Arab J Sci Eng (2011) 36:855–865 DOI 10.1007/s13369-011-0083-3 RESEARCH ARTICLE - MECHANICAL ENGINEERING H. M. T. Khaleed · Z. Samad · A. R. Othman · M. Abdul Mujeebu · A. Badarudin · A. B. Abdullah · A. R. Ab-Kadir · Irfan Anjum Badruddin · N. J. Salman Ahmed Computer-Aided FE Simulation for Flashless Cold Forging of Connecting Rod Without Underfilling Received: 12 May 2009 / Accepted: 9 February 2010 / Published online: 29 July 2011 © King Fahd University of Petroleum and Minerals 2011 Abstract In this work, computer-aided finite element analysis to determine conditions for flashless cold forging of a connecting rod is presented. The workpiece specifications were calculated by developing mathe- matical relations between the volumes of the die cavity and workpiece. The three dimensional FE simulation was made using DEFORM-F3 V 6.0 and geometrical modeling of the die and workpiece was performed with SOLIDWORKS 2007 4.0. The workpiece modeled was of AISI 1045 steel and the die material was die steel (AISI D2). The aspect ratios for the bigger eye, smaller eye and column of the connecting rod were optimized to obtain the minimum flash volume without underfilling. Three workpiece geometries were modeled: cylin- drical, pre-form 1 (dumbbell shape with fillet) and pre-form 2 (dumbbell shape without fillet). Pre-form 2 was found to be the optimum workpiece to obtain flashless forging without underfilling, while minimizing the material volume and forging load. Keywords Cold forging · Flashless forging · Underfilling · Plastic deformation · Optimization · Connecting rod H. M. T. Khaleed (B ) · Z. Samad · A. R. Othman · M. Abdul Mujeebu · A. B. Abdullah · A. R. Ab-Kadir · N. J. Salman Ahmed School of Mechanical Engineering, University Science Malaysia, Engineering Campus, 14300 Nibong Tebal, Penang, Malaysia E-mail: khalid_tan@yahoo.com Tel.: 006045996369 Fax: 006045941025 A. Badarudin · I. Anjum Badruddin Department of Mechanical Engineering, University of Malaya, Kuala Lumpur, Malaysia 123