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Mr Simon Dawson

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¬¬¬Production of the Connecting Rod

Drop Forged Connecting Rods

Connecting rods are most commonly drop forged, firstly a blank steel bar with a rectangular or round cross section, it is heated to around 1300°C and is rolled to redistribute the masses to the larger and smaller ends. The most important part of the process takes place in a hammer unit, the steel rod is placed in a die and after a few consecutive blows of a hammer the steel bar is forced into the shape of the die, giving the connecting rod its shape. Drop forging produces flash around the edges of the connecting rod which is removed, the larger hole and sometimes the smaller hole (in larger connecting rods) are also simultaneously punched in this process. After the flash is removed the connecting rod is heat treated and then machined, the final stage of the process is the separation of the cap from the rod (unless the cap and the rod have been forged separately), this is usually done by sawing but an alternative is to use splitting.

Alternative methods of production

A newer technology called Sintering is becoming more popular to produce control rods; it begins with the sevrohydraulic pressing of powdered metal in its final alloy, to create a powdered preform of the control rod. Next the preform is heated to around 1120°C in an electrically heated furnace for around 15 minutes, the finished piece is now ready. The reason this technology has not taken the place of the drop forging process is because of the cost, it takes a lot of energy to heat the powder for 15 minutes in the furnace; developments are being made in an effort to make this process more cost effective.

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