GROUP # 3

Muhammad waseem
Saim khalid
Zafar 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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 MANUFACTURING PROCESS

FORGING CASTING

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FORGING

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 Forging Vs Casting
Forging
Total processes approximate
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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
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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

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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

DEBURRING
MACHINING OF TOP SURFACE
MACHINING
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 C

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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