Group 3's presentation discusses the manufacturing of connecting rods. It compares the forging and casting processes, outlining the advantages of forging such as higher dimensional accuracy, lower costs for high production volumes, and smoother engine running. The presentation then details the specific forging and machining steps used to manufacture connecting rods, including heating, piercing, trimming, shot peening, fracturing, assembly, and inspection. Limitations discussed include the need for an environmentally friendly process and cost-effective finished product with limited mass deviation. Forging is considered more economical than casting for production volumes above 20,000 pieces.

1. GROUP # 3
Muhammad waseem
Saim khalid
Zafar iqbal
Muhammad imran
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2. Agenda
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Manufacturing of connecting rod
Forging Vs Casting
Defects of forging
Designing and manufacturing processes
Limitation of forging
Economics limitation
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3. MANUFACTURING PROCESS
FORGING
CASTING
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4. FORGING
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5. Forging Vs Casting
Forging
Casting
 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
 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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6. Forging Defects
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7. Design of
connecting rod
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9. Manufacturing process
MATERIAL
CUTTING TO LENGTH OF MATERIAL
BILLETS HEATING
HOT FORGING
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10. PLERCING
TRIMMING
SHOT BLASTING /SHOT PEENING
 DEBURRING
MACHINING
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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11. 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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12. INSERTION OF CRANK END BEARING SHELLS
INSERTION OF SMALL END BEARING BUSH
INSPECTION
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13. 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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14. 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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15. the metal is deformed the strain-hardening effects are
negated by the recrystallization process.
piercing:
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16. Trimming:
Shot peening:
Machining:
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17. • Fracture splitting
• Assembly
• Insertion of bearing shell
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18. • Insertion of bering bushes
• Inspection
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19. 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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20. Economic limitation
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