The closed-die multi-directional forging press for three-way valve bodies employs a coordinated multi-cylinder configuration comprising a vertical main cylinder, dual horizontal extrusion cylinders, a vertical piercing cylinder, dual horizontal piercing cylinders, and an ejection cylinder. The billet is placed within a closed die cavity, enabling multi-directional extrusion and simultaneous piercing. The forging is produced in a single operation with virtually no flash. It is suitable for manufacturing large-scale, high-pressure valve body forgings for the petrochemical, hydrogenation, and pipeline sectors.

The forging process utilizes vertical flow-splitting to facilitate material flow within the die cavity. The horizontal piercing cylinders feature a “cylinder-within-a-cylinder” design, ensuring a compact structure and concentrated pressure. The oil supply lines for the piercing cylinders utilize a hollow piston rod design, eliminating the need for flexible hose connections and thereby removing potential safety hazards.

Structure of Multi-directional Closed-die Forging Press for Three-way Valve Bodies

1) Machine Frame

Heavy-duty frame structure designed to withstand immense lateral extrusion loads and resist off-center loading. It accommodates the massive lateral forces generated by the high-tonnage (5000T × 2) dual horizontal cylinders. The large daylight opening between platens accommodates large valve body molds and hot forging billets.

• Distance between upper and lower platens: 3200 mm
• Distance between left and right push plates: 2200 mm
• Horizontal cylinder centerline height: 660 mm

2) Cylinder Configuration

1. Main cylinder (vertical clamping cylinder): 3000T. Performs mold closing and locking, seals the mold cavity, and withstands the forging clamping force.
2. Vertical piercing cylinder: 1500T. Performs vertical piercing to form the main through-bore of the valve body.
3. Horizontal extrusion cylinders: 5000T × 2 (one set each on left and right). Performs bidirectional lateral extrusion to fill the branch ports on both sides of the tee. With a horizontal
4. cylinder tonnage exceeding that of the main cylinder, this model is ideal for large-diameter, thick-walled tees and applications involving high resistance during branch formation.
5. Horizontal piercing cylinders: 1500T × 2 (one set each on left and right). Performs synchronous lateral piercing to form the through-holes in the branch outlets.
6. Ejection cylinder: 50T. Handles forging demolding and part extraction.

Total motor power: 1080 kW. Features a high-flow, high-pressure cartridge valve hydraulic pump station to meet the demands of simultaneous multi-cylinder operation, pressure holding, and high-flow piercing.

3) Control System

PLC + touch screen with closed-loop servo-hydraulic control. Pressure, speed, dwell time, and stroke are independently programmable for each cylinder: main cylinder, vertical piercing cylinder, dual horizontal extrusion cylinders, and dual horizontal piercing cylinders. Stores multiple valve body process recipes.

Closed-loop displacement control ensures synchronization accuracy between the left and right horizontal cylinders, preventing uneven branch lengths and mold wear caused by off-center loading. Includes overload protection, cushioned pressure relief, and safety interlocks for hot forging operations.

Features of Multi-directional Closed-die Forging Press for Three-way Valve Bodies

• Horizontal cylinder increases speed, fast mold closing speed.
• The horizontal mold lock adopts the machine action of small cylinder mold closing and large cylinder pressurization, which can prevent damage to the positioning pin caused by asynchronization.
• Horizontal cylinder mold closing and vertical cylinder mold closing, electric movement-free switch.
• Pressure and position are controlled by imported sensors.
• The sliding block adopts a double safety valve setting to prevent the vertical perforated cylinder from being out of sync with the master cylinder and crushing the return cylinder.
• The four main cylinders are equipped with a flow distributing and collecting valve to prevent the sliding block tilt due to asynchrony.

Advantages of Multi-directional Closed-die Forging Press for Three-way Valve Bodies

1. Suitable for large-scale high-pressure valve bodies:

Equipped with 5,000-ton horizontal extrusion cylinders on both sides, the system delivers sufficient force to ensure complete material filling at the roots of thick-walled, large-bore tee branches. Multi-directional synchronous piercing maintains continuous, intact metal flow lines throughout the valve body channels, resulting in high flaw-detection pass rates. Ideal for the rigorous operating conditions of hydrogenation and high-pressure pipeline applications.

2. High material utilization:

Utilizes closed-die forging with virtually no flash, achieving a material utilization rate of 70–85%. This significantly reduces raw material consumption and the machining allowance required for subsequent processing.

3. Simplified process flow:

Combines die forging and multi-directional piercing in a single heating cycle, thereby reducing the number of heating steps and minimizing material loss due to high-temperature oxidation.

4. Processable materials:

Carbon steel, alloy steel, and stainless steel; supports both hot die forging and warm die forging processes.

Applications of Multi-directional Closed-die Forging Press for Three-way Valve Bodies

Multi-directional closed-die forging press for three-way valve bodies is suitable for large-diameter, thick-walled, high-pressure tee and cross valve body forgings.

• Oil & Gas Pipelines: Long-distance transmission pipelines; high-pressure tee and cross fittings for stations
• Hydrogenation & Coal Chemical Industry: High-pressure valve bodies for hydrogen service; process valve forgings for coal chemical applications
• Power Generation: Piping tees for supercritical thermal power units; high-pressure valve bodies
• High-Pressure Pumps & Valves: Gate, ball, and globe valve bodies; manifold and distribution fittings
• Wellhead & Heavy Industry: Multi-port valve bodies for Christmas trees; heavy-duty, multi-channel pressure-bearing forgings

Parameters of Multi-directional Closed-die Forging Press for Three-way Valve Bodies

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