Preform geometry determination for a connecting rod forging by CEL model in Abaqus™

Abstract

Forging is a widely used manufacturing process, and its design and modeling are important to reducing production costs, increasing die lifespan, and improving the mechanical properties of the final product. In this study, the forging process of a connecting rod was modeled using 3D coupled Eulerian Lagrangian (CEL) analysis by FEM. The methodology adopted achieved to determine a preform geometry that reduces final flash and forging load, while ensuring complete filling of the stamp. Starting from the final geometry, the final die was designed. After the first result for an approximately 27% of flash, the material distribution was adjusted decreasing it at the regions where the flash was too large. After an iterative method was applied to determine better preform, a proposal was found that reduced forging force by approximately 42% and the percentage of flash volume by 64% in comparison with the first one. A final flash of about 10% is considered a good objective to reach. Lower values may cause many iterations, not a significant difference in forging loads, the risk of an unfilled die, and complex preform geometries.