Open Die Forging Notching for BOP End Loss Reduction
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Solution Overview
Problem
Conventional open die forging methods for manufacturing blowout preventers (BOPs) result in significant material wastage, inefficient machining operations, and poor yield due to the formation of fish-tails and lack of near-net shape forming, leading to increased energy consumption and manufacturing costs.
Innovation Solution
The proposed solution involves an optimized open die forging process that includes notching and piercing operations to control material flow, minimizing end losses and incorporating these steps into the existing process of forming, cogging, cutting, and machining, with a focus on achieving a near-net shape before final machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional open die forging method is used, then large and critical components can be manufactured, but material wastage is significant (58% wastage, 42% utilization)
Solution Approach 1:
The patent applies preliminary action by performing notching at the ends of the ingot before the main forging operations. This preliminary shaping action prepares the material flow pattern in advance, preventing fish-tail formation during subsequent forging and enabling near-net-shape production, thereby significantly reducing material wastage from 58% to much lower levels.
Solution Approach 2:
The patent changes the geometric parameters of the ingot by introducing notches at the ends, which fundamentally alters the material flow characteristics during forging. This parameter change transforms the conventional forging process into a near-net-shape process, improving material utilization by controlling where the material flows and consolidates during deformation.
2Productivity
If conventional open die forging method is used, then components can be produced, but fish-tail formation occurs at the end shape
Solution Approach 1:
The notching operation is performed as a preliminary action before main forging to pre-condition the material flow. By removing material at the ends and creating notches, the process prevents the peripheral material from moving ahead of central material during forging, thereby eliminating fish-tail formation and improving end shape quality while maintaining production capability.
Solution Approach 2:
The patent applies the extraction principle by removing notches at the ends of the ingot before forging. This selective removal of material prevents the formation of fish-tails by ensuring that peripheral material does not protrude beyond central material during the forging process, thereby improving end shape quality.
3Ease of manufacture
If conventional open die forging method is used, then forging can be completed, but extensive machining operations are required
Solution Approach 1:
The notching operation is performed preliminarily to set up the material flow pattern that will enable near-net-shape forging. This preliminary action ensures that subsequent forging operations produce components closer to the final shape, thereby reducing the extent of machining required and the time associated with machining operations.
Solution Approach 2:
By changing the geometry through notching, the patent transforms the forging process into one that produces near-net-shape components. This parameter change reduces the discrepancy between forged and final dimensions, thereby reducing machining time while maintaining manufacturing simplicity.
4Productivity
If conventional open die forging method is used, then components can be manufactured, but energy consumption is high
Solution Approach 1:
The notching operation is performed preliminarily to optimize material flow, preventing defects like fish-tails that would require rework or additional processing. By establishing correct material flow patterns early, the process reduces energy-wasting operations and improves overall manufacturing efficiency, thereby reducing energy consumption per unit of output.
Solution Approach 2:
The geometric parameter changes introduced by notching create more efficient material flow during forging, reducing the energy required for deformation. The near-net-shape production also reduces subsequent machining energy requirements, thereby lowering total energy consumption while maintaining manufacturing output.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces material wastage, enhances material utilization, and improves the mechanical properties of BOPs by minimizing machining time and energy consumption while maintaining the desired strength and quality of the components.
Implementation Method 1
cogging said ingot wherein said notching and said cogging are carried out without formation of fishtails at the ends
Implementation Method 2
open die forging process which involves a step of notching, wherein a transverse notch is made near each end of the ingot before cogging said ingot
Data Source
AI summary
The invention discloses a process of manufacturing heavy and critical components such as a blowout preventer (BOP) with a combination of open die forging, piercing and machining process which results in to better material utilization and saving in the machining time. The forging process of the invention involves a step of notching, wherein a transverse notch is made near each end of the ingot before cogging said ingot. The invention allows development of safety and critical components with effective material utilisation.