Numerical and experimental study of open die forging process design for producing heavy valves

In this study, the finite element method was used to produce a Y-block valve with a weight of 2042 kg. To compare the new process with the traditional production process for this workpiece, both were simulated using finite element ABAQUS software. The viscoplastic properties of material were measured using a thermomechanical simulator (plasto-dilatometer),and then the two models were simulated in three dimensions, incorporating a fully coupled thermal stress analysis. The material flow, stress, strain and temperature distributions, dimensions of the original workpiece, and force required were compared via simulations. The new process was found to not only reduce the machining required but also increase the strength of the workpiece, reduce the force needed for forging, and allow the use of a smaller initial ingot. Finally, the new model was tested experimentally and a good match was found between the experimental and simulation results. The new introduced finite element model has potential applications in real production.

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