Forging of Connecting Rod without Flash

This paper presents results of theoretical and experimental research of a forging process of a connecting rod without flash in a three-slides forging press. In order to design a process guaranteeing obtaining a proper product, numerous simulations and experiments were made, in which material flow kinematics, strain and stress distributions and forming forces were analyzed. On the basis of obtained results, a preform shape was designed, guaranteeing proper filling of the impression. It was assumed that a preform can be obtained in a cross-wedge rolling process. A model of such process was worked out and, on the basis of simulation, it was stated that obtaining the preform proper shape is possible. Experimental and theoretical results within the range of forming force and material flow kinematics were compared and their conformity was obtained. On the basis of conducted research, it was stated that forging without flash of connecting rod in the three-slides forging press is possible.