The New Technology of Die Forging of Automotive Connecting Rods from EN AB-71100 Aluminium Alloy Cast Preforms

Abstract

This article presents a new technology for forming automotive connecting rod forgings by means of die forging from cast performs from EN AB-71100 (EN AB-AlZn10Si8Mg) aluminum alloy. A premise was made that the production process would be carried out on forging presses. The process of forming connecting rod forgings was analyzed considering different deformation rates related to the type of machine used: a crank press and a screw press. The billet in the form of in-house designed, shaped preforms cast into sand molds with two variants of geometry was used in the process. The numerical analysis of the new process was carried out on the basis of the finite element method using Deform 3D, the simulation software for metal forming. The simulations were conducted in the spatial deformation conditions, considering the full thermomechanical analysis. Based on the simulations, certain important findings concerning the novel process were acquired, including the distribution of stress, deformation, temperatures, cracking criterion and energy parameters. The results of numerical tests confirmed the possibility of producing defect-free forgings of connecting rods from EN AB-71100 aluminum alloy on forging presses by means of the proposed technology. The proposed process of forging using crank and screw presses was verified in the course of tests conducted in industrial conditions. The properly formed connecting rod forgings were subjected to quality tests in terms of their structure and mechanical properties.

Possibilities of Increasing the Durability of Dies Used in the Extrusion Process of Valve Forgings from Chrome-Nickel Steel by Using Alternative Materials from Hot-Work Tool Steels

“…Currently, a number of IT engineering tools and numerical methods based on FEM [19][20][21] are used to analyze and optimize industrial forging processes, often combined with thermal imaging measurements as well as microstructural research or dimensional analysis using laser scanners [22,23]. However, it seems that the most information can be obtained from numerical modeling, because such computational packages allow the determination of many physical quantities and other technological parameters that are difficult or even impossible to determine experimentally [24][25][26], and by introducing new functions verified in industrial conditions, they allow for quick the analysis of the entire industrial process, e.g., determining the distribution of temperatures, stresses, forging forces, flow errors of the deformed material, and even defects in forgings and many other technological aspects [27,28]. Currently, the combination of the above-mentioned research and measurement methods, in particular using increasingly advanced simulation programs based on FEM and FVM, enables comprehensive analysis on the basis of which it is possible to solve many scientific and technological issues [29][30][31].…”

Semi-Solid Forging Process of Aluminum Alloy Connecting Rods for the Hydrogen Internal Combustion Engine

“…Traditional manufacturing processes for connecting rods include hot forging [21][22][23], powder metallurgy [24], liquid-die forging [25], and die casting [26]. Although the above methods can obtain connecting rods with high dimensional accuracy and qualified mechanical properties, these methods have some shortcomings as follows.…”

Investigation of a New Screw Press Forming Process for Manufacturing Connectors from ZK60 Magnesium Alloy Preforms

“…Computer simulations of metal forming processes are based on the finite element method-an advanced method of solving systems of differential equations, based on the division of an area (continuous medium) into a finite number of elements (so-called discretization), for which the solution is approximated by specific functions and actual calculations are carried out only for the nodes of this division. The following FEM software is used to simulate forming processes on a screw press: DEFORM 3D; Forge; MSC.SuperForm; Qform; Simufact.Forming [4,[14][15][16].…”