3-D FEM-simulation of hot forming processes for the production of a connecting rod

A fully three-dimensional thermo-mechanically coupled FEM-simulation of the production of a connecting rod has been performed. The production process consists of five stretch-rolling and subsequent die-forging steps. Workpieces from all stages of the process are used to examine the geometry, microstructure and local mechanical properties. Combining the results of these examinations with information on local process variables like strain and temperature from numerical simulation made it possible to study the influence of the deformation history on the local microstructure and mechanical properties. The simulation of the hot forming process shows good agreement with experiments regarding to geometry and temperature fields of the workpiece.