Crimping technology is widely used for making interconnections for low, medium and high power distribution channels. The important problem which the current crimping industry is facing is spring back of terminals on the stress relaxation. Which is influencing the reliability of the electrical crimp connection. A unique type of solenoid coil with square groove geometry over the rectangular cross-section has been analyzed for wire crimping process. The FEM results are validated using experiments results. Numerical results indicated no spring back and uniform compression over the entire terminal which usually doesn’t occurs in conventional crimping process showing the advantage of this EM process. Validation are carried out using radial deformation and the metallurgical cross-section of the crimped terminal. A good agreement between the FEM and experimental results are found.
Higher contact resistance of conventional crimped samples.
Most (about 60%) of the problems in any circuits takes place in crimped region which leads to fires, loosening of crimped joint on thermal variation
Poor durability and a die contact process which decreases the fatigue life of any crimped joints.
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