Computational Modeling of Electrical Contact Crimping and Mechanical Strength Analysis

Mocellin, Katia; Petitprez, Matthieu; Bouchard, Pierre‐Olivier; Desjean, Christophe

doi:10.1109/holm.2010.5619564

Cited by 6 publications

(2 citation statements)

References 7 publications

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“…The electrical sector was one of the first to use electromagnetic crimping. Swaging copper tubes to coaxial cables and connecting metal fittings to ceramic insulators are two examples [16]. The electrical resistance of magnetic pulse crimped cable connections is up to 50% lower than that of mechanical crimped connectors [17].…”

Section: Introductionmentioning

confidence: 99%

Experimental investigations on magnetic pulse crimping of copper lug

et al. 2023

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One of the most complicated issues in the production of electronic circuit boards, vehicles, aircraft, satellite, and communication components is the crimping of electrical wires to produce a secure connection. Furthermore, terminal crimping is crucial to the safe transmission of electricity; improper crimping causes difficulties like overheating of the plug, power loss, arcing, and mechanical connection failure. Magnetic pulse crimping has the ability to effectively address these difficulties. Magnetic pulse crimping is a non-contact technique creating a uniform pressure without any tool marks on lugs. This technique has better compression of conducting metal wires strands inside the lug and also has less voids compared to conventional mechanical crimping techniques. In this technique the pulsed magnetic field is generated inside the electromagnetic coil by the discharge of capacitor bank current. This magnetic field applies uniform pressure across the circumference of lug and crimp it with cable. Significant improvements in leak rate in magnetically crimped lugs is seem compared to mechanically crimped 120 sq mm copper lugs. This technique also reduces the contact resistance and ultimately the temperature during operation in electrical system.

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Section: Introductionmentioning

confidence: 99%

Experimental investigations on magnetic pulse crimping of copper lug

et al. 2023

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“…Multi domain computations are performed using a penalty formulation for contact equations with a master/slave algorithm [5]. K. Mocellin et al [6] performed a simulation study on the crimping process and the mechanical holding of crimped contacts. In this article, the copper rheological parameters are gathered from a database, for both contact and wire.…”

Section: Introductionmentioning

confidence: 99%

Numerical Study of a Crimped Assembly Mechanical Strength

Petitprez

Mocellin

2013

KEM

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Electrical contact crimping is a mechanical fastening process commonly used in aeronautical and aero spatial applications. In order to ensure the perfect electrical conduction and acceptable mechanical properties, the assembly have to fullfil some drastic holding force criteria. This outfit is directly dependent on the indentation depth at the end of crimping. The feedback generally reveals that an over crimping will lead to the cable breakage whereas an under crimping will be characterized by the cable sliding into the contact during pulling. The optimal behavior is a combinaison of both phenomena : the cable must become thinner before slipping into the contact. Numerical simulation is an efficient tool to limit the tedious experimental tests. It is the main topic of our work. This paper deals with prediction of the failure type and the force level required to tear out a contact crimped on multistrand cable for different indentation depths. The determination of optimal crimping condition is determined. In order to simulate the contact tensile test, crimping simulation has to be performed. The first step is then to be able to simulate accurately the crimping stage by using appropriate behavior laws and realistic conditions. One difficulty is linked to the small size of our objects. The first one is a 19 strands cable, in which each strand is about 0.15 mm diameter. The second sample is a 1 mm diameter cylindrical copper contact measuring 7 mm long. Adapted testing devices are described. Geometries and mechanical fields are obtained and then exported in the mechanical holding model to ensure realistic prediction [1]. Impact of crimping conditions on the pulling results is discussed. Pulling simulation results are compared to experimental values. The prediction of breakage mechanisms is also studied. Keywords: Crimping process, mechanical fastening operation, finite element computations, mechanical strength, breakout force, tensile test. [1] Fayolle, S., 2008, Etude de la modélisation de la pose et de la tenue mécanique des assemblages par déformation plastique : application au rivetage auto poinçonneur, Thèse de l'Ecole des Mines de Paris.

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Mathematical model for the tensile strength of the crimping assembly of aviation wiring harness end

Пин

Liu

Fan

et al. 2021

Sci Rep

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In this study, the relationship between the tensile strength and the indentation depth was studied by analysing the deformation mechanism of the crimping assembly of the aviation wiring harness end. Tensile strength tests were performed on samples of crimping assemblies with different indentation depths. The results showed that the experimental and theoretical values were in good agreement, verifying the validity of the established mathematical model for tensile strength. Based on this model, a reasonable design range for the indentation depth corresponding to the specific combination of contacts and strands was determined.

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Computational Modeling of Electrical Contact Crimping and Mechanical Strength Analysis

Cited by 6 publications

References 7 publications

Experimental investigations on magnetic pulse crimping of copper lug

Experimental investigations on magnetic pulse crimping of copper lug

Numerical Study of a Crimped Assembly Mechanical Strength

Mathematical model for the tensile strength of the crimping assembly of aviation wiring harness end

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