The document discusses the significance of aluminum, particularly the 7000 series alloy 7075-T6, in forging operations for producing durable components like connecting rods used in internal combustion engines. It highlights the advantages of forging over casting and machining, emphasizing the stresses on connecting rods and the importance of selecting appropriate die materials for manufacturing. The text concludes with a summary of aluminum's applications and the critical factors influencing the forging process.

2. Contents
 Introduction
 Choosing Forging operation
 Main Project Part (Connecting Rod)
 Part Material
 Manufacturing Operation
 Die material
 Conclusion

3. Introduction
 Aluminium has since been identified as the most
common metal on earth, forming about eight percent
of the earth's crust. It is the third most plentiful element
known to man.
 A number of unique and attractive properties
account for engineering significance of aluminium
.These include its workability ,light weight ,corrosion
resistance and good electrical and thermal
conductivity.
 Aluminium has a specific gravity 2.7 compared to 7.85
for steel , making aluminium about one -third the
weight of steel for an equivalent.

4. Forging operation
 The Natural Development of Manufacturing
requirements urges the need for high quality reliable
Products.
 Forging can produce a piece that is stronger than an
equivalent cast or machined part. As it offers high
strength for the forged products, So it is used in
Automobile Industry and aerospace industry so many
Industries.

5. Connecting Rod
 Connecting rod is one of the most
crucial components in any Internal
Combustion engine.
 It’s a rod that connects the piston to
the crank shaft.
 It’s convert the Reciprocating motion
of the piston to an angular motion to
the crank shaft.

6. Stresses on Connecting Rod
 The connecting rod is under
tremendous stress from the
reciprocating load represented by
the piston,
actually stretching and being
compressed with every rotation, and
the load increases to the square of
the engine speed increase.
 Failure of a connecting rod due to
this fatigue stress is one of the most
common causes of catastrophic
engine failure in cars.

7. Connecting Rod Material
 As it is subjected to cyclic fatigue, thus the selected
Aluminum alloy the 7000 series alloy 7075-T6 which
have a Tensile strength of 570 MPa and a proof
strength of 505 Mpa.
 Alloy 7075-T6

8. Manufacturing Operation
 We produce the Connecting Rod using
the Close Die forging operation.
 the billet is heated up to temperature
350 to 450 Degrees Celsius.
 Strength increased after forging
due to fine graining mechanism
happens in process.

9. Die design
 Die materials must have strength and toughness at
elevated temperatures, hardenability, resistance to
thermal shock, wear resistance.
 From Steel Designation H11 means Strain hardening
only

10. Die design
 Die materials must have strength and toughness at elevated
temperatures, hardenability, resistance to thermal shock, wear
resistance.
 Chromium increases Corrosion resistance
 Chromium , vanadium and molybdenum each combine with
carbon to form Carbides which increases Wear resistance.

11. Conclusion
 Presence of aluminum in earth crust , importance and
applications
 Importance of Forging process and its applications in
industry
 Connecting rod working principle and stresses applied
in
 Aluminum alloy 7075 T6 , its chemical composition and
effect of major alloying element (Zinc) in it
 Manufacturing operation
 Manufacturing considerations as Die Material
 Chemical composition of Die Material

12. Thank you
Mahmoud
Khairy
Toka
Mohamed
Mohamed
Samir
Mohamed
Ibrahim
Khulod
Amer