Die Design Optimization for Connecting Rod Using Simulation Modeling and Taguchi Methodology

This paper presents a novel approach to optimizing the die design for forging used in connecting rods. The combination of Taguchi (orthogonal L9) and the finite element method (FEM) was employed to achieve this optimization. The main objective of this study was to analyze the impact of design parameters on die-filling and yield improvement. The orthogonal L9 design was generated with three input parameters and one response variable. These input parameters were derived from the design dimensions of the forging tool, specifically flash land, draft, and flash thickness. The response variable was the maximum yield percentage, which was obtained through finite element simulations of the forging processes. By conducting an orthogonal analysis, the relationships between the response variable and the input parameters were established. The simulation results were then used to compare the outcomes of two different designs. It was found that Preform one outperformed the other design, achieving an impressive yield of 88% at a forging load of 1.37 × 104 N, with complete die filling observed.