A Sophisticated Method of the Mechanical Design of Cable Accessories Focusing on Interface Contact Pressure

The most critical positions of a prefabricated cable accessory, from the electrical point of view, are the interfaces between the stress cone and its surroundings. Accordingly, the contact pressure on those interfaces needs to be carefully designed to assure both good dielectric strength and smooth installation of the stress cone. Nevertheless, since stress cones made from rubber are under large deformation after installation, their internal stress distribution is neither practical to measure directly by planting sensors, nor feasible to compute accurately with the conventional theory of linear structural mechanics. This paper presents one sophisticated method for computing the mechanical stress distribution in rubber stress cones of cable accessories by employing hyperelastic models in a computation model based on the finite element method. This method offers accurate results for rubber bodies of complex geometries and large deformations. Based on the method, a case study of a composite prefabricated termination for extruded cables is presented, and the sensitivity analysis is given as well.