Fretting wear behavior of brass/copper-graphite composites as a contactor material under electrical contact

Liu, Xin-long; Cai, Zhenbing; Xiao, Qian; Shen, Mingxue; Yang, Wenbin; Chen, Dao-yun

doi:10.1016/j.ijmecsci.2020.105703

Cited by 31 publications

(5 citation statements)

References 31 publications

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“…It is noted that the validation does not include the effect of material wear. These ECR results are quite small compared with electrical contact experimental results [14,16,[39][40][41]. In the electrical contact experiments of copper material, the ECR gradually increased to 0.1 Ω within 10,000 fretting cycles [14,16].…”

Section: Comparison With Experimental Fretting Wear Profilementioning

confidence: 77%

Numerical Study of Coupled Electrical-Thermal-Mechanical-Wear Behavior in Electrical Contacts

Shen

2021

Metals

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Electrical contacts involve complicated electrical, thermal, and mechanical phenomena. Fretting wear as a surface damage mechanism significantly weakens the performance of electrical contact components. In this study, a numerical approach is developed to investigate the electrical-thermal-mechanical-wear coupling behavior of electrical contacts. An electrical contact conductance law is used with the current conservation model to evaluate the electrical behavior. A transient heat transfer model, including the Joule heating behavior and a thermal contact conductance law, is employed to calculate the temperature field. Both contact conductance laws are related to the contact pressure distribution obtained by the contact stress analysis. Based on the predicted contact stress and relative slip on contact surfaces, the energy wear model is used to study the evolution of fretting wear depth and contact surface geometry. The material properties in these models are temperature-dependent. The proposed numerical approach is implemented in a finite element modeling of electrical contacts, which is validated by comparing the predicted and experimental results of the wear scar profile. The effects of the fretting wear on the electric potential, current density, contact resistance, temperature, and contact pressure are numerically studied.

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Section: Comparison With Experimental Fretting Wear Profilementioning

confidence: 77%

Numerical Study of Coupled Electrical-Thermal-Mechanical-Wear Behavior in Electrical Contacts

Shen

2021

Metals

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“…Typically, component conductivity is judged by contact resistance [3] . The existence of contact resistance results in a local high temperature when current passes through two conductors' electrical contacts; thus, changes in contact resistance directly reflect component conductive performance [4] [5] . Contact resistance variation usually relates to the sum of many small raised areas that form a bump's total area.…”

Section: Introductionmentioning

confidence: 99%

Research on electrical contact performance based on machine vision

Li,

Ou,

You

et al. 2024

International Conference on Algorithm, Imaging Processing, and Machine Vision (AIPMV 2023)

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The electrical connection serves as a vital and abundant link in power, electronic equipment, and systems, with the electrical contact acting as its core component. In practical working conditions, fretting wear occurs during the usage of electrical contacts, leading to surface destruction and a decline in their performance. Determining the degree of wear on electrical contacts is crucial for assessing their failure in engineering applications. This study focuses on conducting fretting wear tests on copper material under different cycles for electrical contacts while utilizing machine vision algorithms to detect the morphological characteristics of wear marks. Gray threshold segmentation is applied to extract texture features from wear marks after various oxidation conditions. Pseudocolorization techniques are employed to process extracted morphologies, followed by calculating their characteristic areas. Finally, combining these results with contact resistance curves allows for judging the electrical conductivity of the electrical contact under different cycles.

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“…Electrical connectors, as the carriers of signal and power between electronic equipment, are widely used in aerospace, industrial robots, electronic communications, etc 1–3 . According to previous studies, the reliability of electrical connectors is mainly influenced by their mechanical behavior and fatigue life, which directly affect the working performance of the whole equipment system 4–6 .…”

Section: Introductionmentioning

confidence: 99%

Numerical analysis on mechanical and fatigue behaviors of aviation electrical connector considering structural effect

Luo,

Wang,

Jiang

et al. 2023

Int J Numerical Modelling

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This work is motivated by the fact that the reliability of electrical connectors influenced by their mechanical behavior and fatigue life directly affects the working performance of the whole equipment system. In this paper, theoretical analyses of insertion force, maximum stress, and fatigue life in an aviation electrical connector are presented and the corresponding mathematical models are firstly derived. Then, to numerically investigate its mechanical behavior and fatigue life, a simplified 3D FE model is developed by using ABAQUS and FE‐SAFE software and verified by experiments and theoretical analysis. Finally, the distribution and evolution characteristics of contact forces, stress and fatigue life considering the influences of reed thickness and slot width are quantitatively analyzed in details. The results indicate that the insertion force first increases and then stabilizes at the level of 0.16 N as the pin head is fully inserted into the jack, which shows an opposite to the evolution of extraction force. Moreover, the maximum value of stress and the minimum value of fatigue life are all located at the root of the jack reed. Besides, unlike the small effect of slot width, the Fimax and σmax values obviously increase and the Nf value decreases with the increment of reed thickness.

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Fretting wear behavior of brass/copper-graphite composites as a contactor material under electrical contact

Cited by 31 publications

References 31 publications

Numerical Study of Coupled Electrical-Thermal-Mechanical-Wear Behavior in Electrical Contacts

Numerical Study of Coupled Electrical-Thermal-Mechanical-Wear Behavior in Electrical Contacts

Research on electrical contact performance based on machine vision

Numerical analysis on mechanical and fatigue behaviors of aviation electrical connector considering structural effect

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