Abstract：Electrical connectors are critical components in electronic systems, enabling the conduction of electrical current and the transmission of signals. They are extensively used in various fields such as aerospace, telecommunications, computing, and the automotive industry. The reliability and stability of an entire system often depend on the performance of these connectors. Any failure may not only disrupt normal device operation but also result in severe equipment damage. Among known failure mechanisms, contact failure caused by inadequate insertion and extraction force accounts for a significant proportion. To address this issue, a general analytical formula for calculating insertion and extraction force was derived based on a cantilever beam model. This model was used to analyze the mechanical behavior and force variation during the insertion and extraction of the pin and socket components. A comprehensive understanding of the force distribution during these processes was established through this approach. Subsequently, a finite element model was developed for a specific type of electrical connector’s contact components. Simulation analyses were conducted to examine how the insertion and extraction force changes with displacement. These simulation results were then validated through controlled experimental tests. The findings indicate that the relative error between the theoretical predictions, simulation outputs, and experimental measurements remains below 8%. The strong agreement among these methods confirms the accuracy and applicability of the developed models. To fulfill practical engineering requirements and avoid excessive mechanical stress, the validated theoretical model was further applied to optimize the design parameters of the connector’s contact springs, with a particular focus on their length and thickness. A qualified design range was identified, effectively distinguishing safe and failure regions. This provides clear engineering boundaries for failure-resistant design and enhanced service life. Additionally, the outcomes offer valuable guidance for the structural optimization of contact components in electrical connectors, supporting enhanced performance, stability, and durability in demanding applications.
2025, Vol. 46 
