Flash-less cold forging of connecting rod using computer-aided FE simulation

Abstract

In this work, computer- aided finite element analysis for flash-less cold forging of connecting rod is presented. The work-piece specifications are calculated by developing mathematical relations between volumes of die cavity and workpiece. The aspect ratios for the bigger eye, smaller eye and column of the connecting rod are optimized to obtain minimum flash volume with no under-filling. Among the three types of workpiece geometries namely cylindrical, Preform 1 and Preform 2 (dumbbell shape with and without fillet respectively), Preform 2 was found to be the optimum work-piece to obtain flash-less forging with no under-filling, minimum volume and forging load. The numerical results are successfully validated by the analytical calculations.