Research On Forming Process Optimization Of The Lower Anvil Of Heavy Forging Of Offshore Piling Hammer

In recent years,with the rapid development of offshore wind power,offshore platforms,offshore bridges and other offshore projects,the demand for offshore hydraulic piling hammers has exploded,while the harbor projects are increasingly developing in deep water and large scale,which also requires larger specifications of the impact energy of offshore hydraulic piling hammers.As a key structural component of marine hydraulic piling hammer equipment,the lower anvil of heavy forging is characterized by heavy weight,large size and large size difference,which not only bears huge impact force,but also transmits the impact force to a single pipe pile during operation,which puts high demands on the lower anvil,and now the demand for lower anvil forgings is increasing.This paper takes the lower anvil forging as the research object,and the main research content is to optimize the traditional forming process of the lower anvil forging,so as to improve the forming quality of the lower anvil forging and prolong its service life.First of all,in order to reduce the defects of shrinkage cavity,looseness and uneven composition in the lower anvil of heavy forgings,this paper adopts pure steel smelting technology and AP inverse segregation pouring process to control the foreign inclusions and harmful elements in steel,so as to ensure the purity and uniformity of steel ingots,and then obtain high-quality large steel ingots.According to the characteristics of several free forging methods,this paper selects WHF forging method to pre-forge large steel ingots,and determines the important forging and drawing process.When forging steel ingots are cooled,defects such as shrinkage cavity and looseness are produced,and the coarse grain structure is broken and high-quality formed blanks are processed.Secondly,the forming process of the traditional free forging process is analyzed.In this paper,a new process of die forging is proposed for the final forming of the lower anvil of heavy forgings,and the corresponding die is designed according to the characteristics of die forging.Compared with the traditional forming process,the optimized new process reduces one heat,which not only shortens the production cycle,but also reduces the emission of pollution.Then,through the finite element simulation and the method of combining theory with practice,the optimal blank size and reduction in the forming process of the lower anvil forging are found.It is found that the comprehensive performance of the formed blank is excellent when the height-diameter ratio of the formed blank is about 1.0.By comparing the forming processes of the two processes of the lower anvil through finite element simulation,it is found that the tire film forging process greatly reduces the machining allowance of the lower anvil forging,improves the material utilization rate and brings excellent surface quality.Finally,through the trial production,it is found that the anvil forging manufactured under the tire film forging process not only has excellent comprehensive mechanical properties,which fully meets the use requirements,but also reduces the production time,improves the material utilization rate by more than 22%,reduces the production cost and is more friendly to the environment.