Simulation and Experimental Validation of Unfilling Defect Found In Connecting Rod in Close Die Forging

Abstract

Process of manufacturing of connecting rod in close die forging is studied. Defects found in connecting rod are unfilling, cracks, scale pits and lap. Unfilling defect contributed more toward rejection. To reduce unfilling defect, simulation is to be carried out in FEM based software DEFORM 3D, to visualize the mate rial flow in die cavity. Temperature range is to be found during simulation in DEFORM 3D, where there is complete filling of material in die i.e. removal of unfilling defect. Experiments are to be carried out at temperature range to validate DEFORM 3D result .