Forged powder metal connecting rod with stress riser crease formed in side thrust face

Claim 2

An improved unitary connecting rod which is easily cracked to form a separable bearing cap manufactured by hot forging a molded powder metal sintered preform which has an apertured large end portion and a notched side thrust face, the improved unitary rod comprising: a stress riser crease formed in a side thrust face by to concentrate stress developed during cracking caused by the application of a large tension force upon the rod and across the stress riser crease; the stress riser crease being forge formed by inward movement of the spaced surfaces defining the notch in the sintered preform and being characterized by a great depth with respect to its width.

Claim 3

An apertured connecting rod made by: molding powder metal into a green compact, sintering the green compact to produce a preform, and forging the preform; the green compact having an aperture with an adjacent side thrust face; a pair of generally V-shaped notches mold formed in a side face of the green compact one to either side of the apertrue; the metal particles of the green compact being subsequently bonded by heat to form a sintered preform with the notches intact; each notch having a pair of spaced surfaces inclined with respect to one another; the sintered preform being hot forged to increase its density and strength and cause the spaced surfaces to move inwardly toward one another to create a deep crease with substantially no width so that the rod can be easily cracked by imposing a tension force longitudinally on the rod, whereby a crack starts at the bottom of the creases and the rod is fractured along a generally flat plane progressing form the crease towards and opposite side face.

Claim 4

An apertured connecting rod made by: molding powder metal into a green compact, sintering the green compact to produce a preform, and forging the preform; the green compact having an aperture with an adjacent side thrust face; a pair of generally V-shaped notches mold formed in a side face of the green compact one to either side of the apertrue; the metal particles of the green compact being subsequently bonded by heat to form a sintered preform with the notches intact; each notch having a pair of spaced surfaces inclined with respect to one another; the sintered preform being hot forged to increase its density and strength and cause the spaced surfaces to move inwardly toward one another to create a deep crease with substantially no width so that the rod can be easily cracked by imposing a tension force longitudinally on the rod, whereby a crack starts at the bottom of the creases and the rod is fractured along a generally flat plane progressing form the crease towards and opposite side face.

Claim 5

The connecting rod set forth in either claim 1 or claim 2 in which the side thrust face of the forged rod has an non-planar configuration with a portion inclined with respect to the side face; the V-shaped notch in the green compact and in the sintered preform having a depth which varies in the radial direction from a relatively shallow depth adjacent the aperture to a greater depth adjacent the outer edge whereby forging the preform creates a crease in the forged unitary rod characterized by a generally constant depth measured from the non-planar side face.