ME-549
ASSIGNMENT-1
PART-1
Name
Devanshi Sawhney
Entry Number
2021MEB1281
Course Name
Additive Manufacturing
Course Instructor
Dr. Prabir Sarkar
1. INTRODUCTION
The purpose of this report is to outline the steps involved in the manufacturing of
a connecting rod, a critical component used in internal combustion engines. The
connecting rod transfers motion from the piston to the crankshaft and plays a
crucial role in the engine's operation. This report focuses on the subtractive
manufacturing processes used to create the connecting rod.
2. COMPONENT DESIGN
The connecting rod was designed with intricate geometry, including a rod body,
cap, piston and crankshaft attachments, and threaded holes for fasteners. A
drawing is attached below:
3. PROCESS OVERVIEW
The manufacturing of the connecting rod involves several subtractive
manufacturing processes to achieve the desired geometry, mechanical
properties, and surface finish. The key processes used are as follows:
3.1 Pattern Making
A pattern is created to replicate the shape of the connecting rod. This pattern
serves as the basis for creating the mold for the casting process.
3.2 Casting
The pattern is used to create a mold, into which molten metal is poured to form
the connecting rod. Casting allows for the initial shape to be formed.
3.3 Thread Cutting
Thread cutting is performed on the connecting rod to create precise threads for
attachment points. Threading is essential for secure fastening of the connecting
rod within the engine assembly.
3.4 Cutting Force calculation in Turning
Cutting force calculations are performed during turning operations to ensure the
machining process does not exceed the machine tool's capacity.
3.5. Tool Making
Specialized cutting tools are manufactured to facilitate various machining
operations, including turning and milling, during the subtractive manufacturing
process.
3.6 Heat Treatment
The connecting rod undergoes heat treatment, including quenching and
tempering, to achieve the desired mechanical properties of strength and
durability.
3.7 Metallography
Metallographic analysis is conducted to examine the microstructure of the
connecting rod material post heat treatment. This ensures that the desired
material properties are achieved.
3.8 Non-destructive testing
Nondestructive testing methods, such as ultrasonic testing and dye penetrant
testing, are employed to detect any potential defects or flaws within the
connecting rod.
3.9 Welding
Welding is used for assembly if the connecting rod comprises multiple pieces,
such as a forged cap attached to the main body.
4. CONCLUSION
In conclusion, the manufacturing of a connecting rod involves a comprehensive
sequence of subtractive manufacturing processes. These processes, including
pattern making, casting, machining, heat treatment, and quality control
techniques, collectively ensure the creation of a reliable and high-quality
connecting rod for use in internal combustion engines.