Analysis of insertion force of electric connector

based on FEM
Ying Li1 , Fulong Zhu1*, Yanming Chen2, Ke Duan1, Kai Tang1, Sheng Liu1
1. Institute of Microsystems, School of Mechanical Science and Engineering, HuaZhong University of Science and
Technology, 1037 Luoyu Road, Wuhan, Hubei province, 430074, P. R. China
2. Hubei Institute of Measurement and Testing Technology, No.2 Maodianshan middle road, Automotive Electronics
Industry Park, East Lake High-Tech development Zone, Wuhan, Hubei province,430223, P. R. China,
Phone: (0086-027)87557830-801. Fax: (0086-27) 87557074. Email: zhufulong@hust.edu.cn

Abstract-The paper investigates the insertion force and contact Usually, researchers do not pay sufficient attention to the
reliability of N electric connector. A finite element model (FEM) structure of electric connector. But so far, equip ment cannot
of the contacts was created and simulation of the contact force work well without reliable electric connectors. In addition, the
was completed by ANSYS. Impact of the friction coefficient, failure of contact pair of an electric connector has a negative
shrink range, length of socket, and groove width on the insertion effect on equipment performance [2, 3]. The structure of
force was analyzed by changing the structural parameters.
Variation curves of the insertion force for different structural contact pair plays the major role in imp roving the reliab ility of
parameters were studied. Simulation results showed that the electric connector. Scholars have made a lot of efforts in this
shrink range and length of socket have a great influence on the field. So me researchers have discussed the influences of
insertion force. In contrast, the friction coefficient and groove contact geometry on the reliability o f connection [4-8]. Leidner
width have a much smaller effect on the contact resistance of N presented a novel method to characterize the mechanical
electric connector. The optimized connector structure reduces the quality of electrical contacts [9]. Angadi et al. p roposed a
contact resistance and improves the contact reliability. method of considering rough surface contact [10].
The smaller contact resistance induces less electrical signal
I. INT RODUCTION lose. Contact resistance mainly depends on the contact force.
Insertion force is directly related to the contact force to some
Electric connector is a device for transmitting electrical extent. Insertion force is one of the important mechanical
signal in circuits by inserting and separating the contacts. With properties of contacts and, at the same time, it is convenient to
the development of science and technology, electronic devices estimate and measure. Although the increase of insertion force
have got wide application in electronic, aerospace, and other will decrease the contact resistance in certain range, the
industries fields. Meanwhile, the structure and category of contacts are close enough when the insertion force reached a
electronic devices are more and more co mplex. Polchow et al. certain value; after this the contact resistance will not decrease
introduced the application of electric connector in public obviously. In addition, an excessive insertion force will make
transportation [1]. The contact performance of electric wearing of the contacts faster and decrease life of electric
connector is directly related to whether the structure is connector. Quantitative analysis of contact resistance of
reasonable and reliab le or not. Therefo re, the performance and electric connector can be carried out by studying the insertion
reliability of electric connector have great effect on the quality force. Finally, we can find out the impact factors and improve
and reliab ility of electronic devices. Generally, the contact the electrical properties of electric connectors.
reliability depends on the design, technology, manufacturing,
and management of contacts. Fig. 1 shows some typical II. M ODEL A ND A NALYSIS M ETHOD
contacts of the slotted cylindrical electric connector.
A. Design Variables and Constants
In this paper, a typical N electric connector was selected as
the object. The contacts of N electric connector are made up of
the pin and socket. The socket consists of four grooves . A
simp le model of the N electric connector is shown in Fig. 2.

Fig. 1. Contacts of N electric connector Fig. 2. Geometric model of N electric connector

978-1-4799-3929-9/14/$31.00 2014
c IEEE 195
 The main structural parameters are L (length of socket) and
S (groove width). The value of L and S can be adjusted easily
changing the size parameter. L is 5mm and S is 0.4mm.
2R2 =2.0mm is the external diameter of socket, 2r2 =1.1mm is
the internal diameter of socket, 2R3 =1.0mm is the external
diameter of pin, and 2r3 =0.3mm is the internal diameter of pin.
The external diameter of pin (1.0mm) is smaller than the
internal diameter of socket (1.1mm) to avoid the fitting issues.
For a slot socket contact, the shell nosing treatment of contact Fig. 4. Boundary conditions used for N electric connector
piece is realized by mechanical means. Shell nosing decreases
the internal radius of socket (r2 ) and the initial value of shell The two contact samples are made of tin bronze alloys
nosing (ȝ) is 0.15mm. In this condition, an interference fit is whose properties are: the Modulus of Elasticity is 1.1E11Pa,
obtained and an insertion force that satisfies the national 0.33 is the Poisson’s Ratio. The FEM model was meshed with
standards can be achieved between the socket contact and pin 3-D 8-Node Structural Solid185 for Solid185 element is
contact. Fig. 3 illustrates the changes of socket after shell suitable for modeling general 3-D solid structures. The degrees
nosing treatment. The shrink range between the socket and pin of freedom are displacements UX, UY and UZ. Symmetric
is ı = R3  r2 + —. Different shrink ranges can be achieved by boundary conditions were applied on the symmetric surfaces of
changing ȝ. The friction coefficient can be adjusted by altering FEM model because of the symmetric structure of the FEM
the settings of finite element analysis. model. The contact surfaces of pin were defined as contact
surfaces, the contact surfaces of socket were target surfaces.
Contact surfaces were meshed with Contact174 elements and
target surfaces were meshed with Target170 elements. When
contact areas are not clear and a non-negligible sliding is
expected, this kind of surface-to-surface model is used [12, 13].
In order to simulate the real status of the contact, a friction
coefficient between the contact surface and target surface
(f=0.2) was defined.
The variation curves of insertion force were obtained. One of
friction coefficient, shrink range, length of socket and groove
width was changed while other parameters were kept the same,
and relationships between structural parameters and insertion
force were obtained. The effects of friction coefficient and
Fig. 3. Changes of socket after shell nosing treatment
shrink range, length of socket, groove width on insertion force
were studied by comparative method. The mechanical analysis
of contacts was accomplished and the theoretical value of
B. Finite Element Models
Three-Dimension Motion of electric connector was insertion force was calculated [14]. Comparing the theoretical
simulated with the finite element contact analysis method. values with the simulation values, we find the results of the two
calculation methods basically identical. Finally, the sensitivity
FEM is an effective method in simulating the real physics
system with the method of mathematical approximation. With of contact insertion force on different contact parameters was
the development of computer technologies and computational estimated.
methods, FEM has been widely applied in engineering design
and scientific fields. In this paper, a FEM model of electric III. RESULTS AND DISCUSSION
connector was constructed by ANSYS [11]. Only a quarter of
The distribution of Von Mises stress of N electric connector
the FEM model was meshed because of the symmetry of the
geometrical structure. The mechanical boundary and contact is shown in Fig. 5. Computational result of stress distribution
conditions were applied. Fig. 4 illustrates that all DOFs for showed that stress concentration existed at the root of socket.
The maximum stress was 368 MPa which has exceeded the
bottom of socket were constrained, and the UX and UY DOFs
of pin were constrained. In order to simulate the process of yield limit. However, the stress at root of the socket varied
inserting, the UZ was set at 1.5mm. In this simulation, the rapidly: only a small part of the socket had excessive stress, the
stress in most area of socket is in the specified limits.
applied displacement loading UZ was divided into a serious of
load increments. For nonlinear computation, the solution is Therefore, the N electric connector can work safely and
reached when the calculated force convergence norm is within steadily.
the defined force criterion.

196 2014 IEEE 21st International Symposium on the Physical and Failure Analysis of Integrated Circuits (IPFA)
 Fig. 5. The distribution of Von Mises stress of N electric connector
Fig. 7. Insertion force versus Insertion length under different friction
coefficient
Fig. 6 clearly showed the effect of the shrink range on the
insertion force. Change tendency of the insertion force for
To obtain the influence of length of socket on the insertion
different shrink ranges was almost equal. At the initial stage of
force, we selected different lengths of socket: 5.0mm, 5.25mm,
contact, there was a good linear relationship between shrink
5.5mm, 5.75mm, and 6.0mm for the transfer curves in Fig. 8.
range and insertion force. When the shrink range varied fro m
These curves share the same variation trend with the curves in
0.1mm to 0.15mm, the insertion force in steady state varied
Fig. 7. When the contact is stable, the curves indicated that
fro m 1.30N to 2.05N. The peak of the insertion length was
with the length of socket increasing fro m 5mm to 6mm, the
delayed at a larger shrin k range because of the larger deflection
insertion force decreases from 1.2N to 0.7N. The sensitivity of
of socket. Simu lation results have shown that the shrink range
insertion force to the length of socket was remarkab le.
has a significant impact on the reliability of electric connector
Fig.9 illustrated the change curves of insertion force under
contacts. Designers should choose an appropriate shrink range
different groove width. Like the curves above, the curves in
for their needs.
Fig. 9 consisted of linear exponential increase process, steep
Fig. 7 presented the relationship between insertion force
decrease process and stable process. But these curves in Fig. 9
under different friction coefficient and insertion length. At the
not only shared the same variation trend, but also had the
beginning of inserting, the insertion force increased sharply
almost same position. When the contact came to a steady state,
and reached the maximu m value of 2 N. There existed certain
although the groove width changed from 0.3mm to 0.4mm, the
linear relations between the insertion force and the insertion
value of insertion force varied a bit, moving fro m 1.48N to
length. When the contact came to a steady state, the insertion
1.27N. The groove width has the smallest influence among the
force decreased rapidly and remained constant because of the
four structural parameters. The friction coefficient, shrink
change of friction coefficient and insertion angle of connector.
range, and length of socket should be preferentially considered
The sensitivity to the friction coefficient is less than that to the
in design phase.
shrink range.

Fig. 6. Insertion force versus Insertion length under different shrink range Fig. 8. Insertion force versus Insertion length under different length of socket

2014 IEEE 21st International Symposium on the Physical and Failure Analysis of Integrated Circuits (IPFA) 197

Fig. 9. Insertion force versus Insertion length under different groove width
IV. CONCLUSIONS
The purpose of this paper was to research the effects of
different structural parameters on N electric connector in order
to improve the reliability of N electric connector. Mechanical
analysis of the insertion force and contacts has been carried out
using ANSYS. Sensitivity of in fluence on contact performance
caused by structural parameters of contacts was obtained.
Co mparison had been made between the results of the model
with different structural parameters. The key factors that
influence the contact performance were determined. The shrink
range and length of socket have a significant effect on the
insertion force. In contrast, friction coefficient and groove
width have a much smaller influence on contact performance
of electric connector. Increasing the shrink range or decreasing
the length of socket decreases the contact resistance and
improves the reliability of contact to some extent. The
numerical simu lation based on FEM made it possible to obtain
the optimal structural design.
Consequently, the optimal design of contacts has been
chosen in order to minimize the contact resistance. It can be
achieved by varying the follo wing parameters: shrink range
and length of socket.
A CKNOWLEDGMENT
This work is supported by the Aeronautical Science
Foundation of China for the Central Un iversities, HUST:
2013TS023. The authors would like to exp ress their sincere
gratitude to the supervisor, Mr. Wei Zhang, for his instructive
advices and useful suggestions.
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