配合误差对电连接器疲劳寿命影响的建模与评估

以某型电连接器通用接触件22^#插针插孔为研究对象，基于Brown-Miller修正准则，建立了电连接器接触件材料的应变-寿命方程.应用有限元方法计算了接触件单次插拔过程中的力学性能，基于Fe-Safe软件建立了接触件接触疲劳寿命的仿真计算模型，进而完成了配合误差对电连接器疲劳寿命影响的定量化评估.疲劳寿命分析结果表明:该型电连接器在满足设计寿命条件下，允许的最大位移误差为0.038mm，角度误差为0.621°，复合误差为0.03mm和0.405°.根据分析结果提出了提高电连接器疲劳寿命的具体建议，为该型电连接器接触件制造、装配误差控制和工艺改进提供了理论依据.

Modeling and Evaluation of the Mating Error Influences to the Fatigue Life of a Electrical Connector

Taking a certain type 22^# pin jack electrical connector as the research object， the strain-life equation of the contact material was established based on the Brown-Miller correction criterion. The mechanical properties of a single insertion and extraction process of the contact part were calculated by finite element method and the contact fatigue life model of the contact part was established based on the Fe-Safe software. Then the quantitative evaluation of the influence of the mating error to the fatigue life of the electrical connector is completed. The results of fatigue life analysis show that the maximum displacement error is 0.038mm， the angle error is 0.621°， and the compound error is 0.03mm and 0.405°under the designed life condition. According to the results， detail fatigue life improving suggests for the electrical connector are proposed， the result provides a theoretical basis for the manufacturing and control of assembling errors and process improvement for the connector.