveidentified manufacturing process, any efficiency in manufacture can result in substantial cost and time savings. Connecting rods manufacturing improvements and process planning. Standardization can be repetitive operation,the repeatability is capable of producing consistent forged connecting rods,guarantee the. The threedimensional modeling, logistics analysis and witness simulation analysis are. Manufacturing process of connecting rod assembly and. Selection of material, shape, and manufacturing process for a.
A comparison of manufacturing technologies in the connecting. To this end, the diffusion bonding method was optimized, and a process of manufacturing a hollow connecting rod was developed. After perform analysis on steel material connecting rod and s. Forged connecting rods, forged conrods drop forging. 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%. Connecting rods link oscillatory motion to rotary motion in ic engines, and rotary to oscillatory motion in pumps. The reason aluminum is used is that its lightweight, rustproof, and easy to cut. Solution of manufacturing defects in connecting rod. Introduction connecting rods are widely used in variety of automobile engines. Method of manufacturing connecting rods metaldyne company llc. Agenda manufacturing of connecting rod forging vs casting defects of forging designing and manufacturing processes limitation of forging economics limitation 2 3.
Piston manufacturing process piston cylinder engine. Project, design and fabrication of connecting rods has been a subject of number of papers. Hot rods connecting rod manufacturing in depth behind the scenes look at hot rods u. Pdf preparation steps of a connecting rods 3d geometry to be. The side connecting rod is formed with palm ends at both ends of the rod to which the top and bottom end bearings are bolted. Strict quality specifications and regular inspections guarantee the absolute reliability of. The connecting rod manufacturing art is constantly looking for ways to make the manufacture of connecting rods faster, cheaper, and easier. There are far more manufacturers of con rods who offer steel rods than any other material. Not only does the oil ring have the responsibility of wiping the excess oil off the cylinder walls, but the job is also shared by all of the rings, leaving a fine layer of oil on the wall to provide lubrication for the following ring. Comparision of manufacturing methods and analysis of. We manufacture proven highquality connecting rods for all types of tractors, automobiles, marine, dg sets, earth moving equipments and. Discuss the choice of these materials for one such part, the connecting rod in a fourstroke sparkignition internal combustion engine. The centre connecting rod top end bearings consist of continuous white metallined shells for the lower loaded halves, while two bearing keeps over the ends of the crosshead pins form the upper halves. This thesis has been focused on the study of the connecting rod manufacturing process.
The next phase involves the selection of manufacturing process for which the constraints are shape, mass, quality and economics. There are several types of materials and manufacturing processes used in the production of connecting rods like casting, forging, and powdered metallurgy. The current manufacturing processes for connecting rods by fracture split drop. The developed connecting rod is lighter in weight and higher in rigidity than a rod with a conventional itype section produced by forging, and. In this report, the application of the fs method was examined for manufacturing the connecting rod which used the jis scm420 carburized steel. The connecting rod rough forging is sized, contentwise, by plating the connecting rod rough forging between two inserts. Abstract connecting rod is a major part inside of a internal combustion engine.
Yoke forgings manufacturers, forged yoke manufacturers. Titanium is definitely on the increase, and possibly the time will come where steel becomes a minority material. Material choices 4 last month, we looked further into the use of titanium for con rods and this month we look briefly into the use of steel, which remains in many cases the material of choice for con rods. 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. So we do some study on the design and manufacturing process of connecting rod to understand the reason of this two problem. Design, simulation and manufacturing of a connecting rod from ultra. Keywords crackable connecting rod, material selection, topsis method, ranking 1. A comparison of manufacturing technologies in the connecting rod industry danielle visser. Selection of material, shape, and manufacturing process.
These fatigue tests were performed to directly mimic the stresses a connecting rod undergoes in an engine. Comparision of manufacturing methods and analysis of connecting. Statistical quality control forms an excellent quality assurance tool for improving the quality of manufacture and ultimately scores on the endcustomer satisfaction. A piston is cylindrical in shape and forms the movable portion of the combustion chamber. The biggest advantages of programmable forging hammer is that it can standardize the production process. Design, simulation and manufacturing of a connecting rod from. Connecting rod manufacturing process highly motivated engineers and technical experts with many years of experience and a trained eye monitor the quality of our products throughout the entire production process. Comparative study of the connecting rod manufactured using.
Together with the crank, it forms a simple mechanism that converts reciprocating motion into rotating motion it is the main function of a conne. A connecting rod basically connects the piston to the crankshaft whilst transmitting power of the combustion from the combustion chamber to rotate the crank. Machining the consideration to be taken for selecting the process are initial i. Here we explore competing processes for casting a small aluminum alloy connecting rod figure 14. Connecting rod manufacturing process power industries. These connecting rods will be manufactured by a variety of manufacturing processes and a variety of materials. The yoke allows the drive shaft assembly to flex or slip within the required application. The current situation of the connecting rod cracking technology development is introduced.
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