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 journalArticle

5 Citations (Scopus)

Abstract

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
Volume36
Issue number5
DOIs
Publication statusPublished - Aug 2011

Fingerprint

Connecting rods
Forging
Steel
Aspect ratio
Specifications
Finite element method
Geometry

Keywords

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

ASJC Scopus subject areas

  • General

Cite this

Computer-Aided FE Simulation for Flashless Cold Forging of Connecting Rod Without Underfilling. / Khaleed, H. M T; Samad, Z.; Othman, A. R.; Mujeebu, M. Abdul; Badarudin, A.; Abdullah, A. B.; Ab-Kadir, A. R.; Badruddin, Irfan Anjum; Ahmed, N. J Salman.

In: Arabian Journal for Science and Engineering, Vol. 36, No. 5, 08.2011, p. 855-865.

Research output: Contribution to journalArticle

Khaleed, HMT, Samad, Z, Othman, AR, Mujeebu, MA, Badarudin, A, Abdullah, AB, Ab-Kadir, AR, Badruddin, IA & Ahmed, NJS 2011, 'Computer-Aided FE Simulation for Flashless Cold Forging of Connecting Rod Without Underfilling', Arabian Journal for Science and Engineering, vol. 36, no. 5, pp. 855-865. https://doi.org/10.1007/s13369-011-0083-3
Khaleed, H. M T ; Samad, Z. ; Othman, A. R. ; Mujeebu, M. Abdul ; Badarudin, A. ; Abdullah, A. B. ; Ab-Kadir, A. R. ; Badruddin, Irfan Anjum ; Ahmed, N. J Salman. / Computer-Aided FE Simulation for Flashless Cold Forging of Connecting Rod Without Underfilling. In: Arabian Journal for Science and Engineering. 2011 ; Vol. 36, No. 5. pp. 855-865.
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