Author:
Pandey A K,Walunj B S,Date P P
Abstract
Abstract
Several attempts have been made to reduce the weight of vehicles in order to increase overall fuel efficiency. Most attempts are focused on the light-weighting of BIW parts. However, very few attempts have been reported on the light-weighting of engine and transmission components. The present study aims at another method of light-weighting and manufacture of the light-weight connecting rod. To reduce the weight of connecting rod a new innovative manufacturing route using tube hydroforming has been proposed. A seamless tube is used as the raw material, which is deformed to its final shape by tube hydroforming. An innovative set of design features were needed for manufacturability using a tube as a raw material. Critical parameters of the solid connecting rod, such as diameters of holes at the big end as well as the small end, and the centre to centre distance, have been maintained equal to the reference solid forged connecting rod. Forming limit diagram has been used to predict the forming safety of the material during the forming process.