| Contact performance of the electric connector directly affects signal transmission. Failure of the connector will lead to aerospace electronic product breakdown, and even cause serious consequences, so it’s of great significance to study and optimize the connector. A certain type of radar connector has been researched: the connector pin forming process, the stress and force of pin insertion process. Pin insertion and extraction force optimization analysis has been executed in four stages.The corresponding 3D solid model and finite element model of pin, orifice plate, sleeve, pawl spring and pin seat have been built adopting parametric modeling technology before and after the forming process. Based on finite element model of pin and orifice plate before the forming process, the pin forming process has been studied according to boundary condition and load of the pin during the forming process. The result shows: in the first 0.2 seconds the pin was pressed by baffle producing convex hull, convex hull increased gradually, rigid plate moved back, pin rebounded, and convex hull formed. Von_Mises equivalent residual stress of the convex hull was about 200 MPa after pin formed.The finite element model of pin and sleeve were adopted to analyze the stress and the insertion force when the pin inserted into the sleeve at a speed of 1.7mm/s. The result of the analysis points out that the largest von_Mises stress of the pin occurred in 0.868 s, which is 984.266 MPa, and the maximum value appeared in the hinge right end; the maximum insertion force occurred in 0.5166 s, which is 0.5182 N, and contact force started to stabilize at 0.286 N from 0.84 s.Thirteen kinds of relative parameters on the pin insertion force were studied. The result reveals that insertion and extraction force increased with the increase of pin filament diameter, outer convex hull diameter, pin convex hull width, pin axiality tolerance, pin positional tolerance relative to the socket and pin outer diameter; decreased with the increase of pin outer pitch, distance from pin convex hull to plug, pin length and socket inner diameter; insertion and extraction velocity and pin inner pitch have little effect on insertion and extraction force.Influence of various parameters on the insertion and extraction force were determined by orthogonal experiment method, and the optimum value was found. The result shows: the influence value of the parameters on the extraction force was highest in convex hull width, followed by outer convex hull diameter, outer convex hull position, outer convex hull pitch, pin length and pin diameter. The optimum parameter combination is 1.60 mm, 0.70 mm, 1.20 mm, 2.80 mm, 2.40 mm, 5.00 mm and 0.42 mm.In order to study the influence of continuous insertion and inner hinge on the insertion force, the corresponding finite element model was established. Continuous insertion with different sleeve inner diameter was studied and insertion without inner hinge was analyzed. The result shows that the insertion force of one-time and three-times insertion are the same; if other parameters were constant, insertion force difference would be small with or without inner hinge.The force analysis result of insertion with pin seat shows that the sleeve pin axiality tolerance affects insertion force, and two pins insertion force is about two times larger than one pin insertion force. |
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