Multi-directional Die Forging Forming Process and Grain Structure Evolution Prediction of Large High-pressure Valve Bodies

doi:10.3969/j.issn.1004-132X.2026.03.021

Abstract

Abstract:

A multi-directional die forging forming processes would proposed for a 7-15K large gate valve bodies made of 4130 steel， and the evolution of the internal microstructure of the forging processes was predicted by numerical simulation. Based on the true stress-strain data of 4130 steels， dynamic recrystallization volume fraction and grain size models were constructed， the reliability of these models was validated through comparisons between the model predictions and metallographic experimental measurements， the calibrated models were integrated into the finite element analysis software to simulate the multi-directional die forging processes of large high-pressure valve bodies. Based on the coupled analysis of temperature and strain fields， the evolution of microstructures in 4130 steel valve body was systematically investigated， and two different methods for evaluating the homogeneity of grain structure were proposed for the fully recrystallized and incompletely recrystallized regions. The results demonstrate that compared with conventional forging processes， the multi-directional die forging process may effectively enhance material plasticity， improve the mechanics properties of the forgings， and increase the uniformity of internal deformations.

Key words: large high-pressure valve body, 4130 steel, dynamic recrystallization, multi-directional die forging, grain structure evolution

摘要：

针对材质为4130钢的某7-15K大型闸阀阀体，提出了一种多向模锻成形工艺，并通过数值模拟预测了锻件内部组织的演变规律。基于4130钢的真应力-应变数据，构建了动态再结晶体积分数模型和晶粒尺寸模型，通过对比模型求解值与金相得到的试验数据，验证了模型的可靠性；将构建的模型集成至有限元分析软件中，对阀体的多向模锻成形过程进行了数值模拟。基于温度场和应变场的耦合分析，系统研究了4130钢阀体组织的演变规律，并针对完全再结晶区域和不完全再结晶区域提出了两种不同的晶粒组织均匀性评价方法。结果表明，与传统的锻造工艺相比，多向模锻成形工艺能够有效提高材料的塑性、锻件的力学性能和材料内部的变形均匀性。

关键词: 大型高压阀体, 4130钢, 动态再结晶, 多向模锻, 晶粒组织演变

CLC Number:

TG316.3

JIN Miao, QIN Rui, LI Wenyu JIN Miao, LI Xiaolong, LUO Linfeng, ZHANG Qingling. Multi-directional Die Forging Forming Process and Grain Structure Evolution Prediction of Large High-pressure Valve Bodies[J]. China Mechanical Engineering, 2026, 37(3): 717-725.

金淼, 秦锐, 李文玉, 金淼, 李小龙, 罗林丰, 张庆玲. 大型高压阀体多向模锻成形工艺及晶粒组织演变预测[J]. 中国机械工程, 2026, 37(3): 717-725.

Figures/Tables 31

Fig.1 3D model of the valve body

Fig.2 Valve body forming process diagram

Tab.1 Chemical compositions of 4130 steel for testing（mass fraction）

w（C）	w（Mn）	w（Si）	w（Cr）	w（Ni）	w（Mo）	w（Fe）
0.29	0.557	0.319	1.04	0.04	0.261	余量

Fig.3 Original microstructure of 4130 steel

Tab.2 The processing parameters of hot deformation

工艺条件	范围
温度/°C	850、1000、1100、1150、1200、1250
应变速率/s^-1	0.01、0.1、1、5
变形程度/%	60

Fig.4 Rheological stress curves under different conditions

Fig.5 Curve of work hardening rate and rheological stress

Fig.6 Critical strain under different conditions

Fig.7 Fitting curves under different deformation conditions

Tab. 3 Deformation conditions of the sampling

	变形温度/℃	应变速率/s^-1	应变
条件1	1150	0.1	1.2
条件2	1000	5	0.6
条件3	1100	5	1.2
条件4	1000	1	0.35

Fig.8 Grain structure under different conditions

Tab.4 Comparison of dynamic recrystallization parameters

		再结晶体积分数（%）	再结晶晶粒尺寸（μm）	残余原始晶粒尺寸（μm）	平均晶粒尺寸（μm）
条件1	模型求解值	100	68	0	68
条件1	实际测量值	100	65	0	65
条件2	模型求解值	12	14	91	81
条件2	实际测量值	11	16	93	84
条件3	模型求解值	100	31	0	31
条件3	实际测量值	100	32	0	32
条件4	模型求解值	1	7	94	92
条件4	实际测量值	1	9	89	85

Fig.9 Schematic diagram of formed valve body device

Fig.10 Finite element simulation model（1/4 model）

Fig.11 Multi-directional die forging forming of valve body

Fig.12 Metal flow line distribution in large valve body

Fig.13 Large valve body forming results

Fig.14 Temperature field of valve body forgings

Fig.15 Equivalent strain field of valve body forgings

Fig.16 Dynamic recrystallization volume fraction of formed parts

Fig.17 Residual original grain size of formed parts

Fig.18 Dynamic recrystallization grain size of formed parts

Fig.19 Average grain size of formed parts

Fig.20 Proportion of dynamic recrystallization volume fraction

Fig.21 Proportion of dynamic recrystallization grain size

Fig.22 Proportion of residual original grain size

Fig.23 Proportion of average grain size

Fig.24 Grain size distribution of large valve body forgings

Fig.25 Side flange point tracking position

Fig.26 Relationship curve between complete recrystallization zone nodes and grain size

Fig.27 Proportion of grain size grade

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