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Connecting Rod Manufacturing

Technical Report · January 2019

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Technology of Automotive Production
E341076 - 2018

Connecting Rod

ABSTRACT
Connecting rod is an essential component of an internal combustion
engine. The project focuses on selection of suitable material, design
considerations, comparison of manufacturing methods, machines,
tools and gauges used in the production of connecting rod from a rod
to finished product.

Anurag Kar
Table of Contents
1 INTRODUCTION 1
1.1 Background
1.2 Mechanism
1.3 Forces and Moments
1.4 Parts
1.5 Product Environment
1.6 Production Quantity
2 MATERIAL 2
2.1 Comparison of Possible Materials
2.2 Material Selection
2.3.1 Chemical Composition
2.3.2 Physical Properties
2.3.3 Mechanical Properties
3 DESIGN CONSIDERATIONS 4
3.1 Forces Acting on the Connecting Rod
3.2 Design of Connecting Rod
4 POSSIBLE METHODS FOR MANUFACTURING SEMI PRODUCT 6
4.1 Casting
4.2 Powder Metal Manufacturing
4.3 Forging
5 MANUFACTURING OF SEMI PRODUCT 7
5.1 Design of forged part
5.2 Material preparation for forging
5.3 Pre-heating
5.4 Forging Machine
6 MANUFACTURING OF FINAL PRODUCT 9
6.1 Annealing
6.2 5 Axis VMC (Vertical Milling Centre)
6.3 Post Machining Operations
7 CONCLUSIONS 9
8 REFERENCES 10
List of Figures 11
List of Tables 11
List of Appendices 11
1 Introduction
The purpose of this assigned project is to define production technique of a selected component
used in the automotive industry. In this case, the component is a connecting rod for an internal
combustion engine. A connecting rod is a rigid member which connects a piston to a crank or
crankshaft in a reciprocating engine. Together with the crank, it forms a simple mechanism that
converts reciprocating motion into rotating motion.

1.1 Background
Connecting Rod transfers the motion of the piston to
the crankshaft for the crank and functions as a lever
arm. Connecting rod can be of two types - H-Beam
or I-Beam. H-Beam can handle more stress without
bending and is used in high power engines. I-Beam is
both light weight and strong but the type of material Figure 1 Picture of real part (6)

used limits its capacity to handle loads.

1.2 Mechanism
Connecting rod transmits thrust of the piston to crankshaft and a result it forms simple mechanism
that converts reciprocating motion to rotating motion of crankshaft. It is capable of transmitting
axial tension (pull), axial compression (push) and bending stress caused by trust of piston by
centrifugal force.

1.3 Forces and Moments

Connecting rods are subjected to forces generated by mass and fuel combustion. These two forces
result in axial load and bending stresses.

1.4 Parts
1.4.1 Pin End - (Small End) The small end of the connecting rod connects to the piston with a
piston pin. The piston pin, or wrist pin, provides a pivot point between the piston and
connecting rod. Spring clips, or piston pin locks, are used to hold the piston pin in place.
1.4.2 Shank - (Middle) The middle rigid part which connects the small end and the large end.
1.4.3 Crank End - (Large End) The large end of the connecting rod connects to the crankpin
journal to provide a pivot point on the crankshaft.
1.4.4 Rod Cap - Connecting rods are produces as one piece or two-piece components. A rod cap
is the removable section of a two-piece connecting rod that provides a bearing surface
for the crankpin journal. The rod cap is attached to the connecting rod with two cap
screws for installation and removal from the crankshaft.

1.5 Product Environment

Product environment is engine lubricating oil at 98 oC. At the engine start in the winter, it could also
be somewhere around -20 oC. Only lubricating oil and air can get inside the engine crankcase. The
oil assures that the air humidity and oxygen does not affect the surface quality (prevents corrosion)
and decreases friction in the bearings, pins and other moving parts.

1.6 Production Quantity

For the Chevrolet V8, 7.4L & 8.2L engines, the number of cars produced per annum was 10 000
approximately. From this fact, 80 000 connecting rods should have been produced per year.
1
2 Material
2.1 Comparison of Possible Materials
Table 1. Comparison of Mechanical Properties of possible connecting rod materials (1) (2) (3) (4) (5)
Alloy Steel Aluminium Alloys
Properties 8620 4118 4140 4340 Al 6061 Al 7075
Tensile strength MPa 530 517 655 745 310 572
Yield strength MPa 385 365 415 470 276 503
Elastic modulus GPa 190-210 190-210 190-210 190-210 68.9 71.7
Shear modulus GPa 80 80 80 80 26.2 26.9
Fracture Toughness MPa 59 28 30 50 24 24
Poisson’s ratio 0.27-0.30 0.27-0.30 0.27-0.30 0.27-0.30 0.33 0.33
Hardness, Brinell 149 137 197 217 95 150
Machinability 65 60 65 50 50 70

2.2 Material Selection

The material used for the manufacture of the connecting rod used in Chevrolet Big Block Gen V V8
8.2L, i.e., Chevrolet Performance Connecting Rods 19170198 (6) is Forged 4340.
Characteristics of AISI 4340 forged steel (1) (7)

• Heat-treatable
• Low iron-carbon alloy steel, Nickel-Chromium-Molybdenum
• Addition of molybdenum prevents the steel from being susceptible to temper brittleness
• Utilized where other alloy steels do not have the hardenability to give the required strength
• May be heat treated to high strength levels while maintaining good toughness
• Good balance of tensile strength, yield strength, toughness and hardness
• Ability to attain high strengths in the heat-treated condition
• Good fatigue resistance, shock and impact resistance
• Wear and abrasion resistance
• Excellent choice for highly stressed parts
• Fracture toughness increases with increasing
test temperatures (8)
• Can be machined by all customary methods
• Referred to as ‘aircraft quality steel’

Forging Considerations:
Figure 2: Temperature effect on
Forging should be carried out between 980 oC and 1230 oC. fracture toughness of 4340 steel
Parts should be slow cooled after forging in sand etc. (1)
Machining considerations:
Machining is best done with the alloy steel 4340 in the annealed or normalized and tempered
condition. It can be readily machined by all conventional methods such as sawing, turning, drilling
etc. (1)

2
2.2.1 Chemical Composition
Table 2 Chemical Composition of AISI 4340 steel (1)

Element Content (%)

Iron, Fe 95.195 - 96.33
Nickel, Ni 1.65 - 2.00
Chromium, Cr 0.700 - 0.900
Manganese, Mn 0.600 - 0.800
Carbon, C 0.370 - 0.430
Molybdenum, Mo 0.200 - 0.300
Silicon, Si 0.150 - 0.300
Sulphur, S 0.04
Phosphorous, P 0.035

2.2.2 Physical Properties

The physical properties of AISI alloy steel are given in the following table.
Table 3 Physical Properties of AISI 4340 steel (1)

Properties Metric
Density 7.85 g/cm3
Melting point 1427°C

2.2.3 Mechanical Properties

The mechanical properties of annealed AISI alloy steel are displayed in the following table.
Table 4 Mechanical Properties of AISI 4340 steel (1)

Properties Metric
Tensile strength 745 MPa
Yield strength 470 MPa
Bulk modulus (typical for steel) 140 GPa
Shear modulus (typical for steel) 80 GPa
Elastic modulus 190-210 GPa
Poisson's ratio 0.27-0.30
Elongation at break 22%
Reduction of area 50%
Hardness, Brinell 217
Hardness, Knoop (converted from Brinell hardness) 240
Hardness, Rockwell B (converted from Brinell hardness) 95
Hardness, Rockwell C (converted from Brinell hardness.
Value below normal HRC range, for comparison 17
purposes only)
Hardness, Vickers (converted from Brinell hardness) 228
Machinability (annealed and cold drawn. Based on 100
50
machinability for ASTM 1212 steel.)
3
3 Design Considerations
3.1 Forces Acting on the Connecting Rod (9)
3.1.1 Force on the piston due to gas pressure and inertia of the reciprocating parts
𝜋𝐷2
Force due to gas pressure 𝐹𝐿 = 𝑝 ×
4

𝑐𝑜𝑠2𝜃
Inertia force of reciprocating parts 𝐹𝐼 = 𝑚𝑅 . 𝜔2 . 𝑟 (𝑐𝑜𝑠𝜃 + )
𝑛

Net force acting on piston pin 𝐹𝑃 = 𝐹𝐿 ∓ 𝐹𝐼 ± 𝑊𝑅

3.1.2 Force due to inertia of the connecting rod or inertia bending forces
𝑚
Inertia Force 𝐹𝐼 = × 𝜔2 𝑟
2
1
Maximum Bending Moment 𝑀𝑚𝑎𝑥 = 𝑚 × 𝜔2 𝑟 ×
9√3

𝑀𝑚𝑎𝑥
Maximum Bending Stress due to inertia of connecting rod (Whipping Stress) 𝜎𝑚𝑎𝑥 =
𝑍

3.1.3 Force due to friction of the piston rings and of the piston
𝐹 = 𝜋𝐷 ⋅ 𝑡𝑅 ⋅ 𝑛𝑅 ⋅ 𝑝𝑅 ⋅ 𝜇
3.1.4 Force due to friction of the piston pin bearing and the crankpin bearing
Maximum compressive stress
𝜎𝑐(𝑚𝑎𝑥) = 𝐷𝑖𝑟𝑒𝑐𝑡 𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑣𝑒 𝑠𝑡𝑟𝑒𝑠𝑠
+ 𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑏𝑒𝑛𝑑𝑖𝑛𝑔 𝑜𝑟 𝑤ℎ𝑖𝑝𝑝𝑖𝑛𝑔 𝑠𝑡𝑟𝑒𝑠𝑠 𝑑𝑢𝑒 𝑡𝑜 𝑖𝑛𝑒𝑟𝑡𝑖𝑎 𝑏𝑒𝑛𝑑𝑖𝑛𝑔 𝑠𝑡𝑟𝑒𝑠𝑠

3.2 Design of Connecting Rod

3.2.1 Dimensions of cross-section of the connecting rod
The cross-section of the shank may be rectangular, circular, tubular, I-section or H-section. Circular
section is seldom used. I-section is preferred for high speed engines.
For I-Section
According to Rankine’s formula:
[𝜎𝑐 ×𝐴]
• 𝑊𝑐𝑟 about x-axis = [for both ends hinged, 𝐼 = 𝐿]
𝐼+𝑎[𝐿/𝐾𝑥𝑥 ]2

[𝜎𝑐 ×𝐴]
• 𝑊𝑐𝑟 about y-axis = [for both ends fixed, 𝐼 = 𝐿/2]
𝐼+𝑎[𝐿/2𝐾𝑦𝑦 ]2

4
 • For a connecting rod equally strong about both axes, the buckling loads must be equal, i.e.,

𝐼𝑥𝑥 = 4 × 𝐼𝑦𝑦 [𝐼 = 𝐴 × 𝐾 2

Generally, 𝐼𝑥𝑥 = 3 to 3.5 times 𝐼𝑦𝑦 , and the connecting rod is designed to buckle in X
direction.

Max power P = 575 hp

Piston diameter (bore) = 113.4 mm
Stroke = 101.6 mm
Factor of safety = 5
𝜎𝐶 𝐴
𝑊𝐵 =
𝐿 2
1+𝑎( )
𝑘𝑥𝑥
t = 6 mm

Figure 3 I-Section of the Connecting Rod (for design) (18)

3.2.2 Dimensions of the crankpin at the big end and the piston pin at the small end
Diameter of crank end bore diameter 𝑑𝐶 = 60 𝑚𝑚
Diameter of piston end bore diameter 𝑑𝑝 = 25 𝑚𝑚
3.2.3 Size of bolts for securing the big end cap
Nominal diameter = 10 mm
3.2.4 Thickness of the big end cap
𝑡𝐶 = 10 𝑚𝑚
Table 5 Design of Connecting Rod (6)

Connecting Rod Length Centre to Centre 180 mm

Connecting Rod Beam Style I-beam
Connecting Rod Material Forged 4340 steel
Connecting Rod Finish Shot-peened
Wrist Pin Style Press-fit
Cap Retention Style Screwed Bolt
Connecting Rod Bolt Diameter 10 mm
Connecting Rod Bolt Material 4740 chromoly alloy
Connecting Rod Bolt Head Style Hex socket
Rod Journal Diameter 56 mm
Big End Bore Diameter 60 mm
Pin End Bore Diameter 25 mm
Horsepower Rating 575 hp

5
4 Possible Methods for Manufacturing Semi Product
There are three primary methods of manufacturing connecting rods: casting, powder
metal manufacturing rolled plate stock, and forging.
4.1 Casting
Casting involves heating the metal alloy which will be used until it is molten, and pouring the molten
metal alloy into "sprues" which are connected to "runners" which channel the molten metal alloy
into a multiple cavity mould. The molten metal alloy fills the mould, and vents through "risers." After
cooling, the metal casting is separated from the mould, the sprues, runners, and risers are removed,
and the casting is machined.

Advantages Disadvantages
• Low cost • Low strength characteristics
• Tight dimensional tolerance • Porosity

The shape of the connecting rod does not permit the use of casting as a method of manufacturing
the semi product because of the complexity of design which is not possible to create by casting.
Presence of non-uniform section thickness will create shrinkage cavities and hot spots. (10)
4.2 Powder Metal Manufacturing
This involves placing a mixture of metal powder into a preformed die, and then compressing the
powder in the die with a compacting press to mechanically bond the metal powder into a preform.
The preform is then sintered to chemically bond the powder in the preform, and the preform is then
heated and forged in a press. The resulting article is then machined to finish it.

Advantages Disadvantages
• High tolerance • High cost of powder metal, tooling
• Uniform material composition • Lack of grain flow strength
• Good surface finish • Low tensile & impact strength
• Good material utilization • Limited part size and complexity

Considering the number of parts produced, this process is not economically viable. Produced parts
have low strength compared to forging. (11)
4.3 Forging
Forging involves heating a piece of bar stock or rod stock (referred to as a forge slug) to a forging
temperature, placing the heated forge slug into a two-piece forging die defining a cavity within, and
forging the forge slug using a forging press or forging hammers with multiple impacts. The part is
then machined to finished dimensions.
Forging can be somewhat labour intensive due to the amount of machining which is necessary to
produce the finished article, but it produces a product which has strength characteristics which are
superior to those produced by casting or powder metal manufacturing. This results from the fact
that the natural grain of rolled metal stock is maintained in the finished product. The natural grain
extends along the full length of the forged rod, from one end where it is expanded. The natural grain
is not truncated, as is the case with a billet.

6
5 Manufacturing of Semi-Product
After comparison of the primary manufacturing methods, forging is the ideal process to
manufacture connecting rod semi product. Advantages of forging (12)

• Directional flow enables the improvement of impact and mechanical resistance properties
• Minimum porosity
• Facilitates inspection in non-destructive tests
• Elimination of chemical segregations
• Better metallic yield
• Saving in machining hours
5.1 Design of forged part
Forged part (semi-product) drawing is in Appendix B.
Outside/inside drafts for forged parts on hammer are under 2° [0].
Dimensions of corner and fillet radii are specified in Tab 0.
Table 6 Corner radii r and fillet radii R for steel forgings (ČSN 42 9030) (13)
Height (depth) Corner radii r and fillet radii R for the ratio
H h/f <= 2 2 <= h/f <= 4 h/f >= 4
Over To R R R R r R
25 2 6 2 8 3 10
25 40 3 8 3 10 4 12
40 63 4 10 4 12 5 20
63 100 5 12 6 20 8 25

Tolerances of forged part are based on EN 10243-1. Tolerance grade for most of forgings is F,
material AISI 4340 has 0.40% of carbon, which places it into the group of steels M1 (C≤0,65%). The
ratio between the weight of the forging (1365 g) and its envelope (6 kg) is 0,23. Therefore, the group
is S3. For tolerance values see Picture 0.

Figure 4 Tolerances of Forged part according to EN 10243-1. (13)

7
5.2 Material preparation for forging
Since the production volume is high, two connecting rods are forged simultaneously. Round bar is
cut on an industrial saw from a rod in a cold state. The dimensions are D15 x h250 mm. These values
were calculated from semi product volume, which is 173 772 mm3. This value is enlarged to 177 000
mm3, so there is something left for inaccuracies and flash.
Table 7 Industrial Saw Specifications (14)
Pilous ARG 250 CF-NC Automat
Max. rod dimensions [mm] 250
Engine power [kW] 2,2
Feed rate of material [m/min] 1,6 / 2,5 / 3
Saw blade speed [m/min] 15-90
Working height of vice [mm] 790
5.3 Pre-heating
The material will be pre-heated by induction heater up to 1150oC (7). The bar diameter is 32 mm,
material is carbon steel, therefore the time of heating is 1,75 min (105 s).
Table 8 Time of heating [min] for induction heater (13)
Bar Diameter [mm] 10 20 30 40 50 60 70 80 100
Carbon steels 0,2 0,6 1,2 1,8 2,5 3 3,5 4 5
Low-alloyed steels 0,4 1,2 1,7 2,2 3 3,5 4,2 4,7 6

5.4 Forging machine

Type of forging machine was selected in context with Table 7.
Table 9 Selection Criteria for Forging Machine (13)
Common material Hammer, press
Material
Strain rate sensitive Press
Rotational Mechanical or screw press
Shape of forging
Oblong Hammer (drop h., counterblow h.)
Low Hammer
Weight of forging Middle Press (up to 60 kg), hammer
Large Counterblow hammer, hydraulic p.
Low - middle Hammer; all type of presses
Production run
High Forging press
Type of the forging machine will be hammer. The forging energy was calculated (13):

A = 13,62 * 𝐺𝑣0.59 = 13,62 * 0.90.59 = 12,8 kJ

For gravity hammer the minimal weight of the ram [7]:
𝐴 12.8
𝑚𝑏 = = = 1,16 𝑡
11 11
Table 10 Forging Machine Specifications (15)
Smeral KHZ 2A
Forging energy [kJ] 20
Clamping surface for dies [mm] 250 x 440
Lowest height of dies [mm] 250
Max. stroke of ram [mm] 400
-1]
No. of ram runs [min 20
Installed power [kW] 30
8
6 Manufacturing of Final Product
After the semi-finished part is finished, machining should be performed. First of all, the preform
should be annealed to enlarge its machinability. Then the main shape will be done on a turning
machine. Afterwards it is important to machine the functional parts – piston end bore, crank end
bearing surface, bolt holes and threads and when it is done, the part will be surface hardened. After
finishing this operation, grinding will take also its part. The whole procedure is described with all
details in Appendix C. The list of tools is specified in Appendix E.
Of course, there are several checks (dimensions and surface roughness) during the procedure. For
List of Gauges see Appendix F.
6.1 Annealing
Induction heater is used for pre-heating the preform for forging. It will be also used for annealing.
A full anneal may be done at 844°C (7) followed by controlled (furnace) cooling at a rate not faster
than 15°C per hour down to 315°C. From 315°C it may be air cooled (7). Annealing realigns the
internal molecular structure to make the metal stronger which imbibes this steel with excellent
durability.
6.2 5 Axis VMC (Vertical Milling Centre)
5 Axis VMC (16) was selected with respect to the work dimensions and the machining operations to
be performed on the semi product. The machine is ideally suited for connecting rod manufacturing
as all machining operations can be completed in one machine and the rotating table provides a
variety of clamping methods so that multiple operations can be completed in one process.
6.2.1 Machining Methods
a) Face milling
b) Boring
c) Drilling
d) Counterboring
e) Thread Tapping
f) Chamfering
6.3 Post Machining Operations
After machining is completed, the bearing end cap is separated from the rod part using fracture
splitting and then assembled with bolts and bearings in the Rotary Table Assembly Machine (17).
The finished part is checked for cracks in a magnetic crack detection machine.

7 Conclusions
The task of this project was to describe a manufacturing process for selected part, connecting rod.
The basic design (taken from Chevrolet V8 Big Block Engine), calculations and material selection
were done. The material is AISI 4340 alloy steel, which is steel with Carbon, Nickel, Chromium and
Molybdenum. This material is cut from rod, then forged by close-die forging in a hammer machine.
After this procedure, semi-product is annealed to make the machining easier. The machining is
done on CNC 5 axis VMC and fracture split and assembled in a Connecting Rod Crack and Assembly
module.
In appendices, are described all process plan operations, as well as all selected tools, used gauges
and machines. In the process plan were calculated basic operation times (for turning machine) to
see, how time demanding is each operation.
9
References
1. AISI 4340 Steel. ASTM Steel. [Online] https://www.astmsteel.com/product/4340-steel-aisi/.

2. Maximizing Hardness and Toughness in 8260 Steel. Emily Anderson, Rachel Freer, Josh Kubiak, Allison
Perna, Katie Sullivan.

3. The effects of surface hardening on fracture toughness of carburized steel.

4. The Engineering Toolbox. [Online] https://www.engineeringtoolbox.com/properties-aluminum-pipe-

d_1340.html.

5. Wikipedia. [Online] https://en.wikipedia.org/wiki/Fracture_toughness.

6. Summit Racing. [Online] https://www.summitracing.com/int/parts/nal-

19170198/overview/make/chevrolet.

7. AZO Materials. [Online] https://www.azom.com/article.aspx?ArticleID=6772.

8. Fracture Toughness and Strength Corrosion Characteristics of Ultrahigh-Strength 4340 Steel - Summary
Review. Anthony K. Wong, Milton Levy, Walter F. Czyrklis. 1979, p. 5.

9. Shigley, Joseph Edward. Mechanical Engiineering Design.

10. Groover, Mikell P. Fundamentals of Modern Manufacturing.

11. NPTEL. [Online]

https://nptel.ac.in/courses/112107144/Metal%20Forming%20&%20Powder%20metallurgy/lecture12/le
cture12.htm.

12. Frisa. [Online] https://www.frisa.com/files/downloads/advantages-of-forging.pdf.

13. FS ČVUT. [Online] moodle.fs.cvut.cz.

14. Pilous. [Online] www.pilous.cz.

15. Šmeral. [Online] Šmeral.cz.

16. Chiron. [Online] https://chiron.de/en/products/machine-tools/the-16-series.

17. Alfing Corporation. [Online] https://aks-amt.alfing.de/en/products/aks/con-rod-machining/rotary-

table-assembly-machine.html.

18. R.S. Khurmi, J.K. Gupta. Machine Design.

10
List of Figures
Figure 1 Picture of real part................................................................................................................................1
Figure 2: Temperature effect on fracture toughness of 4340 steel ...................................................................2
Figure 3 I-Section of the Connecting Rod (for design) .......................................................................................5
Figure 4 Tolerances of Forged part according to EN 10243-1. ...........................................................................7

List of Tables
Table 1. Comparison of Mechanical Properties of possible connecting rod materials ......................................2
Table 2 Chemical Composition of AISI 4340 steel ..............................................................................................3
Table 3 Physical Properties of AISI 4340 steel....................................................................................................3
Table 4 Mechanical Properties of AISI 4340 steel ..............................................................................................3
Table 5 Design of Connecting Rod ......................................................................................................................5
Table 6 Corner radii r and fillet radii R for steel forgings (ČSN 42 9030) ...........................................................7
Table 7 Industrial Saw Specifications .................................................................................................................8
Table 8 Time of heating [min] for induction heater ...........................................................................................8
Table 9 Selection Criteria for Forging Machine ..................................................................................................8
Table 10 Forging Machine Specifications ...........................................................................................................8

List of Appendices
A – Drawing of Final Product (1 page)
B – Drawing of Semi Product (1 page)
C – Process Plan and Operation Plan (2 page)
D – List of Machines
E – List of Tools
F – List of Gauges

11
 4 3 2 1

+0.2
37 Ra 1.2 28 - 0.2
F F
25 H6
.025 2 X 45°
.01 A B
R5
R10
+0.1
20 - 0.1
E +0.2 +0.2 E
18 - 0.2 6 - 0.2
+0.1
R34 A 180 - 0.1

+0.2 A A
Ra 1.6 238.5 - 0.2
R2

D M10x1.0 D
+0.1
20 - 0.1
+0.2
56.0 - 0.2

+0.1
36 - 0.1
2 X 45°
10 +0.1
R40 24 - 0.1
C 60 H4 +0.2 +0.1 C
108 - 0.2 28 - 0.1
.025
.02 A B B
3 20
R2
+0.2
24 - 0.2 6
R2
B R10 11 H4
6 30 B
.05
R2
.05 A - B F
SECTION A-A
SCALE 1:1

Fastener: 2x Allen Key Bolt (56 mm length, M10x1.5 thread length 20 mm)
A DWG NO.
A
CONNECTING ROD
TITLE:

MAE-2018-TAP-01
- Final Product
UNLESS OTHERWISE SPECIFIED: MATERIAL: MASS: NAME: SCALE SIZE
DIMENSIONS ARE IN MILLIMETERS AISI 4340 STEEL 1270 g ANURAG KAR 1:2 A4
4 3 2 1
 4 3 2 1

29
F 37 F
R2
23.2
R2
R4.5
R2
18 20
E E
30
R2
R2

180
238
R2

R34 R40 R2

D D
R3 R2

R2
R2
56
80 R2
C C
R10 29

20
29 20
6
R2
6
30
B B
108
R2
SECTION A-A
SCALE 1:1
o
ALL DRAFTS UNDER ANGLE 2
All tolerances in accordance with EN 10243-1 standard for Forging Grade F
A DWG NO.
A
CONNECTING ROD
TITLE:

MAE-2018-TAP-02
- Semi Product (Forged)
UNLESS OTHERWISE SPECIFIED: MATERIAL: MASS: NAME: SCALE: SIZE
DIMENSIONS ARE IN MILLIMETERS AISI 4340 STEEL 1365 ANURAG KAR 1:2 A4
4 3 2 1
 MANUFACTURING Pages: Page No:
TECHNOLOGY PROCESS ROUTE SHEET
DEPARTMENT
Material: AISI 4340 Part Name: Connecting Rod - Final Product Quantity: 80 000
Part No: MAE-2018-TAP-02
Machinability: 50% Blank: Connecting Rod - Semi Product Lot size: 1000
Op. Machine tool Operation description tAC tBC
10 Induction heater Annealing of Forged Semi Product at 844 C 36 hours
20 Chiron FZ16 S Face Milling
5 Axis VMC Check face width
30 Piston End, Crank End Boring 17.30
Bolt Seat Spot Facing
Chiron FZ16 S Bolt Hole Drilling
5 Axis VMC Counterboring of Bolt Hole
Thread Tapping
Check dia, surface roughness
40 Chamfering of Piston Bore, Crank Bore
Chiron FZ16 S
5 Axis VMC Oil Hole Drilling
Check cylindricity, oil hole dia
50 Alfing Crack and Fracture splitting
Assembly Module Assembly - Installation of bearings, bolts
60 DCM Tech MPI 3062 Magnetic crack detection
70 Final quality check, set making

Total

Revisions:

Op. Machine tool Operation description tAC tBC

Date: Signature:
Vypracoval:
 MANUFACTURING OPERATION SHEET Pages: Page No:
TECHNOLOGY
DEPARTMENT for operation No.: 20

Material: AISI 4340 Steel Part Name: Connecting Rod Quantity: 80 000

Machinability: 50% Part No.: MAE-2018-TAP-02 Lot size: 1000

Machine-tool: Chiron FZ16 S Blank: Connecting Rod Semi Product

Operation drawing:

Machining surface
Clamping from side
Clamping from front and back
tA
No. Operation step vc f d i
tmach tman
1 Clamping
2 Facing of gudgeon pin bore 28
3 Facing of crank pin bore 28
4 Unfix
5 Testing

Total

No. Tools Fixtures Equipment

1 2,3-CoroMill 300 face milling cutter R300-035C3-12M
2
3
4
5
6

No. Testing Check description Gauges

1 Face Width 28 Check the face width on gudgeon pin end and crank end Calliper
2
3
No. Revisions Former New Standard time
1 tAC tBC
2

Date Signature:
 MANUFACTURING OPERATION SHEET Pages: Page No:
TECHNOLOGY
DEPARTMENT for operation No.: 30

Material: AISI 4340 Steel Part Name: Connecting Rod Quantity: 80 000

Machinability: 50% Part No.: MAE-2018-TAP-02 Lot size: 1000

Machine-tool: Chiron FZ16 S Blank: Connecting Rod Semi Product

Operation drawing:

Machining surface
Clamping from side
Clamping from front and back
vc f tA
No. Operation step d i
m/min mm/s tmach [s] tman [s]
1 Clamping
2 Gudgeon pin rough boring ø 24.5 30 20 28 1 1.40
3 Gudgeon pin finish boring ø 25 15 10 28 1 2.80
4 Crank pin rough boring ø 29.5 30 20 28 1 1.40
5 Crank pin finish boring ø 30 15 10 28 1 2.80
6 Bolt hole drilling ø 8.5 60 30 56 2 3.70
7 Counterboring ø 11 50 20 36 2 3.60
8 Thread tapping M10x1.5 20 mm 32 25 20 2 1.60
9 Unfix
10 Testing
Total 17.30

No. Tools Fixtures Equipment

1 2 - CoroBore BR20 BR20D-29SP06Y-C4L
2 3 - CoroBore 825 fine boring tool 825-29TC06-EH20
3 4 - CoroBore BR20 BR20D-36SP06Y-C3L
4 5 - CoroBore 825 fine boring tool 825-36TC06-EH25
5 6 - CoroDrill 860 solid carbide drill 860.1-0850-080A1-PM 4234
6 7 - Pramet MB-H A 027 006
7 8 - CoroTap 200 cutting tap T200-XM100DA-M10 C110

No. Testing Check description Gauges

1 Bore ø 25 H6 Check bore diameter GO or NO-GO
2 Bore ø 30 H4 Check bore diameter GO or NO-GO
3 Bore ø 25 H6 Check bore surface roughness Ra 1.2 Roughness Meter
4 Bore ø 30 H4 Check bore surface roughness Ra 1.6 Roughness Meter
5 Hole ø 11 Check hole diameter GO or NO-GO
6 Thread M10x1.5 Check thread Thread Plug Gauge
No. Revisions Former New Standard time
1 tAC tBC
2

Date Signature:
 MANUFACTURING OPERATION SHEET Pages: Page No:
TECHNOLOGY
DEPARTMENT for operation No.: 40

Material: AISI 4340 Steel Part Name: Connecting Rod Quantity: 80 000

Machinability: 50% Part No.: MAE-2018-TAP-02 Lot size: 1000

Machine-tool: Chiron FZ16 S Blank: Connecting Rod Semi Product

Operation drawing:

Machining surface
Clamping from side
Clamping from front and back
tA
No. Operation step vc f d i
tmach tman
1 Clamp
2 Chamfering of gudgeon pin bore 2x45
3 Chamfering of crank pin bore 2x45
4 Oil Hole Drilling ø 3
5 Unfix
6 Testing
Total

No. Tools Fixtures Equipment

1 2,3 - CoroMill 495 495-020EH20-4509M
2 4 - CoroDrill 452 452.1-0310-045A0-CM H10F
3
4
5
6

No. Testing Check description Gauges

1 Hole ø 3 Check the hole diameter Visual inspection
2 Bore ø 25 Check cylindricity 0.025 Cylindricity Gauge
3 Bore ø 30 Check cylindricity 0.025 Cylindricity Gauge
No. Revisions Former New Standard time
1 tAC tBC
2

Date Signature:
 APPENDIX A – List of Machines

• Chiron FZ16S 5 Axis VMC

o Operations 20, 30, 40

Figure 1 Chiron FZ16S 5 Axis VMC

Table 1 Specifications of Chiron FZ16S 5 Axis VMC

 • Alfing Rotary Table Assembly Machine
o Operation 50

cFigure 2 Alfing Rotary Table Assembly Machine

Figure 3 Fracture Splitting Mandrel

• Heat Treatment WZP 160
o Operation 10

Table 2 Specifications of WZP 160 KW

Figure 4 Heat Treatment WZP 160

• Magnetic Particle Inspection System MPI 3062

o Operation 60

Figure 5 MPI 3062

 APPENDIX B – List of Tools
• CoroMill 300 face milling cutter
o R300-035C3-12M – Operation 20/2, 20/3

Figure 6 CoroMill 300 R300-035C3-12M

https://www.sandvik.coromant.com/en-gb/products/pages/productdetails.aspx?c=R300-035C3-12M
• CoroBore BR20 twin-edge damped rough boring tool [0]
o BR20D-29SP06Y-C4L – Operation 30/2
o BR20D-36SP06Y-C3L – Operation 30/4

Fig 0: CoroBore BR20 BR20D-29SP06Y-C4L, BR20D-36SP06Y-C3L

https://www.sandvik.coromant.com/cs-cz/products/pages/productdetails.aspx?c=BR20D-29SP06Y-C4L

https://www.sandvik.coromant.com/en-gb/products/pages/productdetails.aspx?c=br20d-36sp06y-c3l
CoroBore 825 fine boring tool [0]
o 825-29TC06-EH20 – Operation 30/3
o 825-36TC06-EH25 – Operation 30/5

Figure 7 CoroBore 825 fine boring tool 825-29TC06-EH20, 825-36TC06-EH25

https://www.sandvik.coromant.com/en-gb/products/pages/productdetails.aspx?c=825-29tc06-eh20
https://www.sandvik.coromant.com/en-gb/products/pages/productdetails.aspx?c=825-36tc06-eh25
 • CoroDrill 860 solid carbide drill []
o 860.1-0850-080A1-PM 4234 – Operation 30/6

Figure 8 CoroDrill 860 860.1-0850-080A1-PM 4234

https://www.sandvik.coromant.com/en-gb/products/pages/productdetails.aspx?c=860.1-0850-080a1-pm+4234
• Pramet MB-H
o A 027 006 – Operation 30/7

Figure 9 Pramet MB-H A 027 006

• CoroTap 200 cutting tap

o T200-XM100DA-M10 C110 – Operation 30/8

Figure 10 CoroTap 200 cutting tap T200-XM100DA-M10 C110

 • CoroMill 495
o 495-020EH20-4509M – Operation 40/2, 40/3

Figure 11 CoroMill 495 495-020EH20-4509M

https://www.sandvik.coromant.com/en-gb/products/pages/productdetails.aspx?c=495-020eh20-4509m

• CoroDrill 452
o 452.1-0310-045A0-CM H10F – Operation 40/4

Figure 12 CoroDrill 452 452.1-0310-045A0-CM H10F

https://www.sandvik.coromant.com/en-gb/products/pages/productdetails.aspx?c=452.1-0310-045A0-CM+H10F
 APPENDIX C – List of Gauges
• Calliper
o Face width measurements – Operation 20

• GO or NO-GO Gauge for following dimensions:

o Bore ø25H6 – Operation 30
o Bore ø30H4 – Operation 30
o Hole ø11 – Operation 30

• Thread Plug Gauge

o Thread – Operation 30

• Surface roughness tester

o Surface roughness check – Operation 30

• Cylindricity Gauge
o Cylindricity check – Operation 40

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