Modeling and Measuring of Relative Motion at Contact Point of Electrical Connector for the Prediction of Vibration-Induced Fretting Damage

The relative motion at the contact interface induced by engine vibration is one of the most significant causes of fretting damage. However, at present, several vibration simulation models have been investigated in literature to predict fretting degradation. Unfortunately, those finite element (FE) models do not take into account all the connector components (more than 10) with the cable, the non-linear mechanical contact, and the prestress state of different components after the assembled process. This article describes and illustrates the approaches used for 3-D FE modeling and vibration simulation of electrical connectors to evaluate the relative displacement between the terminals at contact point, and when the fretting occurs. A series of experimental tests were also conducted to validate the simulation. A sinusoidal vibration with a single frequency and amplitude was applied to the connector system. It was demonstrated that the test and simulation presented similar results. Finally, an approach for predicting the connector risk of fretting damage is established by combining the contact endurance and relative motion at the contact point and eventually quantifying the threshold amplitude of fretting.