Optimal design of a multi-ram forging mold for large-diameter valve bodies

HU Fusheng; ZHANG Lei; LIN Feng

doi:10.16511/j.cnki.qhdxxb.2016.22.026

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Journal of Tsinghua University(Science and Technology) ›› 2016, Vol. 56 ›› Issue (6) : 646-649,655. DOI: 10.16511/j.cnki.qhdxxb.2016.22.026

MECHANICAL ENGINEERING

Optimal design of a multi-ram forging mold for large-diameter valve bodies

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Abstract

Multi-ram forging is the main production process for large-diameter valves. However, premature cracking at the root of the punch and plastic deformation at the top of the punch are the main problems in the forging process with the punches often having short service lives. This study analyzes the forging process, especially the irregular metal flow that creates offset loading forces on the punch, which leads to punch failures. The low thermal resistance causes the plastic deformation at the top of the punch. This analysis optimizes the metal flow during the forging through die optimization to reduce the stress concentrations at the punch root by changing the joint between the punch and the press. The FGH96 super alloy is used to improve the deformation resistance at high temperatures. Optimization of the fillet radius in the mold and smoothing of the punch surface reduce the stress concentration at the joint to effectively reduce cracking. The stresses at the top of the punch are below the yield strength with the FGH96 super alloy so plastic deformation does not occur at the top of the punch. A horizontal punch made to forge a 3 inch (7.62 cm) valve body works very well with no cracks or deformation at the punch top for 100 cycles. The punch service life is then much longer.

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multi-ram forging / valve body / punch / super alloy

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HU Fusheng, ZHANG Lei, LIN Feng. Optimal design of a multi-ram forging mold for large-diameter valve bodies[J]. Journal of Tsinghua University(Science and Technology). 2016, 56(6): 646-649,655 https://doi.org/10.16511/j.cnki.qhdxxb.2016.22.026

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