Modeling and Measuring of Relative Motion at Contact Point of Electrical Connector for the Prediction of Vibration-Induced Fretting Damage

Abstract

The relative motion at the contact interface induced by engine vibration is one of the most significant causes for the fretting damage. However, at present, several vibration simulations models have been investigated in literature to predict fretting degradation. Unfortunately, those finite element (FE) models do not take into account all the connector components (more than 10) with the cable, the non-linear mechanical contact and the prestress state of different components after assembled process. This paper describes and illustrates the approaches used for a three-dimensional FE modeling and vibration simulation of electrical connector to evaluate the relative displacement between the terminals at contact point, and when the fretting occurs. A series of experimental tests were also conducted to validate the simulation. A sinusoidal vibration with a single frequency and amplitude were applied to the connector system. It was demonstrated that, test and simulation presented similar results. Finally, an approach for predicting connector risk of fretting damage is established by combining the contacts endurance and relative motion at contact point and eventually quantify the threshold amplitude of fretting.