Podcast
Questions and Answers
What is the primary purpose of using steel blooms in the axle manufacturing process?
What is the primary purpose of using steel blooms in the axle manufacturing process?
- To enhance aesthetic appearance of the axles
- To improve electrical conductivity
- To reduce the weight of the axles
- To provide a base material for forging axles (correct)
Which mechanical property is defined as the stress at which plastic deformation begins?
Which mechanical property is defined as the stress at which plastic deformation begins?
- Elastic modulus
- Yield strength (correct)
- Ultimate strength
- Tensile strength
What material is commonly used for forging hammers in the railway industry?
What material is commonly used for forging hammers in the railway industry?
- DIN 56NiCrMoV7 (correct)
- CAST Iron
- Stainless Steel
- Aluminium Alloy
How is ductility measured?
How is ductility measured?
What must be documented during the reclamation process of forging hammers?
What must be documented during the reclamation process of forging hammers?
Which property gives the maximum information about a material's mechanical characteristics?
Which property gives the maximum information about a material's mechanical characteristics?
What analysis method is used to determine the hydrogen content in liquid steel?
What analysis method is used to determine the hydrogen content in liquid steel?
What is the formula for calculating yield strength?
What is the formula for calculating yield strength?
What does a high percentage elongation indicate about a material?
What does a high percentage elongation indicate about a material?
Which process is required for producing steel blooms for axles?
Which process is required for producing steel blooms for axles?
What does malleability refer to in materials?
What does malleability refer to in materials?
What is ultimate tensile strength defined as?
What is ultimate tensile strength defined as?
How is fracture strength mathematically represented?
How is fracture strength mathematically represented?
What does toughness measure in a material?
What does toughness measure in a material?
At what temperature does BCC iron undergo allotropic changes to become FCC iron?
At what temperature does BCC iron undergo allotropic changes to become FCC iron?
What structure does pure iron exist in at room temperature?
What structure does pure iron exist in at room temperature?
What is the point at which necking occurs in a material?
What is the point at which necking occurs in a material?
Which form of iron is known as austenite?
Which form of iron is known as austenite?
What does the right vertical axis of the Iron carbon equilibrium diagram represent?
What does the right vertical axis of the Iron carbon equilibrium diagram represent?
How does fracture strength differ from ultimate tensile strength?
How does fracture strength differ from ultimate tensile strength?
What is the maximum amount of carbon that can be added to molten iron before it becomes saturated?
What is the maximum amount of carbon that can be added to molten iron before it becomes saturated?
Which phase of iron has a maximum solid solubility of 0.025% carbon at 727 degrees Celsius?
Which phase of iron has a maximum solid solubility of 0.025% carbon at 727 degrees Celsius?
Austenite has which of the following characteristics?
Austenite has which of the following characteristics?
What phase of iron is considered the hardest structure on the Fe-C diagram?
What phase of iron is considered the hardest structure on the Fe-C diagram?
Which phase forms when austenite containing exactly 0.83% carbon is cooled very slowly below 727 degrees Celsius?
Which phase forms when austenite containing exactly 0.83% carbon is cooled very slowly below 727 degrees Celsius?
What is the solid solubility of carbon in δ-Ferrite at its maximum temperature of 1495 degrees Celsius?
What is the solid solubility of carbon in δ-Ferrite at its maximum temperature of 1495 degrees Celsius?
What is the crystal structure of Cementite?
What is the crystal structure of Cementite?
Ledeburite is formed from a mixture of which two phases?
Ledeburite is formed from a mixture of which two phases?
Which phase is described as having a fingerprint-like appearance?
Which phase is described as having a fingerprint-like appearance?
What happens to the structure of austenite at 1394 degrees Celsius?
What happens to the structure of austenite at 1394 degrees Celsius?
Flashcards
Ductility
Ductility
The ability of a material to undergo permanent deformation without breaking. It's measured by how much the material stretches before it fractures. Higher ductility means more stretch.
Yield Strength
Yield Strength
The stress at which a material begins to permanently deform. It's a measure of how much force a material can withstand before it starts to change shape permanently.
Tensile Test
Tensile Test
A type of test that measures the strength of a material by subjecting it to a pulling force. It provides information about yield strength, ultimate tensile strength, and ductility.
Shear Test
Shear Test
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Impact Test
Impact Test
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Hardness Test
Hardness Test
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Compression Test
Compression Test
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Bending Test
Bending Test
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Steel Blooms for Forging Axles
Steel Blooms for Forging Axles
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Forging Hammers
Forging Hammers
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Malleability
Malleability
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Ultimate Tensile Strength
Ultimate Tensile Strength
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Fracture Strength
Fracture Strength
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Toughness
Toughness
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Allotropy
Allotropy
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Ferrite (α-iron)
Ferrite (α-iron)
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Austenite (γ-iron)
Austenite (γ-iron)
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δ-Ferrite
δ-Ferrite
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Iron-Carbon Equilibrium Diagram
Iron-Carbon Equilibrium Diagram
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Elasticity
Elasticity
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Austenite
Austenite
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Cementite (Iron Carbide)
Cementite (Iron Carbide)
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Pearlite
Pearlite
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Ledeburite
Ledeburite
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Carbon Saturation Point in Molten Iron
Carbon Saturation Point in Molten Iron
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Pearlitic Transformation
Pearlitic Transformation
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Equilibrium Cooling
Equilibrium Cooling
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Fe-C Equilibrium Diagram
Fe-C Equilibrium Diagram
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Study Notes
Consumables Used in Axle Shop
- Consumables used in Rail Wheel Factory are required from multiple suppliers
- Specifications are provided to help suppliers develop and supply to RWF
- Steel Blooms for forging Diesel/Electric locomotives and EMU driving axles:
- Manufactured using basic electric arc furnace or other approved processes
- Steel must meet requirements from IRS R 43 and IRS R 16
- Hydrogen and nitrogen content must be analyzed using standard LECO analyzers
- Forging Hammers:
- Used to forge steel axles and armature shafts
- Made from DIN 56NiCrMoV7 steel, quenched and tempered to 34 HRC
- Reclamation process documentation is required and made available to inspecting officials
Properties of Materials
- Materials are characterized by various properties
- Mechanical properties are evaluated and compared using tests
- Popular tests include tensile tests, compression tests, shear tests, hardness tests, impact tests, and bending tests
- Tensile tests provide the most comprehensive information about mechanical properties
Mechanical Properties (Tensile Tests)
- Yield Strength: Stress at which plastic deformation begins without significant load increase
- Ultimate Stress: Highest stress the material can withstand before failure
- Yield Stress: Stress at which the material starts to deform permanently
- Proportional Limit: Stress limit where stress and strain are directly proportional
- Fracture: Point of material failure
- Necking: Reduction in cross-sectional area of the specimen at the point of failure
- Linear region /Plasticity or yielding: region where stress and strain are linearly related
- Perfect hardening: Region where the specimen continues to deform plastically without any noticeable increase in strength
Ductility
- Ability of a material to undergo plastic deformation under tensile load
- Measured by percentage elongation: ((L-Lâ‚€)/Lâ‚€) *100, Where L = length after test, Lâ‚€ = Original length
Malleability
- Ability of a material to undergo plastic deformation under compressive load
Ultimate Tensile Strength
- Maximum stress a material can withstand before failure
- Calculated as (Ultimate load / Original cross-sectional area)
Fracture Strength
- Stress at the point of material failure
- Calculated as (Fracture load / Original cross-sectional area)
Toughness
- Material's ability to withstand both elastic and plastic deformation before failure
- Higher toughness indicates the material can absorb more energy before fracture
Iron-Carbon Equilibrium Diagram
- Study of the constitution and structure of steels and irons
- Iron exhibits allotropy (exists in multiple crystal structures at different temperatures)
- Different phases of iron and carbon at varying temperatures and compositions are detailed on the diagram
Phases in the Iron-Carbon System
- Alpha ferrite, Austenite, Delta ferrite, Cementite, Pearlite, and Ledeburite are explained
- Their properties and structures are described.
- Solid solubility of carbon is discussed for each phase at various temperatures.
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