3-Dimensional Numerical Simulation of Open-Barrel Crimping Process

A study of an open-barrel crimping process of 7-stranded wire has been conducted using a full 3-dimensional non-linear explicit dynamic finite element model. 3D dynamic simulation of the crimping process allowed capturing parameters not available in commonly used 2D models, such as barrel and wire e...

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Bibliographic Details
Published in2008 Proceedings of the 54th IEEE Holm Conference on Electrical Contacts pp. 178 - 184
Main Authors Zhmurkin, D.V., Corman, N.E., Copper, C.D., Hilty, R.D.
Format Conference Proceeding
LanguageEnglish
Published IEEE 01.10.2008
Subjects
Adhesives
Conducting materials
Conductors
Copper
Crimping
Finite element methods
Geometry
Numerical simulation
Solid modeling
Wire
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Summary:A study of an open-barrel crimping process of 7-stranded wire has been conducted using a full 3-dimensional non-linear explicit dynamic finite element model. 3D dynamic simulation of the crimping process allowed capturing parameters not available in commonly used 2D models, such as barrel and wire extrusion, effect of serrations, and effect of crimper geometry. The model was validated using experimental results. Numerical results indicate that elastic springback of the crimp, upon release of the tool pressure after crimping, is an essential design parameter engineered into a reliable crimped termination. The springback behavior was confirmed experimentally using metallurgical cross sections of terminals treated to reduce adhesion between the wire and the terminal.
ISBN:1424419018
9781424419012
ISSN:1062-6808
2158-9992
DOI:10.1109/HOLM.2008.ECP.41