| Electronic Connectors are basic parts that support IT products more effectively play its leading role in this information society. For various reasons, there are many problems in manufacturing high-performance electronic connector products in the conventional approach, which seriously constrained the expansion of production capacity. These problems are: First, the old process of producing electronic connectors cannot meet the requirement of high quality. Moreover, the old production process requires two sets of molds and dies, which requires higher fixed investment costs, and prolongs the product production process. Besides, the old system can not meet the standard to save energy, raw materials and reduce the cost further.In response, this thesis is to develop a kind of new process, namely, stamping process of square needle parts of electronic connectors with multi-way parallel co-feeding to replace the old process. Work undertaken and finished in this thesis includes:Initially, combined with the classical Hertz contact theory, the contact existing in electronic connector interference assembly process is analyzed in this thesis. Moreover, this thesis puts forward the shrapnel model of mechanical analysis on electronic connectors'assembly. The result from the analysis can be used to calculate the radius of Hertz contact in the contact surface, the compression and the peak contact stress. Thirdly, the thesis establishes a FEM model based on ABAQUS simulation, together with an orthogonal simulation test, which is used to optimize the assembly structure. Fourth, the concept of multi-way parallel co-feeding metal stamping process, was proposed and explained in this thesis in depth. Besides, it is the first time the concept of single-step in-mold assembly (IMA) and progressive IMA are prompted. Lastly, a new guideline, namely C1B4, which feeds in two directions is developed for the production of electronic connectors.
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