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Fretting Analysis of Connector Terminals

As the number of circuits used in automobiles increases, larger force is required to mate connectors. The larger insertion force necessitates the use of an assembling robot, otherwise increasing the cost due to complicated structure of connectors. In order to reduce the cost, connectors with low insertion force are required. This may cause an increase in the fretting failure in electric contacts of terminals. The authors have developed a computational model based on cellular automata to simulate the contact failure. This model can calculate both the behavior of moving particles and chemical reactions simultaneously, which is difficult by the conventional FEM model. In experiments, the fretting probability depends on the contact pressure, slip distance, and surface conditions. The dependence of electric contact resistance on the slip cycle is calculated by this method. When the contact pressure is very high or the slip distance is very small, fretting is absent. The effects of contact materials and the thickness of plated metals are evaluated. The calculated electric contact resistance profiles of the electric contacts agree well with the experimental results.