Numerical modeling and optimization on micro‐D electrical connector

Micro-D electrical connectors are extremely crucial, highly reliable industrial devices in the fields of aerospace, military, and medicine. The geometry and size of the twisted wire contacts of micro-D electrical connector are vital for its mechanical properties and structural stability. In this investigation, dynamics modeling, numerical simulation and experimental tests of the insertion-extraction processes were applied on the twisted wire contacts of micro-D electrical connector. The computer aided design and engineering (CAD-CAE) parameterized models of the twisted-wire contacts were developed, and the theoretical models were also built on the basis of the mechanics of the materials. Nonlinear dynamics simulation was performed by ANSYS/LS-DYNA finite element software to analyze the force and stress distribution of the insertion-extraction processes. The results showed that the insertion force (~0.34 N) was higher than the extraction force (~0.32 N), and the stress concentration occurred on the clamping end and the convex hull of the pin. The mechanical model and numerical simulation were then verified by the experimental tests. By the orthogonal test and the sequential quadratic programming optimization method, the insertion-extraction forces could be reduced to obtain the optimal contacts structural parameters. This theoretical study will help researchers in the design, manufacture, and employment of micro-D electrical connectors.