Monitoring and Simulation of Curing-Induced Residual Strain in Epoxy Core of Ultra-High-Voltage Bushing

The UHV dry-type bushing plays a critical role in power transmission by enabling electrical connection, electrical insulation, and mechanical support, making it a core component for ensuring the safe and stable operation of UHV direct current (DC) transmission projects. Epoxy resin, serving as the fundamental insulating material for the bushing core, undergoes significant residual strain during high-temperature curing due to chemical shrinkage and thermal strain, which directly affects the molding quality and service reliability of the component. This paper investigates the curing process of a large-thickness epoxy material, which is on the same scale as a UHV bushing. An in situ monitoring system combining fiber Bragg grating (FBG) sensors and thermocouples, together with COMSOL Multiphysics simulations, is employed to systematically study the evolution of the temperature field and residual strain throughout the entire curing process, considering the demolding effect. The results show that during the curing stage, the internal temperature distribution is non-uniform, with a maximum temperature difference of 65 °C between the center and the edge. The residual strain is dominated by chemical shrinkage (accounting for 73.25%) and exhibits a pronounced radial gradient. Mold constraint and demolding cause abrupt changes in the strain. The developed thermo-chemo-mechanical coupled model shows good agreement between simulations and experimental measurements. Thermal cycling relaxes the residual stress, achieving a reduction of 3.89–5.77%. This study provides support for process optimization and defect prevention in large-scale epoxy insulation components.