Abstract: Deformation measurement and integrity evaluation of the frame are vital for normal running of the heavy hydraulic press with steel wire wound. The full-field deformation measurement of the frame is realized hardly due to the limitations of the conventional testing method. By using the digital image correlation method(DIC), the full-field measurements of the deformation for the frame are performed for the loading-unloading cycles of the 400 MN die forging press. Cooling method is employed for simulating the pre-stress of the wound wire and then finite element method(FEM) simulations are performed for the pre-stressed and the combined loading cases of the frame. The FEM results agree well with the DIC experimental data, which verifies the validities of the FEM modelling. Researches on the frame deformation during the working cycles show that the deformation of the frame is basically symmetrical. The maximum changes of the horizontal spacing A2D2 and the vertical spacing A1A3 are 5.45 mm and 1.53 mm respectively which meets the design requirement. The DIC method is used to effectively solve the problem of the full-field deformation measurement of the frame of the heavy hydraulic press, verify the FEM modeling of the frame and provide the beneficial reference for the design of the heavy hydraulic press with steel wire wound.

Key words: cooling method, deformation measurement, digital image correlation(DIC), finite element method(FEM), hydraulic press