Advanced Numerical Simulation of the Crimping Process of Electric Connectors

Abstract

Crimping is a classical technology process to ensure the electrical and the mechanical link between a wire and a connector. Numerical modelling of the process is helpful to choose and to optimize the dimensions of the crimping part of the connector. In this paper, we discuss a 2D simulation of the crimping process, using implicit and explicit finite element methods (ABAQUS/Standard and ABAQUS/Explicit) and we compare the results with experimental data from the industrial process of crimping (geometry, shape, surfaces and punch force). This non-linear problem involves large elasto-plastic strains and multiple contact conditions, with friction between the strands and the grip. One of the major difficulties of the simulation is due to the definition of all possible contact couples between strands. The explicit method is preferred for the modelling of multi-contact problems, in spite of the quasi-static process of crimping. Thus, some simulations with the implicit method have been performed to compare the results and tune the simulation parameters of the explicit approach (space and time discretization). Subsequently, parametric studies are performed to show the effect of the friction ratio or the position of the strands in the wire.