Connecting Rod Manufacturing Solutions
Connecting rods are critical components that transfer power from pistons to crankshafts, directly affecting engine performance, reliability, and fuel efficiency.
Common Customer Challenges
- Complex geometry (big end, small end, shank) machining requires precise dimensional control and surface quality
- High-strength materials (alloy steel, titanium) cause rapid tool wear and machining difficulties
- Weight optimization while maintaining structural integrity and fatigue resistance
- Big end bore roundness and surface finish critical for bearing performance
- Heat treatment distortion control and hardness uniformity across different sections
- Batch production quality consistency and traceability requirements
Manufacturing Solutions
Automotive Connecting Rods
- Program Points: Forging → Rough machining → Heat treatment → Precision machining → Surface treatment → Quality control
- Key Process: High-volume production, weight optimization, cost efficiency, automotive standards compliance
Heavy-Duty Engine Connecting Rods
- Program Points: Forging → Machining → Heat treatment → Precision grinding → Balancing → Coating
- Key Process: High load capacity, extended service life, reliability under extreme conditions
Racing/Performance Connecting Rods
- Program Points: Precision forging → CNC machining → Heat treatment → Precision finishing → Weight optimization → Surface enhancement
- Key Process: Lightweight design, high RPM capability, extreme precision, racing specifications
Marine Engine Connecting Rods
- Program Points: Forging → Machining → Heat treatment → Precision finishing → Corrosion protection → Quality verification
- Key Process: Corrosion resistance, high load capacity, marine environment compatibility
Connecting Rod Manufacturing Process
Raw Materials And Incoming Materials Inspection
Process step description: Verify aluminum/titanium alloy grade, thickness, surface quality and heat treat condition; sample chemistry and mechanical properties. Equipment: Optical spectrometer, universal testing machine, CMM, ultrasonic thickness gauge, hardness tester, metallographic microscope.
Material Preparation And Cutting
Process step description: Cut sheet metal to required dimensions with minimal waste and proper edge quality for subsequent forming operations. Equipment: CNC cutting machine, laser cutter, waterjet cutter, shearing machine, edge deburring machine.
Forging/Casting Preparation
- Process step description: Prepare forging billets or casting molds to achieve proper grain flow and material distribution for crankshaft blanks.
- Equipment: Forging hammer, hydraulic press, casting equipment, heating furnace, temperature monitoring system.
Rough Machining And Stock Removal
- Process step description: Remove excess material and establish basic geometry using high-efficiency roughing operations with proper fixturing.
- Equipment: CNC turning center, milling machine, machining center, roughing tools, precision fixtures.
Heat Treatment And Hardening
Process step description: Apply solution treatment, aging or stress relief to achieve target mechanical properties and dimensional stability. Equipment: Heat treatment furnace, aging furnace, stress relief furnace, temperature monitoring system, atmosphere control. Heat treatment furnace, aging furnace, stress relief furnace, temperature monitoring system, atmosphere control.
Precision Machining And Finishing
- Process step description: Machine main journals, connecting rod journals, and fillets to specified dimensions and surface quality requirements.
- Equipment: CNC turning center, precision grinding machine, CBN grinding wheels, CMM, surface roughness tester.
Weight Optimization And Balancing
- Process step description: Perform weight optimization and balancing to achieve specified weight targets and balance requirements.
- Equipment: Precision scales, balancing machine, weight correction equipment, vibration analyzer.
Surface Treatment And Coating
Process step description: Apply anodizing, primer coating or specialized surface treatments for corrosion resistance and paint adhesion. Equipment: Anodizing line, coating booth, curing oven, surface preparation system, thickness gauge.
Final Inspection And Documentation
Process step description: Conduct final quality checks, generate inspection reports and prepare documentation for airworthiness certification. Equipment: Visual inspection station, documentation system, barcode printer, quality management software.
Packaging And Shipping
Process step description: Apply protective packaging and shipping preparation to prevent damage during transportation and storage. Equipment: Protective packaging system, shipping fixtures, environmental monitoring, handling equipment.
Data Traceability And Quality Control
- Process step description: Maintain complete traceability of materials, processes and inspections for airworthiness compliance and quality control.
- Equipment: MES, data acquisition system, quality management system, barcode/RFID system, document management.
Connecting Rod Production Line
Production Line Layout And Configuration
- Overall Layout: Linear layout to minimize material handling distance and optimize production flow
- Section Division: Material Preparation Area → Forging/Casting Section → Rough Machining Section → Heat Treatment Section → Precision Machining Section → Weight Optimization Section → Surface Treatment Section → Inspection Section → Packaging Area
- Logistic Passage: Main Passage Width 4 meters, Auxiliary Passage 2.5 meters, to ensure smooth passage of connecting rods and equipment
- Buffer Setup: Buffer inventory is set up for 3-6 hours between each section to balance production tempo
Equipment Configuration And Automation
Forging/Casting Section Equipment Configuration
- Forging Hammer: 2 sets, maximum forging force 3000 tons, forging capacity up to 50kg
- Hydraulic Press: 1 set for precision forging of connecting rod geometries
- Casting Equipment: 1 set for cast iron connecting rods
- Automation: Automatic billet handling, temperature monitoring, forging parameter control
Rough Machining Section Equipment Configuration
- CNC Turning Centers: 3 units, maximum swing diameter 400mm, length 1000mm
- Milling Machines: 2 units for machining connecting rod features and surfaces
- Machining Centers: 2 units for complex geometry machining
- Automation:Automatic tool change system, in-process measurement, adaptive control
Heat Treatment Section Equipment Configuration
- Heat Treatment Furnace: 2 sets, capacity 1.5m×1m×1m, temperature control ±5°C
- Induction Hardening Machine: 1 set for selective hardening of critical areas
- Tempering Furnace: 1Au1 set for stress relief and hardness adjustment
- Automation: Automatic loading system, temperature curve control, atmosphere monitoring
Precision Machining Section Equipment Configuration
- Precision Grinding Machines: 2 units, grinding accuracy ±0.002mm, surface roughness Ra≤0.2μm
- Honing Machines: 1 unit for big end bore finishing
- CMM: 1 unit for dimensional inspection and quality control
- Automation: Automatic dressing system, in-process gauging, adaptive grinding
Production Flow And Material Handling
- Material Flow: Raw materials → Forging/Casting → Rough machining → Heat treatment → Precision machining → Weight optimization → Surface treatment → Inspection → Packaging
- Information Flow: Order information → Process parameters → Quality data → Traceability information
- AGV System: 6 AGVs, automatic handling of connecting rods between work sections
- Vision System: Automated conveyors for small connecting rod handling and positioning
