Abstract Electrical connectors widely used in electrical and electronic devices suffer from severe contact failure problems, which is determined to the reliable service of these devices or even cases their destruction. In this paper, the finite element method is used to simulate the insertion and withdrawal processes of an electrical connector and the wear profile due to the repeated processes in the application. In cooperation with the adaptive mesh of the finite element software ABAQUS, the wear model based on the frictional dissipation energy is applied to predict the wear morphology. Based on the development of the FEM model of the electrical connector, the equivalent insertion and withdrawal forces with and without the consideration of wear are calculated. The wear profiles of the contact surface are obtained at different numbers of the insertion and withdrawal processes, and the effect of the wear on the insertion and withdrawal forces of the electrical connector is discussed.
Received: 21 February 2023
Published: 28 February 2024
2024, Vol. 45 
