Differences in Forging Process for a Component Type "Convergent Venturi" Evaluated in Different Materials

A.Caracciolo, V.Baruffaldi
Officine Ambrogio Melesi

PURPOSAL: Convergent 20 "x 6" height 800 mm in material INC 800H
Object of study is the forging process of a component for convergent Venturi OIL & GAS, obtained by starting round section billet. Although of simple geometry, the product presents criticality and difficulty of the process for its thin thickness.
The use of the FEM has allowed to compare the behavior of the material flow during the process, comparing carbon steel and INC 800H. The thermal evolution of the material deformation is the major difference, consequently entailing a significant change in the behavior of the two materials.
The behavior of the two materials considered is different even comparing the strain rate, the analysis of the contacts and the correct filling of the die, the different thermal evolution involves variation of ductility and workability of the materials but also the press load. It was evaluated various geometric configurations and processes, with particular attention to the stability of the final forged product and the upper punch that appeared possible instability problems [peak loads], looking for process optimization and feasibility.
The FEM analysis has proved extremely robust and consistent with the experimental data measured during the real process, this approach has allowed to optimize the process of deformation minimizing the mass of material used (-20%) with consequent reduction of energy and total costs of production.