Manufacturing Connecting Rods by Powder Forging
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Transcript of Manufacturing Connecting Rods by Powder Forging
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CONNECTING ROD EDI JUNEDI
2613093051
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WHAT IS CONNECTING ROD ?
• A rod in engine block that connecting piston to crankshaft
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FUNCTION
• Transmitting the thrust of the piston to the crankshaft
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TYPE OF CONNECTING ROD
• I-Beam Rods the most popular type of connecting rod cheap to make and very reliable.
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• H-Beam Rods used in high hp and low rpm have more strenght in compression
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• Alumunium Rods popular among high rpm race engines very light and strong but a short fatigue lift
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• Titanium Rods highest strength to mass ratio of all materials
used to make connecting rods higher cost
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MANUFACTURING PROCESS
• Conventional Forging
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• Powder Forging
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CHEMICAL COMPOSITION REQUIREMENT FOR POWDER FORGED PATRS
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POWDER FABRICATIONSource : Randall M. German, Powder Metallurgy Science
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• Electrolytic Fabrication Serbuk kemurnian tinggi, berpori,
bentuk dendrit Serbuk: Cu, Fe, Pd, Zn, Au, Ag Perlu dicuci, milling, annealing Parameter:
Jenis & konsentrasi elektrolit, Konsentrasi total logam dlm elktrolit, Anodic & cathodic current density, temp elektrolit, voltase, komposisi elektroda
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• Chemical Fabrication :Decomposition of Solid by Gas
Reduksi oksida (FeO) oleh gas reduktor (CO, H2)
– T rendah: berpori – T tinggi: masif, poligonal
Oksida, pemurnian (magnetik), pelumatan, proses reduksi, pelumatan, annealing Termodinamika:
– Fe3O4 + 2H2 → 3Fe+4H2O
– K=pH2O/pH2
– FeO + CO → Fe + CO2
Kinetika:– J=Aexp(-Q/RT)– DH2 in, DH2O out, reaksi di interface
Contoh serbuk: Fe, Mo, W, Cu Kemurnian: 2N Parameter: ukuran dan bentuk oksida, komposisi gas, T, Kinetika, tebal muatan
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• Atomization FabricationWater Atomization
Pembentukan serbuk dari cairan yang disemprot oleh air Serbuk: elemental, prealloyed, berbentuk ligamental, 5 s/d 100 m, laju
produksi tinggi 400kg/min, kemurnian rendah Parameter: Tm, Tpouring, laju - tekanan - kecepatan air, sudut tembak,
susunan nozel, diameter nozel, laju alir logam cair Contoh produksi Stainless Steel Tm=1365oC, Tpouring=1510oC, Dnozle= 6mm, laju logam= 22kg/min,
water jet= 8, Pair= 9 MPa, Sudut tembak= 8o, Kec. Air=110 m/s, laju air=200 l/min
Serbuk: ligamental, 60m
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Gas Atomization Pembentukan serbuk dari cairan yang disemprot oleh Udara/Gas Serbuk: elemental, prealloyed, berbentuk bulat, 50 s/d 200 m, laju
produksi tinggi 200kg/min, kemurnian tinggi Parameter: Tm, Tpouring, jenis gas, laju - tekanan - kecepatan gas, sudut
tembak, susunan nozel, laju alir logam cair Contoh produksi Nickel Tm=1400oC, Tpouring=1550oC, Argon, laju logam= 20kg/min, water jet= 8,
Pair= 2 MPa, Sudut tembak=40o, Kec. gas=100m/s, laju air= 8 m3/min Serbuk: bulat, 120m
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Centrifugal Atomization• Jenis: Rotating Electrode, Rotating Disk, Rotating Cup, Rotating Wheel,
Rotating Screen• Logam cair terlempar oleh gaya sentrifugal, saat membeku membentuk
serbuk• Produk: serbuk elemental, pre-alloyed, reactive materials (Zr, Ti, Ni-base
super alloys). 5 – 250m, berbentuk bulat.• Parameter: putaran (10.000 – 20.000 rpm), atmosfer (Ar, He, udara),
Chamber Size, Del,
• Ukuran Serbuk43.0
m64.0
12.0
d
MD m
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but the most appropriate for iron and steel are the atomization methods. Water atomization is widely used for conventional iron and mass-produced low alloyed steels. The gas atomization process is used for special steels (such as high speed steels) and steels obtained by non conventional methods.
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POWDER MIXING
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COMPACTION
• Powder blank is pressed to a simple shape halfway• Powder are compacted on computer-numerical-controlled
(CNC) servohydraulic multiplaten powder press• Hydraulic press slowly than mechanical press in operation and
less economical• But Hydraulic press offer advantage : adjustable tonnage and
constant pressure can be maintained• Density product 6.4 to 6.6 g/cm3
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SINTERING
Sintering is carried out at 1120 oC for 15 minutes
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FORGINGDensification process in which an unsintered, presintered, or sintered preform made out of powders is forged to higher densities
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• The specified densities of more than 7.6 or even 7.8 g/cm3 are achieved
• After ejection, the forged connecting rods will be cooled down to room temperature under controlled conditions in a protective atmosphere
• Shot peening is performed to remove the connecting rod forging pale
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Advantage of Powder Forging : • Greater homogenity as regards composition• Finer microstructure• Dimensional consistency and accuracy• Minimum material waste• Consume less energy• Provides longer tool life• smoother running in the engine• reduced engine weight
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Limitation :• Steels containing readily oxidisable elements such as
chromium and manganese cannot easily be used• Production costs in powder forging are generally
higher than in conventional casting or forging due mainly to the high price of the starting material and tooling
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Comparative Study Forged Steel and PM Connecting Rods
• Chemical Composition
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• Mechanical Properties
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• Reversal to failure
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• Fracture surface
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• Cost Manufacturing Process
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DAFTAR PUSTAKA
1. Agus Wahyudi dkk, Material Selection and Manufacturing Processes Connecting Rod in Diesel Engine Locomotive, 2003.
2. Connecting Rods from www.grapeaperacing.com.3. James R. Dale, Connecting Rod Evaluation, MPIF, 2005.4. P. Ramakrishnan, Residual Stresses in Powder-Metal Processing in Handbook of
Residual Stress, ASM Internastional, 2002.5. Randall M German, Powder Metallurgy Science, MPIF, 1984.6. Slameto Wiryolukito, Produksi Komponen Melalui Jalur Teknologi Logam Serbuk,
Teknik Material ITB7. G S Upadhyaya, Powder Metallurgy Technology, Cambridge International Science
Publishing8. www.circletrack.com9. Adila Afzal and Ali Fatemi , A Comparative Study of Fatigue Behavior and Life
Predictions of Forged Steel and PM Connecting Rods, SAE International, 2003