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Material Flow Lines in Forgings

The document discusses material flow lines in forgings. It explains that the deformation from forging causes the microstructure of the material to become oriented in the direction of greatest deformation. This appears as flow lines or a fiber structure when magnified. While this structure gives strength in the longitudinal direction, it reduces ductility and fatigue properties in the transverse direction. The document also summarizes common forging defects such as incomplete forging penetration, surface cracking, cracking at the flash, cold shuts, scale pockets, and internal cracks. It provides the causes and remedies for each defect. Residual stresses from forging can be reduced through proper die design and slow cooling of the forging.

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Prashant Puri
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169 views2 pages

Material Flow Lines in Forgings

The document discusses material flow lines in forgings. It explains that the deformation from forging causes the microstructure of the material to become oriented in the direction of greatest deformation. This appears as flow lines or a fiber structure when magnified. While this structure gives strength in the longitudinal direction, it reduces ductility and fatigue properties in the transverse direction. The document also summarizes common forging defects such as incomplete forging penetration, surface cracking, cracking at the flash, cold shuts, scale pockets, and internal cracks. It provides the causes and remedies for each defect. Residual stresses from forging can be reduced through proper die design and slow cooling of the forging.

Uploaded by

Prashant Puri
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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MATERIAL FLOW LINES IN FORGINGS

Fig. Material Flow Lines

The deformation produced by forging gives a certain degree of directionality to the


microstructure of the work material.

Due to this, second phases and inclusions are oriented parallel to the direction of
greatest deformation.

When magnified, this appears as flow lines or fiber structure, a major characteristic of
all forgings.

Limitation of flow lines:

Flow lines (fiber structure) lead to lower tensile ductility and lower fatigue properties in
the direction normal to it ( in transverse direction).

Hence optimal balance between ductility in longitudinal and transverse directions is


very essential. (Deformation limited to 50% to 70% reduction in c/s area.

Forging defects
1.Incomplete forging penetration:

- Dendritic ingot structure at the interior of forging is not broken. Actual forging takes place
only at the surface.

- Cause: Use of light rapid hammer blows

- Remedy: To use forging press for full penetration.

2. Surface Cracking

- Cause: Excessive working on the surface and too low temperature. High sulfur in
furnace leading to hot shortness

- Remedy: To increase the work temperature


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3.Cracking at the flash:

- This crack penetrates into the interior after flash is trimmed off.

- Cause: Very thin flash

- Remedy:-Increasing flash thickness, relocating the flash to a less critical region of the
forging, hot trimming and stress relieving.

4. Cold shut (Fold)

Two surfaces of metal fold against each other without welding completely

Cause: Sharp corner (less fillet), excessive chilling, high friction

Remedy: increase fillet radius on the die

5.Scale pockets and Underfills:

They are loose scale/ lubricant residue which accumulate in deep recesses of the die.

Cause: Incomplete descaling of the work

Remedy: Proper decaling of work prior to forging

6. Internal cracks

Cause: Secondary tensile stresses developed during forging

Remedy: Proper die design

Residual stresses in Forging:

Causes: Inhomogeneous deformation and improper cooling (quenching) of forging.

Remedy: Slow cooling of the forging in a furnace or under ash cover over a period of time.

Source : http://elearningatria.files.wordpress.com/2013/10/mp3_unit3_forging_final.pdf

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