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For the forming of branch pipe of nuclear power AP1000 main-pipe, a novel partial radial upset-extruding (PRUE) process was developed, which produces the branch pipe directly in the part of a pipe billet based on an extruding pipe billet. According to the PRUE process, a multi-ram forging die which could close dies vertically and upset-extruding the billet horizontally was designed. The structure includes die cavity structure, closing guide structure, mandrel structure, mandril structure and upset-extruding shafts, etc. The design of the above structures was presented in detail, and the stress and the distortion of the die cavity structure under the heavy load were analyzed by FEM. The experimental results from the reduced scale model show that the structure is applicable, and its strength and stiffness meet the requirement of experiments. The test parts are successfully extruded with the scale of 1 to 5 of carbon steel and stainless steel 316 LN, which can be the design foundation in the PRUE process of real size main-pipe.
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