Newly developed 3D hot forging process simulation has been introduced to optimize the process control of automotive forging parts. Fracture splitting steel connecting rod has the near net shaped geometry. So the shape of connecting rod is more complicated than general assembled connecting rod and thus, more difficult to forge. The hot forging process involves rolling, busting, blocking and finishing. Blocking is a major process to form a rough shape of part. We investigate the optimum design of preform and die shape for busting and blocking stages.

Various process parameters were evaluated by the FEM analysis such as temperature, strain and strain rate. The analyzing technique has been used as an effective tool to understand the change of process parameter at various metal forming processes. However, it is difficult to analyze the forging process precisely because the parameters are strongly dependent on the shape of forging product as well as process conditions. Therefore, it is essential that materials characteristics at high temperature should be assessed to the FEM analysis. We observed thermomechanical behaviors which involve a possible engineering process application. We also demonstrate the correlation of manufacturing variables and microstructures of forged samples by using thermo-mechanical simulator. We proposed the optimum preform design and forging parameters-such as temperature, time and forging pressure-to obtain the desirable near net shaped connecting rod.

In this research, the simulation data are reviewed and discussed for a successful mass application of connecting rod forging. Consequently, simulation techniques are proposed to optimize the forging process and eliminate all the possible troublemaking factors at the prototyping stage. To do this, we need to quantify forging process as well as to simulate forming process and eventually, we should get to predict the microstructural properties, as well.