Simulation Optimization Of Twist Contact Insertion Characteristics And Prediction Of The Insertion Life

With the rapid development of the aerospace technology, the performance of the electrical connector has been put forward higher requirements. Micro-D connector is widely used for its small size, dense contact point and reliable connection. Twist contact is the core component of the micro-D connector. Because of its complicated structure, the twist contact has been the key and difficult point in design of micro-D connector performance. Due to the lack of theoretical analysis in twist contact performance, the produced twist contact has the problem of poor reliability and low yield. It also cannot meet the increasing market demand, hindering the development of the micro-D connector process. Therefore, the further study on the performance of the twist contact is of practical significance.In this paper, the twist contact of the micro-D connector is used as the research object. Based on the analysis of many domestic and foreign research methods and results on electric connector’s insertion force and insertion life, this paper has studied the twist contact’s insertion characteristics and insertion life. By using the finite element simulation analysis and the sequential quadratic programming, the structure parameters of the twist pin has been optimal designed.As the twist pin has a special twisted spiral structure, the twist contact’s dynamic simulation process is more complex and difficult than general contact simulation. In this paper, the parametric model of the twist pin has been built, and the simulation analysis of the contact insertion process has also been made by using ANSYS/LS-DYNA. The simulation results shows that the maximum stress(1055 MPa) appears in the front end of the twist pin in the process of insertion, which is slightly greater than the yield strength of beryllium bronze material(1000 MPa). Compared with each other through the theoretical results, the simulation results and test results, the accuracy of the theoretical model and simulation model has been verified.On the basis of the simulation model, the research of the influence of the twist pin’s 7 structure parameters on the insertion force has been finished through the single variable analysis and orthogonal test analysis. Combined with the theoretical model,this paper carried out the optimization analysis of the twist pin’s structure parameters by the sequential quadratic programming method, getting the optimal values of the pin’s structure parameters.Based on the stress and strain results of the contact’s insertion process dynamic simulation, this paper predicted the insertion life of the twist contact by using nCode DesignLife. The results showed that the fatigue dangerous point mainly concentrated in the front and clamping position of the twist pin. Ignoring the environmental effects like temperature and vibration, the insertion life of twist pin is 822 times without the optimization of structure parameters. With the optimization of structure parameters, the insertion life of twist pin can increase to 1886 times. The optimum structural parameters of twist pin can improve reliability and insertion life of the contact, therefor, this paper’s research methods and results have the guiding significance for the design and production of the twist contact.