-

UNIVERSITI TUN HUSSEIN ONN MALAYSIA

FACULTY OF MECHANICAL ENGINEERING AND MANUFACTURING

SESSION/SEMESTER: 20182019/I

BDD 40203

CADCAM

PROJECT REPORT

GROUP 6

TITLE: CONNECTING ROD ASSEMBLY

NAME MATRIC NO.

AZURA SHARMEEN BINTI NAJIB AD130245

CHAN YIEN YIEN AD150255
KHOO KELLY AD150239

SECTION: 1
LECTURER NAME: ASSOC. PROF. DR. ERWEEN ABD RAHIM
 CHAPTER 1

1.1 Product Background

Connecting rod is a rigid member which connects a piston to a crank or crankshaft that are
normally used in combustion engines especially the automotive field. The main function of the
connecting rod is to convert the reciprocating motion into rotating motion or vice versa. Figure
1.1 show the connecting rod.

Figure 1.1: Connecting Rod.

Connecting rod has mainly two ends, small end and big end. The small end is connected
to piston pin and the big end is hold by the crankshaft through crankpin. The small end may
have a solid or split eye but the big end is always split. The split shoulder end is assembled
with the cap by clamping bolt. Figure 1.2 show the connection of connecting rod to the
crankshaft and the piston.

Figure 1.2: Connection of connecting rod to crankshaft and piston.

 The mostly material used for connecting rod is steel for production engines, but, the
aluminum alloy (T6-7075 aluminium alloy) is still used for lightness and the ability to absorb
high impact. Titanium is also used for a combination of lightness with strength but higher cost
is needed. The connecting rod is usually used under tremendous stress from reciprocating load
represented by piston. Connecting rod is actually being stretching and compressed in every
single rotation. Long-term compression and stretching will cause failure called throwing a rod
shown in Figure 1.3.

Figure 1.3: Throwing a Rod.

1.2 Objective

The main objective for this project is to produce the engineering drawing of connecting rod
assembly and do the simulation for manufacture process of manufacture.

1.3 Scope

The scope of this project including:

i. Produce the engineering drawing part of connecting rod using Solidworks

Software.
ii. Convert the Solidworks file into IGES file that can be read using Mastercam
software.
iii. Plan the process planning to manufacture the connecting rod.
iv. Do the simulation of manufacturing process using Mastercam software.
 CHAPTER 2

ENGINEERING DRAWING

2.1 Engineering Drawing

Engineering drawing is a type of technical drawing that use to define the requirements of
engineering product or components. The engineering drawing is help to make a clearly and
accurately capture all geometric features of part design so manufacturer or others engineer able
understand it and produce the required item. As this, engineering can be said that is a
communication way between design engineers mind, engineers and workshops which produce
the product. It also describes of item produce process to convey engineering ideas during design
process, it provides a record of existing product to improve it at future.

2.2 Engineering Drawing of Connecting Rod Assembly

The connecting rod assembly is drawn by Solid works software as shown in Figure 2.1.
Connecting rod assembly has two main part which are bearing cap and connecting rod. The
two main part of connecting rod assembly in Solid Works are shown in the Figure 2.2.

Figure 2.1: Connecting Rod Assembly.

 Connecting Rod Assembly

Bearing Cap Connecting Rod

Figure 2.2: The main part of the connecting rod assembly.

2.3 Geometric Dimension and Tolerance

Geometric Dimension and Tolerance (GD&T) is a precision language for engineering, it acts
as an engineering symbols which able to understand the design part more clearly. It able to
improve the communication and part quality.

Since quantity is very important in manufacturing process, hence cost should be control
carefully and the processes also have to minimize waste and use resources wisely. A good
geometric dimension and tolerance engineering drawing able to increase the accuracy of part
design. As this it help to control the quality and cost of product. Figure 2.3 and Figure 2.4
shows Geometric Characteristics and Symbols.

Figure 2.3: Geometric Characteristics and Symbols.

 Figure 2.4: Geometric Characteristics and Symbols.

2.3.1 Fit and limits

Normally, mechanical product are assembly by two or more components to produce an item.
The mating of the components depends on the function of the components compound.
Although the fasteners can make the components mate in tight but the tightness between two
surfaces may be need in high for some case whereas it not required in too much tight for some
others case. The tightness and looseness between two mating components is known as fit of
features. The types of Fits is consider by the status of components is for the case moving
components or fixed together. The types of fits are categorized into three group that are
Clearance Fit, Interference Fit and Transition Fit. Figure 2.5 shows the symbol and definition
of Fit and Limit. The table of the type of fits is shown as Table 2.1 below.

Figure 2.5: Symbol and Definition of Fit and Limit.

 Table 2.1: The Detail of Type of Fits.

Type of Fit Description Fit of the type

- Slide Fit
 Gap between mating part
- Easy Slide Fit
 The diameter of shaft is smaller than the diameter
Clearance Fit - Running Fit
of hole
- Slack Running Fit
 Can easily slide into the hole.
- Loose Running Fit
 Neither loose nor tight
- Push Fit
Transition Fit  The tolerance zones are overlapped between the
- Wringing Fit
interference and clearance fits
 No gap between the faces
- Force Fit
Interference  The shaft diameter is larger than hole diameter
- Tight Fit
Fit  Intersection between two mating components
- Shrink Fit
 Require additional force to fit into the hole

2.4 Geometric Dimension and Tolerance in Connecting Rod Assembly

2.4.1 Position

Product positioning is an important element of market plan. The position of the hole is quite
important so that the screw can be screw inside both part of hole and the crank shaft and bearing
is able to connect into the hole. To allow the hole able to function as it expected, the position
of the hole should be control at 0.05mm so it does not affect its function.

2.4.2 Circularity

To allow the hole able to function as it expected, the circularity of the hole is under control at
0.05mm. It is circle enough to support its function. The screw is able to screw inside the hole,
the crank shaft and bearing is able to connect to the hole.
2.4.3 Flatness

Since connecting rod assembly has two different part which are bearing cap and connecting
rod. Therefore, the surface contact should be smooth and flat enough. As this, the flatness
should be mention at the drawing. The flatness of the surface is allowed two surfaces able to
connect to each other so the flatness should control about 0.05mm.

2.4.4 Cylindricity

The connecting rod and bearing cap are assemble together and connect to shaft. Thus, the inner
diameter for both parts should precise to enable fit connection with shaft. The cylindricity of
both parts are mentioned in the drawing and the tolerance allowable is 0.05mm.

2.4.5 Fit and limit

The bottom part of connecting rod assembly, the small hole, is connected with the crank shaft.
As this the hole should enough to assembly the crank shaft when mating and it does not loose
without addition force. Based on the situation, the fit and limit of the small hole is H7/n6.

2.5 Engineering Drawing

The engineering drawing for bearing cap and connecting rod are shown in next page.
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 CHAPTER 3

PROCESS PLANNING

3.1 Introduction

Process planning is the important key in the manufacturing system that enable the
utilization of product. It is a process of planning for manufacturing and realisation of a product
according to the product specification. In process planning, the way part of product been
produced, machine types used and process times needed can be found.

The purpose of the process planning is to translate the design requirement into
manufacturing process detail. The process planning acts as the bridge between design and
manufacturing process. The process will start with the selection of raw materials and ends with
the completion of the part.

In this chapter, the process planning for the connecting rod assembly will be done. The
parts of the connecting rod assembly are done in stainless steel workpieces.

3.2 Process Planning

The connecting rod assembly has two main part which are bearing cap and connecting rod.
First, outer shape of 166.04 X 65.92 milimeters stainless steel workpiece is cut to produce the
rough shape of connecting rod assembly. After that, finishing process is to make the product
become more accurate and then it cut into two pieces. The first part bearing cap of the
connecting rod assembly is first place vertically to drill the two hole and thread is make on the
drilling hole. However, the same procedure is act on the second part connecting rod of the
connecting rod assembly. First, it is put vertically in the machine and then drill two holes on it
and mill the thread in the hole.
3.2.1 Tool Specification

Type of Operation Tool Spindle Feed Rate Depth Total No of

No Type of tool
process Surface Identification Speed (rpm) (mm/min) of Cut Run Flute
Full
Ball-nose End 4787.232
1 Contour Assembly- T6 15915 0.6 41m 44s 4
mill 6
Top
Full
Ball-nose End
2 Contour Assembly- T6 15915 4787.232 0.6 40m 38s 4
mill 6
Bottom

Part A- Solid carbide

3 Drilling T2 8403 1554.555 - 12.19s 1
Side drill 5x DC-5.0

Part A-
4 Threading T10 Thread tap- M5 350 280 - 2.82s 1
Side
Part A- Ball-nose End 2h 20m
5 Finishing T8 31830 3946.92 0.3 4
Top mill 3 26s
Part A- Ball-nose End
6 Finishing T8 31830 3946.92 0.3 10m 39s 4
Bottom mill 3

Part B- Solid carbide

7 Drilling T2 8403 1554.555 - 7.52s 1
Side drill 5x DC-5.0

Part B- Thread- mill

8 Threading T10 350 280 - 19.32s 1
Side 2mm
Part B - Ball-nose End
9 Finishing T8 31830 3946.92 0.3 20m 6s 4
Top mill 3
Part B - Ball-nose End
10 Finishing T8 31830 3946.92 0.3 20m 52s 4
Bottom mill 3

Total 4h 26m 12 s
3.2.2 Connecting Rod Assembly

PROJECT PART 1 NAME DATE

CONNECTING ROD ASSEMBLY BEARING CAP 10/1/2018
MATERIAL SIZE
STAINLESS STEEL 220mm X 110 mm X 26mm

OP # MACHINE STD SETUP TOTAL TIME INSTRUCTIONS TOOL AND PARAMETERS FIGURE
Spindle Speed: - Put stainless steel
Tool:
15915 RPM workpiece horizontally
1. Contour 41 minutes - Roughly mill the upper Ball-nose End mill 6
Feed Rate:
Milling 44 sec part of workpiece Diameter:
4787.232 - Clamping jig with height 6.0 mm
mm/min of 8 mm
Spindle Speed: - Turn the stainless steel
Tool:
15915 RPM block 180°
Contour 40 minutes - Roughly mill the bottom Ball-nose End mill 6
3. Feed Rate:
Milling 38 sec part of workpiece Diameter:
4787.232 - Clamping jig with height 6.0 mm
mm/min of 8 mm
3.2.3 Bearing Cap

PROJECT PART 1 NAME DATE

CONNECTING ROD ASSEMBLY BEARING CAP 10/1/2018
MATERIAL SIZE
STAINLESS STEEL 60 mm X 110 mm

OP # MACHINE STD SETUP TOTAL TIME INSTRUCTIONS TOOL AND PARAMETERS FIGURE
Spindle Speed:
- Turn the stainless steel Tool:
8403 RPM
block vertically Solid carbide drill 5x DC-5.0
1. Drilling Feed Rate: 12.19 sec
- Drill two hole in end of Diameter:
1554.555
the rod. 5.0 mm
mm/min
Spindle Speed:
Tool:
350 RPM - Change the tools
Thread tap- M5
2. Threading Feed Rate: 2.82 sec - Drill the thread in the
Diameter:
280 hole
5 mm
mm/min
 Spindle Speed:
Tool:
31830 RPM
Finishing 2h 20 minutes - smooth milling process Ball-nose End mill 3
3. Feed Rate:
(Top) 26 sec - the upper part Diameter:
3946.92
3.0 mm
mm/min
Spindle Speed:
Tool:
31830 RPM
Finishing 10 minutes - Smooth milling process Ball-nose End mill 3
4. Feed Rate:
(Bottom) 39 sec the bottom part Diameter:
3946.92
3.0 mm
mm/min
3.2.4 Connecting Rod

PROJECT PART 1 NAME DATE

CONNECTING ROD ASSEMBLY CONNECTING ROD 10/1/2018
MATERIAL SIZE
STAINLESS STEEL 154 mm X 110 mm

OP # MACHINE STD SETUP TOTAL TIME INSTRUCTIONS TOOL AND PARAMETERS FIGURE
Spindle Speed:
- Turn the stainless steel Tool:
8403 RPM
block vertically Solid carbide drill 5x DC-5.0
1. Drilling Feed Rate: 7.52 sec
- Drill two hole in end of the Diameter:
1554.555
rod. 5.0 mm
mm/min

Spindle Speed:
Tool:
350 RPM
- Change the tools Thread tap- M5
2. Threading Feed Rate: 19.32 sec
- Drill the thread in the hole Diameter:
280
5 mm
mm/min
 Spindle Speed:
Tool:
31830 RPM
Finishing 20 minutes - smooth milling process Ball-nose End mill 3
3. Feed Rate:
(Top) 6 sec - the upper part Diameter:
3946.92
3.0 mm
mm/min

Spindle Speed:
Tool:
31830 RPM
Finishing 20 minutes - Smooth milling process Ball-nose End mill 3
4. Feed Rate:
(Bottom) 52 sec the bottom part Diameter:
3946.92
3.0 mm
mm/min

After the process by Coordinate Numerical Control (CNC) milling machine, the small hole at the bottom part for the second part of connecting
rod assembly is then grinding by a grinding machine.
3.2.4.1 Grinding Equipment for Fit and Limit

Since for the second part of connecting rod assembly, the hole of connecting rod is
require to mate with crank shaft. To make sure the surface of the small hole is under
control by its fit and limit H7/n6. There are a grinding machine is used to grinding
cylindrical and tapered hole in cylindrical parts. The workpiece is clamped in a prepared
jig and the tools of machine is rotated and then moving toward the workpiece. The hole
is then ground by grinding tool.

Figure 3.1 Double Disc Grinding Machines.

 CHAPTER 4

MASTERCAM SILMULATION PROCESS

4.1 Introduction

Mastercam is a comprehensive set of predefined toolpaths that including the contour,

drill, pocketing, face, peel mill, engraving, surface high speed and advances multi-axis.

4.3 Mastercam Simulation

4.3.1 Full Connecting Rod Assembly

The workpiece with dimension 220x110x26 mm is used. Then, the full connecting rod
assembly with jig is first being sketching using Solidworks software as shown in the
Figure 4.1.

Figure 4.1: Full Connecting Rod with Jig.

1. Stock setup

2. Contour milling- top

3. Contour milling- bottom

4. End Product
4.3.2 Bearing Cap

First, the bearing cap is sketched using Solidworks software with the ribs included as
shown in Figure 4.2. The sketched part of the connecting rod assembly is saved as IGS
file so that the Mastercam software can read the file.

Figure 4.2: Solidworks Drawing of Bearing Cap with Ribs.

1. Hole drilling

2. Thread drilling
 3. Finishing

4. End product

4.3.3 Connecting Rod

The connecting rod is sketched using Solidworks software with the ribs included as
shown in Figure 4.3 and save in IGES file.

Figure 4.3: Solidworks Drawing of Bearing Cap with Ribs.

1. Hole drilling

2. Thread drilling

3. Finishing
4.3 G CODE DEFINITIONS TABLE

G Code Definition
G0 Rapid linear interpolation
G17 X-Y plane selection
G40 Tool radius compensation cancel
G49 Tool length compensation cancel
G80 Fixed cycle cancel
G90 Absolute value command
G91 Incremental value command
G28 Return to reference point
G92 Work offset set
G43 Tool length compensation + (H,Z)
G1 Linear interpolation
G99 Return to initial R plane after canned cycle
G3 Counter clockwise circular interpolation
N100 Line (block) number in program
X0, Y0, Z0 Coordinate for X, Y, Z
M6 Tool change
M1 Program Stop
M3 Spindle on clockwise rotation
M8 Flood coolant on
M5 Spindle stop
M9 Coolant off
M30 End of program, rewind and reset modes
S15915 Spindle speed 15915 rpm
F1000 Feed rate 1000 mm/min
R112.5 Radius 112.5
T6 Tool function
A0 Absolute or incremental position of A axis (rotational axis
around X axis)
I0 Defines arc center in X axis for G02 or G03 arc commands
J0 Defines arc center in Y axis for G02 or G03 arc commands.
4.2 FULL CONNECTING ROD

i. Area roughing (top)

ii. Area roughing (bottom)
4.3 PART A: BEARING CAP

i. Drill hole

ii. Thread mill hole

iii. Finishing-top
iv. Finishing- bottom
4.4 PART B: CONNECTING ROD

i. Drill hole

ii. Thread mill hole

iii. Finishing-top
iv. Finishing- Bottom
 CHAPTER 5

INSPECTION PROCESS

5.1 Introduction

An inspection is the critical appraisal involving examination, measurement, testing,

gauging and comparison of materials or items. The inspection process helps to
determine if the material or item is in proper quantity and condition.

5.2 Inspection Process for Connecting Rod

After the product manufacturing of connecting rod, the product will go through the
inspection process in order to identify any defects. For this project, our group will define
and propose inspection process in two different way, there are visual and machine
inspection.

5.2.1 Visual Inspection

Visual inspection is the method of quality control, data acquisition and data analysis.
Normally, the visual inspection used in the maintenance of facilities, that means
inspection of equipment and structures using human senses such as vision, hearing,
touch and smelling.

After the part bearing cap finished produce through manufacturing process, the
part is inspected through visual. The part will be inspected in all side, top, bottom, front,
rear, left and right side to check if there is any defects or cracks and if the surface is
straight and accurate. Same goes to the part connecting rod.
5.2.2 Machine Inspection

Besides visual inspection, the product connecting rod will undergoes inspection using
machine to check more accurately the geometric dimension and tolerance (GD&T). The
measurement that need inspection using machine including flatness measurement,
circularity measurement and position measurement.

i. Flatness Measurement
The inspection of flatness measurement will be carried out for the part bearing cap and
the connecting rod as shown in the Figure 5.1. There is a need to do the flatness
measurement in both part because the part will be assembly afterward. So, there is a
need to make sure the flatness to ensure the good assembly.

Figure 5.1: Flatness measurement for bearing cap and connecting rod.

The machine used to check the flatness is digimatic indicator shown in Figure 5.2.

Figure 5.2: Digimatic Indicator.

 Since the part bearing cap and the connecting rod is not rectangular block to be
placed on the table, there is a need to create the jig that can hold the part. When creating
the jig, make sure that the part can be placed 180º on the granite table. After clamping
the part with the jig, the button of START of the surface roughness tester is ON. The
probe of the machine is adjusted to be touch on the surface that need to be inspect with
the flatness. Figure 5.3 show the example where the probe of the machine touching on
the workpiece that need inspection. The flatness of the part can be determine based on
the reading. Three or more reading can be taken to calculate the average reading so that
the accuracy of the reading is higher.

Figure 5.3: Example where the probe touches the surface of the workpiece.

ii. Circularity Measurement

For the inspection for circularity measurement, the machine used is the roundness tester
model number Mitutoyo RA-2100.

Figure 5.4: Roundness Tester Model Number Mitutoyo RA-2100.

 The part of connecting rod assembly need to do the circularity inspection is the
connecting rod part as shown in the Figure 5.5. The connecting rod part is connected to
the shaft of the engine; thus, the precision of circularity is vital.

Figure 5.5: Part of connecting rod.

To test the circularity, first, clamp the connecting rod part into the jig clamping
as shown in the Figure 5.6. Make sure the clamping is no loose to avoid sliding or
vibration during inspection. Next, the stylus of the roundness tester will be adjusted to
touch the internal surface of the part and the clamping jig will rotate to check the
circularity of the part.

Figure 5.6: Clamping Jig and Stylus of the Roundness Tester.

iii. Cylindricility
The machine that used to inspect the cylindricity is the roundness tester model number
Mitutoyo RA-2100. The figure of the roundness tester model number Mitutoyo RA-
2100 is shown in Figure 5.4. The part that need inspection of cylindricity is bearing cap
and connecting rod shown in Figure 5.7.

Figure 5.7: Part that need cylindricity inspection.

To check the cylindricity, first the jig is needed to hold and clamp the part. Make sure
the part is placed well and no loose to avoid vibration. Next, the stylus part of the
roundness part need adjusted to the surface of the part that need cylindricity inspection
and the part will be move and rotate to check the cylindricity.

iv. Position Measurement

The machine that carry the position measurement inspection is coordinate measuring
machine with model number Zeiss Seatan 700 CMM shown in Figure 5.8.

Figure 5.8: Coordinate Measuring Machine Model Number Zeiss Seatan 700 CMM.
 There is two thread hole that used to assembly the part using the bolt and nuts
shown in Figure 5.9. Thus, the position for the thread hole need to be very precise. Both
the part bearing cap and connecting rod need undergo the position measurement. To
check for the position measurement, first, switch on the machine and wait until there is
light on the joystick. Next, on desktop click the calypso and login. Move the CMM
machine to the home position adjust the base alignment. Then, take the reading for the
position several times and get the average reading. Same as the small end part of the
connecting rod shown in Figure 5.10 is also need the inspection of the position.

Figure 5.9: Thread Hole for Assembly that need position inspection.

Figure 5.10: Small end of connecting rod.

 CHAPTER 6

CONCLUSION

In a nutshell, we have achieve our objective of this project that we had design
and do the simulation of connecting rod manufacturing using Mastercam software.
Basically, the connecting rod is divided into two main part, bearing cap and
connecting rod. We successful drawn the part using Solidworks software and convert
them into IGES file. The process planning for connecting rod assembly is done with the
overall time used for manufacture a connecting rod is 4 hours 26 min and 12 seconds.