Abstract: The pre-stress test is critical for steel wire wound process of heavy forging press. The structure of the moving beam of 400 MN aviation forging press is so complex that there is no distinct characteristics on the distribution of surface stress field, for which the stress test is a difficult problem. The absence of stress test brings much inconvenience for quality evaluation and control of the winding process. Therefore, in order to study the winding process of moving beam in detail, the finite element method (FEM) is used to study the characteristics of the stress field, and determine the radial and circumferential uniaxial stress regions on the moving beam surface. The strain gage test is also designed based on the FEM results to solve the pre-stress test problem. The FEM results agree well with the experimental results, it indicates that the quality of the winding process could satisfy the design requirement, and the test method based on FEM is feasible. The method could be extended to the stress test of other complex engineering structures.

Key words: Bumpy ridge, Finite element method (FEM), Forging press, Steel wire wound, Stress test