MANUFACTURING PROCESS

FORGING

CASTING

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Design of Machine
Members
(Crank Shaft & Connecting Rod)

Dr. Manda Varaprasada Rao

2

FORGING

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Forging Vs Casting
Forging

Casting

Total processes approximate

16
Dimensional consistency
andaccuracy
Reduce mass by 10%
Consume less energy
Provides longer tool life
smoother running in the
engine
Less cost for > 20,000
pieces
High production rate
Less time consumes
Reduce cost about 25%
It performed at low
temperature

Total processes approximate

36
Less accuracy
More time consuming
Required high temperature
for melting
Low production rate
Defects such as pin hole,
shrinkage, porosity,
Rough surface etc.
high cost for >20,000 pieces
More waste of materials
More labor cost
Machining process
Low strength

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Forging Defects

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Design of
connecting rod

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DR M VARAPRASADA RAO

Manufacturing process
MATERIAL

CUTTING TO LENGTH OF
MATERIAL

BILLETS HEATING

HOT FORGING

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PLERCING

TRIMMING
SHOT BLASTING /SHOT
PEENING
DEBURRING
MACHINING

MACHINING OF TOP
SURFACE
GRINDING THE SIDE
FACES
DRILLING THE PISTON
END
BROACHING OF CRANK
AND PISTON ROD
DRILLING OF BOLT HOLE
DRILLING OF HOLE

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MACHINING OF BOLT

MACHINE FRACTURE SPLITTING

GROOVE

FRACTURE SPLITTING

ASSEMBLY OF CONNECTING
ROD

MACHINING

FINISH GRINDING
I=OF SIDE FACES
FINAL DRILLING OF
CRANK AND PISTON
MILLING OF BEARING
OF POSITIONING
GROOVE

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INSERTION OF CRANK END BEARING

SHELLS

INSERTION OF SMALL END BEARING

BUSH

INSPECTION

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Selection of material
the connecting rods are most usually
made ofsteel(for lightness and the ability
to absorb high impact at the expense of
durability)
titanium(for a combination of lightness
with strength, at higher cost) for high
performance engines, or ofcast ironfor
applications such as motor scooters.

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Cutting of material
Cut the material a little greater than the
required due to further process

heating billets
Billet is heated in the furnace
at 500-600 C

Hot forging
Hot forging isdefined as working a metal
above its recrystallization temperature.
The main advantage of hot forging is that as
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the metal is deformed the strain-hardening

effects are negated by the recrystallization
process.

piercing:
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Trimming:

Shot peening:

Machinin
g:

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 Fracture splitting

Assembly

Insertion of bearing shell

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 Insertion of bering bushes

Inspection

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Limitation of forging
It must be enviourment friendly
It finished product cost must be moderate
Limitation of the mass deviation along the
longitudinal axis
materials are generally less expensive
than the materials required for casting.
Limited scrap and rework. Reduced labor
costs and lower tooling equipment
expenses than casting
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Economic limitation

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DR M VARAPRASADA RAO

CRANK SHAFT DESIGN

Design a side or overhung crankshaft for a
250 mm 300 mm gas engine. The weight
of the flywheel is 30 kN and the explosion
pressure is 2.1 N/mm2. The gas pressure at
the maximum torque is 0.9 N/mm2, when
the crank angle is 35 from I. D. C. The
connecting rod is 4.5 times the crank radius

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GIVEN DATA
.

Given : D = 250 mm ;
L = 300 mm or r = L / 2 = 300 / 2
= 150 mm ;
W = 30 kN = 30 103 N ;
p = 2.1 N/mm2,
p = 0.9 N/mm2 ;
l = 4.5 r or l / r = 4.5
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How to Design
.

Design the crankshaft for the two

positions of the crank
1.when the crank is at the dead
centre and
2. when the crank is at an angle of
maximum twisting moment.
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FORMULE & CONSTANTS FROM

DATA BOOK
14.4 OF DESIGN DATA BOOK BY
JALALUDDEEN

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DIAMETER = 250 MM
Design of crankshaft when the crank
is at the dead centre.
We know that piston gas load-

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BEARING DESIGN

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CRANK WEB

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SHAFT LENGTH & DIAMETER

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OTHER INFORMATION
CALCULATIONS AS PER DESIGN DATA
BOOK

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CONNECTING ROD DESIGN

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LOAD & INERTIA FORCE

.

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