During injection forging, the ratio of axial and radial deformation of each section of billet in the diecavity prescribes the pattern of material-flow, thereby determining the scope of the process and the quality of the product. To date, research on the quantification of the pattern of material-flow has been superficial; the models which were used invariably referred to particular conditions. FE simulation and corresponding experimental analyses were conducted with a view to characterising the flow of material during Injection Forging of solid billets and enabling the definition of the practical process range and a proposal for an approach for the design of preforms to eliminate the development of flaws.

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