Preform geometry determination for a connecting rod forging by CEL model in Abaqus™

Abstract Forging is a widely used manufacturing process, and its design modeling are important to reducing production costs, increasing die lifespan, improving the mechanical properties of final product. In this study, forging process connecting rod was modeled using 3D coupled Eulerian Lagrangian (CEL) analysis by FEM. The methodology adopted achieved determine preform geometry that reduces flash load, while ensuring complete filling stamp. Starting from geometry, designed. After first result for an approximately 27% flash, material distribution adjusted decreasing it at regions where too large. iterative method applied better preform, proposal found reduced force 42% percentage volume 64% in comparison with one. A about 10% considered good objective reach. Lower values may cause many iterations, not significant difference loads, risk unfilled die, complex geometries.