Computer-Aided FE Simulation for Flashless Cold Forging of Connecting Rod Without Underfilling

H. M.T. Khaleed, Z. Samad, A. R. Othman, M. Abdul Mujeebu, A. Badarudin, A. B. Abdullah, A. R. Ab-Kadir, Irfan Anjum Badruddin, N. J.Salman Ahmed

Research output: Contribution to journalArticlepeer-review

7 Citations (Scopus)


In this work, computer-aided finite element analysis to determine conditions for flashless cold forging of a connecting rod is presented. The workpiece specifications were calculated by developing mathematical relations between the volumes of the die cavity and workpiece. The three dimensional FE simulation was made using DEFORM-F3 V 6.0 and geometrical modeling of the die and workpiece was performed with SOLIDWORKS 2007 4.0. The workpiece modeled was of AISI 1045 steel and the die material was die steel (AISI D2). The aspect ratios for the bigger eye, smaller eye and column of the connecting rod were optimized to obtain the minimum flash volume without underfilling. Three workpiece geometries were modeled: cylindrical, pre-form 1 (dumbbell shape with fillet) and pre-form 2 (dumbbell shape without fillet). Pre-form 2 was found to be the optimum workpiece to obtain flashless forging without underfilling, while minimizing the material volume and forging load.

Original languageEnglish
Pages (from-to)855-865
Number of pages11
JournalArabian Journal for Science and Engineering
Issue number5
Publication statusPublished - Aug 2011


  • Cold forging
  • Connecting rod
  • Flashless forging
  • Optimization
  • Plastic deformation
  • Underfilling

ASJC Scopus subject areas

  • General


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