Abstract As the successor of soldering, the press-fit electrical connection is more and more widely used on account of a number of advantages, such as fast assembly. However, in practice, some contact failures were found. Most of the failures are related to the force which the structure bears. Because of complex elastic-plastic deformation characteristic, analyzing the mechanical behavior of the press-fit is challenging. Some studies have been done on the assembly force behavior of the press-fit such as press in force. However, the stress behavior on the assembly is not clearly studied. In this paper, the mechanical behavior of a typical press-fit connector named as eye of needle (EON) was investigated based on finite element (FE) simulation. Firstly, FE models were established and verified. Then, basing on model analysis, the mechanical behaviors (mechanical stress, thermal stress, and contact force) of the EON were obtained, which makes it clear that the relationships between the EON's structural parameters and its work conditions. Finally, the long-term reliability of the EON connector under the stress relaxation and the thermal fatigue was evaluated, respectively. The FE models here are effective on analyzing the press-fit mechanical behavior, which can be adopted to help design and manufacture.

中文翻译：

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基于有限元仿真的压接连接器力学行为研究及其可靠性评估

摘要 压接式电连接作为焊接的后继者，由于具有组装速度快等诸多优点而得到越来越广泛的应用。然而，在实践中，发现了一些接触故障。大多数故障与结构承受的力有关。由于复杂的弹塑性变形特性，分析压配合的机械行为具有挑战性。已经对压配合的装配力行为进行了一些研究，例如压力。然而，组件上的应力行为并未得到明确研究。在本文中，基于有限元 (FE) 模拟研究了称为针眼 (EON) 的典型压接连接器的机械性能。首先，建立并验证有限元模型。然后，根据模型分析，获得了EON的力学行为（机械应力、热应力和接触力），明确了EON的结构参数与其工作条件之间的关系。最后，分别评估了 EON 连接器在应力松弛和热疲劳下的长期可靠性。此处的有限元模型可有效分析压配合力学行为，可用于帮助设计和制造。