The paper presents the results of a thermo-mechanical analysis of the rolling two stepped shafts. One of the shafts has a toothed step with skew teeth, while the other has a worm winding in the shape of a trapezoidal screw. The shape of the rolling tools resembles that of the tools used in the Roto-Flo rolling method; yet unlike in Roto-Flo, the shafts are hot-rolled and no centres are used to stabilize the position of the workpiece during the forming process. For the calculations made with use of the DEFORM-3D process simulation system it has been assumed that the rolled shafts are made from 2618 aluminium alloy. As a result of the calculations made, it has been found that the toothed stepped shafts can be formed in one pass by means of the cross rolling process. Additionally, the temperature and strain distribution in the rolled product have been determined as well as some data concerning the forces which are necessary for the rolling process have been obtained.

Analysis of the cross-wedge rolling process of toothed shafts made from 2618 aluminium alloy

Design, simulation and manufacturing of a connecting rod from ultra-fine grained material and isothermal forging

Modelling the forging and post-forging cooling of C70S6 conrods

The paper overviews the research on roll forging processes in the last two decades. Given the broad scope of this problem, the overview focuses on processes in forging plants, omitting those performed in metallurgical plants. Three rolling processes are discussed in detail: longitudinal rolling, cross rolling and helical rolling. Each of the three techniques is discussed in terms of the main research problems and potential directions of future development.

/pdf/overview-of-the-research-on-roll-forging-processes-39fek204me.pdf

Overview of the research on roll forging processes

Connecting rod of an internal combustion engine is subjected to complex loading conditions. These mainly include the forces created through combustion in the combustion chamber of cylinder causing compression and bending of the connecting rod. This paper reports the results of a project objected to design the connecting rod of a heavy duty marine diesel engine and to modify its structural details based on finite element analysis. For this purpose, the initial design of the connecting rod was conducted by CATIA software and imported as stp file in Abaqus software. Results of the FEM model were utilized to modify the CAD model based on critical stress spots and magnitude of deformations of different sections of analyzed connecting rod model. Also, these results were used to introduce appropriate materials to tolerate the magnitude of forces developed under maximum combustion pressure of 190 bar. Further FEM analyses were carried out to modify the design in order to reduce the weight of final model of connecting rod. Results of finite element analysis of the final model revealed that the levels of stresses of the designed connecting rod are reduced significantly below the yield stresses of suggested materials for production of the connecting rod.

Design of high duty diesel engine connecting rod based on finite element analysis

A review of developments in the forging of connecting rods in China

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A review of developments in the forging of connecting rods in China