Fatigue analysis on die insert of connecting rod in closed die forging process

Sulaiman, Mohd Amri (2006) Fatigue analysis on die insert of connecting rod in closed die forging process. Masters thesis, Universiti Putra Malaysia .

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Abstract

To meet the increasing demand for more accurate forged products with a higher added value and of higher material yield, precision forging-related technology has been making remarkable progress.In this regard, research and development on CAD/CAM/CAE (computer-aided design/computer-aided manufacturing/computer aided engineering) systems for practical use have been vigorously promoted. CAD/CAM/CAE technology has already established itself in the fields of designing and manufacturing sheet metal dies and is extensively used in the aircraft and automobile industries. The CAD/CAM/CAE system developed and operated for the hot forging of connecting rod.In conventional hot forging of connecting rods, the material wasted to the flash accounts approximately 20-40% of the original workpiece. In order to reduce the cost of forged products, the forging must be performed in a closed cavity to obtain near-net or net shape parts. In flash less forging, the volume distribution of the preform must be accurately controlled to avoid overloading the dies and to fill the cavity. Additionally, the preform must be simple enough to be mass-produced. This work used the CAD/CAM/CAE system for fatigue analysis on die insert of connecting rod in closed die forging process. The implementation of this study consists of five stages; i)modelling part (connecting rod) using CAD software (Solidworks 2005), ii) preliminary die insert design, iii) stress-strain simulation of die insert, iv)die insert fatigue analysis and lifetime, and v) developed CNC code programming for die insert. In the first stage, Solidworks 2005 software was used for modeling part connecting rod). The second stage,again CAD software (Solidworks 2005) was used to model the primary design of the die insert based on the shape of the forged part. In third stage, simulated the die inserts of connecting rod and analysed the maximum stress-strain applied on the die insert and the requirement of load to perform the forging operation. Meanwhile in fourth stage,determination fatigue analysis and lifetime on die insert was done by comparing the values from S-N curve and maximum stress-strain value from FEA result. In the last stage,Unigraphics software was used to develop CNC machining code or known GM code for fabricating the die inserts.

Item Type: Thesis (Masters)
Uncontrolled Keywords: CAD/CAM systems,Computer-aided design
Subjects: T Technology > T Technology (General)
T Technology > TS Manufactures
Divisions: Library > Tesis > FKP
Depositing User: Mohd. Nazir Taib
Date Deposited: 30 Nov 2015 02:46
Last Modified: 30 Nov 2015 02:46
URI: http://eprints.utem.edu.my/id/eprint/14870
Statistic Details: View Download Statistic

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