Fluid End Forging Geometry to Cut Machining Waste
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing manufacturing process for fluid end components in the oil and gas industry results in significant material wastage, inefficient machining, and poor utilization of material, leading to increased production time and compromised mechanical properties due to conventional open die forging and machining methods.
Innovation Solution
The optimization of fluid end component geometry and manufacturing process through a combination of open die and closed die forging, where non-assembly areas are left in an as-forged condition, reducing machining time and material input, and utilizing closed die forging to achieve near-net shape forging with continuous grain flow lines, followed by heat treatment and targeted machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional open die forging and machining methods are used, then the component can be manufactured with simple equipment, but material wastage increases to 66% and machining time increases
Solution Approach 1:
The patent applies preliminary action by performing closed die forging to create a near-net shape preform before final machining. This preliminary shaping operation establishes the basic geometry and grain flow patterns early in the process, reducing subsequent material removal requirements and machining time while maintaining manufacturing simplicity through standardized forging equipment
Solution Approach 2:
The patent changes the manufacturing parameters by transitioning from conventional open die forging to closed die forging with controlled deformation parameters. This parameter change enables near-net shape production with optimized material flow, reducing material wastage from 66% to significantly lower levels while maintaining ease of manufacture through established forging technology
2Manufacturing precision
If conventional machining is performed on all surfaces, then the component achieves required surface finish and dimensional accuracy, but machining time increases and productivity decreases
Solution Approach 1:
The patent applies local quality by differentiating surface treatment requirements across the component. Critical assembly surfaces receive precision machining to ensure proper fit and function, while non-critical external surfaces retain the as-forged condition with inherent good surface quality. This selective approach reduces machining time and increases productivity without compromising manufacturing precision where required
Solution Approach 2:
The patent applies partial action by performing machining only on necessary assembly surfaces rather than all surfaces. The as-forged surfaces provide adequate quality for non-assembly areas, allowing partial machining operations that significantly reduce machining time and increase productivity while maintaining required manufacturing precision for functional surfaces
3Ease of manufacture
If open die forging is used to create rectangular blank, then the manufacturing process is simple, but grain flow lines are not continuous along the contours of the fluid end
Solution Approach 1:
The patent applies preliminary action by using closed die forging to establish continuous grain flow lines along the contours during the preform creation stage. This preliminary shaping operation with controlled material flow patterns creates the desired grain structure before final machining, ensuring strength requirements are met while maintaining ease of manufacture through standard forging equipment and processes
Solution Approach 2:
The patent changes the forging parameters by transitioning from open die to closed die forging with controlled deformation conditions. This parameter change enables continuous grain flow along contours while maintaining ease of manufacture through established closed die forging technology, resolving the contradiction between manufacturing simplicity and structural integrity
4Quantity of substance
If high capacity equipment is used for material handling, then large rectangular blanks can be processed, but equipment cost and complexity increase
Solution Approach 1:
The patent applies preliminary action by performing closed die forging to create a near-net shape preform with reduced dimensions before final machining. This preliminary operation reduces the size of material that requires high-capacity handling equipment, thereby reducing equipment complexity and cost while still processing sufficient material quantity for the final component
Solution Approach 2:
The patent changes the material parameters by optimizing the input stock size and shape through closed die forging parameters. This parameter optimization reduces the dimensions and weight of intermediates requiring material handling, decreasing equipment complexity and cost while maintaining adequate material quantity for producing the final component
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 by 66% to 70%, significantly decreases machining time, and enhances mechanical and metallurgical properties by achieving 70-75% of the component's shape through forging and 25-30% through machining, with continuous grain flow lines along the contours.
Implementation Method 1
The optimization of fluid end component geometry and manufacturing process through a combination of open die and closed die forging
Implementation Method 2
followed by heat treatment and targeted machining
Data Source
AI summary
The present invention discloses a Fluid End and its manufacturing method. The conventional fluid end manufacturing methods involve machining of all surfaces. This demands more input stock for manufacturing process and a lot of material wastage during machining process. In the conventional processes involving open die forging followed by machining result into only about 34% utilization of material. In the present invention, fluid end component geometry is optimized. Assembly surfaces are machined whereas other or non-assembly surfaces are as-forged condition. The method of invention also results in significant reduction in machining time and chip removal. The present invention also discloses a process of manufacturing using a combination of open die and closed die forging, and machining. It involves the steps of cogging an ingot to form billet for closed die forging using open die forging, forging the billet in closed die using forging equipment, semi-finish/rough/partial machining, heat treatment, drilling and finish machining the component. Most of the non-assembly areas of the fluid end are left in as-forged condition.