Advertisement

Journal of Mechanical Science and Technology

, Volume 32, Issue 9, pp 4291–4297 | Cite as

Application of electromagnetic forming in terminal crimping using different types of field shapers

  • Ashish K. Rajak
  • Sachin D. Kore
Article
  • 33 Downloads

Abstract

Mechanical crimping is the most used method of pressure connection for permanent electrical contact in electrical and electronic equipment. Terminal plastic deformation on multi-wire strands is carried out to achieve mechanical strength and electrical conductivity. Electromagnetic (EM) is assumed to be an alternative method to overcome the challenges of spring back in the terminal on tool relaxation, cracks, non-uniform deformation, reduced strength, decreased the durability of joints in conventional crimping tool. Implementation of the field shaper (FS) has been proposed to enhance the magnetic field to concentrate the magnetic pressure at the required location for the effective terminal crimping over the wire strands. In this work, crimping was carried out using FS as a tool. Experiments were carried out utilizing tapered FS, single step FS and double step FS on aluminum terminal over seven strands aluminum wire strands that are commercially utilized for making interconnections. Results like contact length, contact resistance, terminal deformation, surface hardness, cross-section hardness and pull-out tests were found out and compared simultaneously. Also, the test results were compared with the samples crimped using a conventional crimping tool. From the results single step FS was found to be the most efficient FS than double step FS whereas the tapered FS was the least efficient. The results will be helpful in determining the geometry for the field shapers in similar applications.

Keywords

Electromagnetic (EM) Field shaper (FS) Wire crimping Terminal 

Preview

Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.

References

  1. [1]
    K. Mocellin and M. Petitprez, Experimental and numerical analysis of electrical contact crimping to predict mechanical strength, Procedia Engineering, 81 (2014) 2018–2023.CrossRefGoogle Scholar
  2. [2]
    A. K. Rajak and S. D. Kore, Experimental investigation of aluminium-copper wire crimping with electromagnetic process: Its advantages over conventional process, Journal of Manufacturing Processes, 26 (2017) 57–66.CrossRefGoogle Scholar
  3. [3]
    D. V. Zhmurkin, N. E. Corman, C. D. Copper and R. D. Hilty, 3-Dimensional numerical simulation of open-Barrel crimping process, Electrical Contacts, Proceedings of the Annual Holm Conference on Electrical Contacts (2008) 178–184.Google Scholar
  4. [4]
    V. Psyk, D. Risch, B. L. Kinsey, A. E. Tekkaya and M. Kleiner, Electromagnetic forming-A review, Journal of Materials Processing Technology, 211 (2011) 787–829.CrossRefGoogle Scholar
  5. [5]
    H. Yu, C. Li, Z. Zhao and Z. Li, Effect of field shaper on magnetic pressure in electromagnetic forming, Journal of Materials Processing Technology, 168 (2005) 245–249.CrossRefGoogle Scholar
  6. [6]
    J. Cui, G. Sun, J. Xu, Z. Xu, X. Huang and G. Li, A study on the critical wall thickness of the inner tube for magnetic pulse welding of tubular Al-Fe parts, Journal of Materials Processing Technology, 227 (2016) 138–146.CrossRefGoogle Scholar
  7. [7]
    Y.-Y. Chu and R.-S. Lee, Effect of field shaper geometry on the Lorentz force for electromagnetic sheet impact forming process, Journal of Engineering Manufacture, Proceedings of the Institution of Mechanical Engineers Part B, 227 (2013) 324–332.CrossRefGoogle Scholar
  8. [8]
    R. Chaharmiri and A. F. Arezoodar, The effect of sequential coupling on radial displacement accuracy in electromagnetic inside-bead forming: simulation and experimental analysis using Maxwell and ABAQUS software, Journal of Mechanical Science and Technology, 30 (2016) 2005–2010.CrossRefGoogle Scholar
  9. [9]
    Y. B. Park, Design of joints for the automotive space frame with electromagnetic forming and adhesive bonding, Ph.D. Thesis, School of Mechanical and Aerospace Engineering, Seoul National University, Korea (2004).Google Scholar
  10. [10]
    H. Suzuki, M. Murata and H. Negishi, The effect of field shaper in electromagnetic tube bulging, Journal of Mechanical Working Technology, 15 (1987) 229–240.CrossRefGoogle Scholar
  11. [11]
    M. A. Bahmani, K. Niayesh and A. Karimi, 3D simulation of magnetic field distribution in electromagnetic forming systems with field-shaper, Journal of Materials Processing Technology, 209 (2009) 2295–2301.CrossRefGoogle Scholar
  12. [12]
    S. Golowin, M. Kamal, J. Shang, J. Portier, A. Din, G. S. Daehn, J. R. Bradley, K. E. Newman and S. Hatkevich, Application of a uniform pressure actuator for electromagnetic processing of sheet metal, Journal of Materials Engineering and Performance, 16 (2007) 455–460.CrossRefGoogle Scholar
  13. [13]
    T. Use, Standard test method for evaluation of crimped electrical connections to 16-gauge and smaller diameter stranded and solid conductors, ASTM International (2003).Google Scholar

Copyright information

© The Korean Society of Mechanical Engineers and Springer-Verlag GmbH Germany, part of Springer Nature 2018

Authors and Affiliations

  1. 1.Department of Mechanical EngineeringIndian Institute of TechnologyGuwahatiIndia

Personalised recommendations