Designing of field shaper for the electro-magnetic crimping process

Abstract

Design of a field shaper plays an essential role in the electromagnetic crimping process. It needs to be designed in such a manner that maximum magnetic field is concentrated at the active working zone. Simultaneously it is essential to take care of the mechanical strength of the field shaper so that the von Mises stress acting over the field shaper should always be lower than the strength of the material used for making field shaper. In this manuscript, numerical and experimental work is carried out in the variation of the effective height of the field shaper, to get the most suitable effective working zone height for maximum magnetic pressure acting over the workpiece. Research is carried out over the electrical interconnectors as an application, to achieve maximum crimping of the terminal over the wire strands. Results like the current density Von-Mises stress, magnetic field, Lorentz force, terminal deformation, and contact length are discussed in detail. These results will help to design a field shaper for different industrial applications.