Procedure: Connecting Rod Forming

Follow the steps below to conduct the virtual experiment and analyze the hot forging process of a connecting rod.

1. Understanding the Objective: Begin the experiment by understanding the purpose of the connecting rod forming process. The objective is to study the closed impression die forging of a connecting rod and to analyze material deformation and strain distribution during hot forging.

2. Observation of Initial Simulation Setup – Part 1

• Action: Play the “Simulation Setup 1” video.
• Observation: Observe the initial cylindrical billet made of manganese alloy steel maintained at a temperature of 1250°C. Study the arrangement of the upper die, lower die, and billet. Note how the billet is positioned between the dies before deformation begins.

3. Closed Impression Die Forming Process

• Action: Continuing in the same video, observe the hydraulic press operation.
• Analysis: Observe how the press applies a high compressive force through the upper die. Due to high temperature and pressure, the billet undergoes plastic deformation and flows into the die cavities. Notice the transition from initial billet → preform → semi-finished connecting rod.

4. Strain Analysis – Part 1

• Action: Play the “Step 1 with Strain” simulation.
• Observation: Observe the equivalent strain distribution shown on the right-hand side of the video.
• Technical Note: Initially, strain is low, but it increases significantly as deformation progresses. Identify regions of high strain concentration, particularly near the fillets and web section of the connecting rod, indicating intense plastic flow.

5. Observation of Advanced Forming – Part 2

• Action: Play the “Simulation Setup 2” video.
• Observation: Observe the continuation of the forging process under controlled parameters. Note the improved material flow into the die impressions and the formation of the final semi-finished connecting rod shape. Study how uniform deformation ensures dimensional accuracy and strength.

6. Strain Analysis – Part 2

• Action: Play the “Step 2 with Strain” simulation.
• Observation: Observe the variation of equivalent strain during the final stage of deformation.
• Comparison: Compare strain patterns with Part 1 and note how strain becomes more uniformly distributed, ensuring improved mechanical properties and reduced chances of failure.

7. Final Shape and Post-Processing Understanding

• Conclusion: Observe the final connecting rod shape shown at the end of the simulations.
• Inference: Understand that the forged connecting rod undergoes heat treatment and machining to obtain the final product with desired strength, fatigue resistance, and dimensional accuracy.