The document outlines a 3 step process for manufacturing a connecting rod using CNC machining. Step 1 involves cutting an aluminum block according to a 3D design using various machining operations. Step 2 performs additional machining operations like helical ramping and finishing. Step 3 removes excess material, completing the connecting rod. Forging requires fewer processes than casting but provides better dimensional consistency, accuracy, and a smoother running engine compared to casting which can have defects.

2. Step 2
Step 1
Step 3
Raw Material
Raw material
-AL 7075 feature high fatigue strength and resistance to wear, corrosion, galling, and
stress relaxation.
It is evident from the Fig.1 that the elastic strain occurs at the piston end of
the connecting rod is 0.003E8 Mpa
Step 1
The CNC machine were use to cut the aluminium block
according to the 3D design of the connecting rod, Facing, Spot Drill, Drilling, Reaming,
Locating Step, Head Bolt Clearance
Step 2
Helical Ramping, Shape Rough, Middle Rod Step Rough, End mill Surface Finish, Small End
Reamer.
Step 3
The rod were put a side to remove all the excess remaining. The produce complete.

3. Forging Casting
16 processes 36 processes
Dimensional
consistency and
accuracy
Less accuracy
Smoother running in
the engine
Defects such as pin
hole, shrinkage,
porosity, rough surface
etc.
It perform at the low
temperature
Low strength
Straightenin
g test
Crack
test
A
length
check
Hardness
test
Round
test
Piston pin
bore and
bearing
tunnel size
check

4. Cost of product from raw materials
Cost of product in market