Insertion and Withdrawal Forces of Electrical Connectors Considering Wear
Electrical connectors widely used in electrical and electronic devices suffer from severe con-tact failure problems which determine the reliable service of these devices or even cause their destruction.The insertion and withdrawal forces are significant factors to evaluate the performance and quality of elec-trical connectors.The wear behavior due to the repeated insertion and withdrawal processes has a non-neg-ligible influence on the forces.Therefore,the forces and wear behavior are investigated in this paper.A simulation model is developed to study and evaluate the performance of electrical connectors.The finite el-ement method(FEM)is used to simulate the insertion and withdrawal processes and the wear profile of an electrical connector in the application.According to the development of the FEM model of the electrical connector,the equivalent insertion and withdrawal forces with and without the consideration of wear be-havior are calculated.Frictional behavior is used to study the insertion and withdrawal forces without con-sidering wear.In cooperation with the adaptive mesh technique of the commercial FEM software ABAQUS,the wear model based on frictional dissipation energy is applied to predict the wear morpholo-gy.The characteristics of the insertion and withdrawal procedure are analyzed using the forces vs.time curves.Furthermore,the wear profiles of the contact surface are obtained at different times of the inser-tion and withdrawal processes,and the effect of wear on the insertion and withdrawal forces of the electri-cal connector is discussed.The critical number of insertions and withdrawals leading to a larger wear depth is found.The size parameter of the contact component is modified to validate the conclusion of wear influ-ence.It is worth emphasizing that this study is significant to the failure problem of electrical connectors and provides a guideline for the production and application of electrical connectors.
electrical connectorwearinsertion and withdrawal forcesfinite element modeladap-tive mesh
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