Connecting rod cracking process

This cannot happen with cracking mandrels from alfing. I have a project where being able to crack a donut shaped steel or iron part like these rod ends are might be beneficial. The application of the fs method for the production of the connecting rod using sintered forged steel was started in the 1990s 1. Modern manufacturing process of forged connecting rod.

The equipments were selected by the ahp, and production layout is realized by the slp. Here, our expertise lies in delivering connecting rod machining solutions for commercial vehicles, passenger cars in different forging weights. Make sure that the connecting rod crack test operator must be experienced in crack testing because a crack may be missed due to inexperience. Con rod fracturing and bolt assembly is one of our unique processes. Hence the total production cost is greatly reduced. While integral connecting rod is refers to the connecting rods that the body and cover is forged in a whole and then seperated by subsequent processing. How a connecting rod works written by natan agius on jun 21, 2010. Forged connecting rods with the development of automobile industry, the increase of the engine power, the requirement about the quality of the connecting rod is becoming more and more high. Connecting rods are typed by the process used to manufacture the rods. The cracking method simplifies the manufacturing process of connection rod omits two processes from the conventional method. The key process of connecting rod fracture splitting includes. Compared with traditional method, the technique has remarkable advantages. Check the connecting rods for damage, cracks, overheating and.

The manufacturing process of a connecting rod fracturesplitting involves. It is used to convert the linear movement of the piston into the rotary motion of the crankshaft. Together with the crank, the connecting rod converts the reciprocating motion of the piston into the rotation of the crankshaft. The fracture splitting method is an innovative processing technique in the field of the automobile engine connecting rod conrod manufacturing. Cracked connecting rods are initially made as a singlepart. Cracking mandrel for connecting rods rivard glen m. Connecting rods are placed under more stress than any other component in the engine. An investigation about failure in diesel engine connecting. The connecting rod cr is the main moving part and an important component of an internal com. The proper condition of a connecting rod is fairly straightforward. On every stroke, the connecting rod is stretched and compressed. The threedimensional modeling, logistics analysis and witness simulation analysis are. Over the last 10 years etxetar has become a world leader in high production connecting rod manufacturing. The applications of the fs method for the connecting rod using a high fatigue strength material were then examined due to the requirement of improving the engine performance and the fuel economy.

Further, the use of higherstrength material also makes these deliver optimum functional performance. These blow energy can forge high deformation so that the resultant force is very low. Connecting rods made of these new titanium alloys could split with the lasercracking process. The machining process creates a smooth surface that is unless there is a problem in the manufacturing process or simply a bad design free of surface inclusions. The steel in the mold is then exposed to a very high temperature to melt it and let it solidify into a rod. A connecting rod basically connects the piston to the crankshaft whilst transmitting power of the combustion from the combustion chamber to rotate the crank.

Fracture splitting technology of automobile engine. Gasp the engine in your new car might have cracked connecting rods. Causes of failure with a connecting rod it still runs. The ductile iron connecting rod experienced an average life of 1,605,902 cycles at a 50% survival rate or 635,811 cycles at a 90% survival rate. We developed steel for cracking connecting rod, which is manufactured by cracking steel products after integrally molding rod and cap parts. Triway manufacturing in windsor ontario manufacture special purpose machines for the automotive industry. The connecting rod is the transmission element between the piston and crankshaft. Tis a slick process saving many operations and a better rod if you can control it know think about hitting something with a big hammer and controlling how and where it. It can decrease manufacturing procedures, reduce equipment and tools investment and save energy. Cracks products and reduces co 2 and processes in manufacturing. We are the only manufacturer in the market offering cnc cracking technology, as opposed to the traditional hydraulic systems. The purpose of this project is the analysis of a main component of internal combustion engines, the connecting rod, hereinafter conrod, focusing in particular on the bsegment small cars field.

The process of making forged connecting rods constitutes forcing the grain of the selected material, such as a steel alloy. Bedse1 1department of mechanical engineering, savitribai phule pune university gokhale education societys r. Connecting rod connecting rod bushing manufacturer from. The apparatus and method of the present invention are directed to cracking the connecting rod 1 into two pieces along the plane so as to create a main rod section 23 and a cap 25, fig. It converts the linear motion of the pistons to the rotary motion of the crankshaft. The connecting rod cracking production line was established on the basis of the actual connecting rod cracking production data. Elastic modulus is about 140 gpa for titaniumboronsb2 and 2 gpa for the titaniummmc alloy. Connecting rod machining services offered are delivered using latest technical support which allows connecting rods to withstand greater power loads. The connecting rod is required to transmit the compressive and tensile forces from the piston, and rotate at both ends. The process also allows the elements of the steel alloy mix together in such a way that the alloy cannot be heated in an ordinary metallurgical condition. The current situation of the connecting rod cracking technology development is introduced. Connecting rods eliminate connecting rod failures hot rod. Firstly, process parameters of notch have been analyzed, and project of machining notch using wedm has been introduced, including. Highstrength steel for cracking connecting rods steelinc.

Process monitoring that informs the user of the quality of the crack process at any time is also available if desired. Fracture splitting is the core of connecting rod cracking processing. Steel optimized for the customers method x customers products with high strength. Connecting rods are used in numerous situations, most commonly in the engines of automobiles. Spark erosion technology is used for serration reconditioning. A guide on connecting rod crack testing mnr reconditioning. A cracked rod is also known as a splitfractured rod, and is a design enhancement meant to strengthen the inner workings of your engine, while boosting the cost effectiveness of manufacturing. Con rod fracturing by triway manufacturing tech, windsor, ontario.

Crack and assembly module alfing special machine group. The bosses 17 terminate in respective machined bolt faces 21. In order to resolve the problem of connecting rod notches machining, a new process of wedm wire electric discharge machine has been presented, and it is greatly possible that expensive laser process can be replaced by wedm in virtue of its unique advantages. Development of fracture splitting method for case hardened. Fracturesplitting processing performance study and. From the end of the last century, due to new technologies in the production and use of special microalloyed steels such c7056by, permitted to introduce in the market connecting rods made of a single part, using the method of fracture splitting process to separate the cap from the body of.

The new material provides excellent cracking capability. Enhances the fatigue strength of the material and prevents weakening of the conflicting workability. The connecting rod connects the pistons to the crankshaft. The connecting rod webs 15 include respective bosses 17 through which holes 19 are drilled. Study of connecting rod cracking production line layout. The rod must be straight, centertocenter rod length must meet design specs, the pin bore and bigend bore must be perfectly round, each bore must be sized appropriately for wrist pin and crank. A connecting rod, also called a con rod, is the part of a piston engine which connects the piston to the crankshaft.

A process for forming a remateable machined titanium powder base alloy connecting rod using a titanium alloy powder having an average particle size of about 120 microns, a mean aspect ratio of about 5 to 300, and a specific surface area of at least about 25 m 2 g. Forged 4340 steel 1,090 forged 5140 steel 71 chromoly 4340 steel 52 forged 4330 steel 42 t651 billet aluminum 21 forged 4260 steel 2 powdered metal 2 300 m alloy 1 t6 billet aluminum 1 connecting rod finish. Sapat college of engineering, management studies and research, nasik 5,india. We offer a wide range of metal cutting machine configurations, a flexible solution for cracking and assembling the connecting rods and the automation of the complete line. The average life of a malleable iron connecting rod was 764,962 cycles at a 50% survival rate or 347,734 cycles at a 90% survival rate. Connecting rod rotates the crank shaft which helps the engine to move on or any vehicle to rotate its. For the connecting rod to be mounted on the crankshaft, the large connecting rod eye must be divided. This pressure, plus other factors, can cause the connecting rod. In the above programmable output part of forging,estimated blow energy of 3 times straightening needs to be 16.

Connecting rod manufacture is a high volume, price sensitive application with strict performance, design and durability requirements. For installation reasons, a split connecting rod connecting rod and cap is normally used when the connection to the crankshaft is made. The cracking of connecting rods has become established as a manufacturing technology in many companies in combustion engines, the connecting rod is the link between the piston and the crankshaft. The connecting rod provides the mechanical linkage between piston and crankshaft and must exhibit properties of high strength, low inertial mass, and uniformity of mass with the other connecting rods attached to the crankshaft. Selecting the strongest rod for a performance target is absolutely essential. Ive seen cracked cap connecting rods in many engines made in the past decade. As the critical link between engine crankshaft and piston, connecting rods are forged and split into two parts by either a sawing or cracking process.

Analysis of quality defects in the fracture surface of. Fracturesplitting process the connecting rod samples are shown in figure 4. Study on machining of cracking notches for automotive. The main dimensions of the connecting rod are as follows. Connecting rod can also be repaired by following the below steps. Check the connecting rods for damage, cracks, overheating and ovality in the bigend bore, as well as check the damage in the smallend bore. Connecting rods form the link between the crankshaft and the pistons and transfer the gas and inertial forces to the crankshaft. Due to our decades of experience and our highspeed crack equipment, we have the perfect solution for every connecting rod size and every material. Additionally, the connecting rods are shotpeened to put compressive residual stress into the exterior of the rods surface, which helps to prevent cracking and crack propagation.