| Currently, aluminum alloy is widely used in pressure casting and forging process production,but there are still some drawbacks. Squeeze casting process combines the advantages of both,so it overcame some of its deficiencies in varying degrees. The connecting rod as an important part to transmit motion and force, which its performance would be affected not only by the part strength,but also the weight of part .With the deepening study of aluminum materials,the manufacturing techniques high-performance aluminum-alloy connecting rod are constantly updated.Based on the structural characteristics and technical points of aluminum-alloy connecting rod,we make a comprehensive analysis of the forming of aluminum-alloy connecting rod program and do a comparative analysis for different options. Finally, decided to form the part by indirect squeeze casting and the double squeeze casting. This paper introduced several mold forming process, including its design and work processes. It used three-dimensional modeling software UG to complete model and the structure design of several mold parts, meanwhile adopted the casting simulation software PROCAST to analyze the filling process of liquid metal and the solidification process, also researched the effect of pouring temperature, filling speed and pressure on casting quality, finally optimized the forming process of aluminum-alloy connecting rod and process parameters. According to the simulation results we decided the optimum process parameters: Pouring temperature is 700℃;Mold temperature is 250℃; Specific pressure is 80MPa;Pressure-keeping time is about 40s.In the double squeeze casting process, the first purpose is to squeeze the liquid metal to ensure a good filling, and the second purpose is that the liquid or semi-liquid metal can be carried out under pressure and feeding. Therefore, the focus of this experimental study is that the affect of the size of pressure on the riser feeding distance. In this paper, regarding the ADC12 aluminum-alloy as the research object, The experiments sample appears different defects and microstructure characteristics under different pressures, the paper analyzes the impact of pressure on the sample's quality. The results show that,①The pressure is effective for the macro-shrinkage feeding of the parts,and with the increasing of pressure, the effect of feeding is better. When the value of pressure increase to 2.5MPa,the casting'macro shrinkage is basically disappeared .②Within the range of pressure feeding, the pressure can affect the density of the parts, meanwhile the greater the pressure, the more dense parts. With the increasing pressure, grain size basic unchanged.
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