Quality Improvement for Crimping Process of Electrical Connector Using FEM Analysis

This paper covers finite element simulations to evaluate the terminal crimping process of automobile electrical connector. Crimping is a classical technology process to ensure the electrical and the mechanical link between a wire and a terminal. Numerical modeling 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 explicit finite element methods (ABAQUS/Explicit) and we compare the results with experimental data from the industrial process of crimping (crimping height, crimping width and compressibility). The explicit method is preferred for the modeling of multi-contact problems, in spite of the quasi-static process of crimping. As compared with CAE analysis, a performance improvement makes certain of the truth of the matter.