Development of a Tricycle Connecting Rod Using Near Net Shape Manufacturing Techniques

This study demonstrated the development of a tricycle connecting rod using a near-net shape manufacturing technique. The purpose was to investigate whether locally manufacturing aluminium connecting rods using near-net shape processes is viable, as this approach reduces reliance on imports, supports small-scale industries, and encourages the use of accessible materials for functional automotive components in developing regions. The component was modeled and analyzed in SolidWorks under a 600 N load, comparing aluminium 6063-T6 and AISI 4140 alloy steel. While steel showed superior strength, aluminium was selected for prototyping due to ease of casting and machining. Hardness testing was conducted on both the fabricated aluminium connecting rod and an original purchased rod, and the results were compared. The aluminium rod achieved a hardness of 56 HRB, compared to 41.2 HRC for steel. This confirms aluminium’s suitability for applications with moderate mechanical demands. Corrosion tests revealed that aluminium had a corrosion rate of 37.44 mm/year and an Ecorr of -0.503 V. This study highlighted the effective fusion of modern simulation tools with traditional methods, showing how even resource-constrained workshops can enhance quality and reliability as the work serves as a scalable model for producing other spare parts, promoting mechanical self-reliance and supporting national industrial growth.