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CONNECTING ROD
A connecting rod is a part of engine which transfers motion from piston to the
crankshaft and functions as a lever arm. With the crank, it forms a
mechanism that converts reciprocating motion into rotating motion.
Connecting rods are mostly used in internal combustion piston engines .
Fig. 1 : Connecting rod
Fig. 2 [1] : Types of Connecting rod
Fig. 3 : Connecting rods
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Fig. 4 : Connecting rods
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Fig. 5 : Powder Forging Process
Fig. 6 [4,Pg 411]
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Fig. 7 [7]: Electrolytic Fabrication
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Fig. 8[5] : Hoganas sponge iron
Fig. 9 [7] : Water Atomization
Fig. 10 : Gas Atomization
Fig. 11 [7] : Centrifugal Atomization
POWDER MIXING
In the manufacturing of sintered
parts, iron powders are always
used and mixed with a
small amount of lubricant in powder
form in order to minimize the friction
in the compacting tool. In many
cases, they are also blended with
alloying elements in powder
form, like graphite, copper, nickel,
molybdenum and others (in order to
achieve increased strength
properties).
Fig. 12 [6] : Powder Mixing
Fig. 13[3,Pg49]
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STRESS AND FAILURE
The rod suffers formidable stress due to its motion, being compressed and extended on each cycle . In the manufacture of connecting rods, stress risers are eliminated by grinding the edges of the rod to a smooth radius, shot peening is done to induce compressive surface stresses (to prevent crack initiation), all connecting rod/piston assemblies are balanced to the same weight. The larger end of the rod is fabricated as a unit and then cracked in two to establish a good fit around the big end bearing shell.
Connecting rods which are made using powder metallurgy, have greater precision over size and weight with less machining. The cap is then separated from the rod by a fracturing process, ensuring that upon reassembly, the cap will be perfectly positioned with respect to the rod.
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Fig. 14 [2,Pg 178,199] : Chemical Composition
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Fig. 15 [2,Pg 179,200] : Mechanical Properties
Fig. 16 [2,Pg 204,225] : Reversal to failure
Fig. 17 [2,Pg 219,234] : Fracture surface
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Fig. 18 [2,Pg 43]