This work is motivated by the fact that the reliability of electrical connectors influenced by their mechanical behavior and fatigue life directly affects the working performance of the whole equipment system. In this paper, theoretical analyses of insertion force, maximum stress, and fatigue life in an aviation electrical connector are presented and the corresponding mathematical models are firstly derived. Then, to numerically investigate its mechanical behavior and fatigue life, a simplified 3D FE model is developed by using ABAQUS and FE-SAFE software and verified by experiments and theoretical analysis. Finally, the distribution and evolution characteristics of contact forces, stress and fatigue life considering the influences of reed thickness and slot width are quantitatively analyzed in details. The results indicate that the insertion force first increases and then stabilizes at the level of 0.16 N as the pin head is fully inserted into the jack, which shows an opposite to the evolution of extraction force. Moreover, the maximum value of stress and the minimum value of fatigue life are all located at the root of the jack reed. Besides, unlike the small effect of slot width, the F_imax and σ_max values obviously increase and the N_f value decreases with the increment of reed thickness.

中文翻译：

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考虑结构效应的航空电连接器力学与疲劳行为数值分析

这项工作的动机是电连接器的可靠性受其机械行为和疲劳寿命的影响，直接影响整个设备系统的工作性能。本文对航空电连接器的插拔力、最大应力和疲劳寿命进行了理论分析，并首先推导了相应的数学模型。然后，为了数值研究其力学行为和疲劳寿命，利用ABAQUS和FE-SAFE软件开发了简化的3D有限元模型，并通过实验和理论分析进行了验证。最后，详细定量分析了考虑簧片厚度和槽宽影响的接触力、应力和疲劳寿命的分布和演化特征。结果表明，当针头完全插入插孔时，插入力首先增加，然后稳定在 0.16 N 的水平，这与拔出力的演变相反。而且，应力的最大值和疲劳寿命的最小值均位于千斤顶簧片的根部。此外，与槽宽影响较小不同，随着筘片厚度的增加，F _{i max}和σ _max值明显增大，N _f值减小。