Optimization of stresses in the end-fittings of composite insulators for distribution and transmission lines

This paper addresses the problem of stress calculation and optimization in a FRP (Fibre-glass Reinforced Plastic) pultruded rod crimped into a metal end-fitting. This type of assembly is used mainly for suspension and line post insulators. We discuss herein some aspects that merit consideration in any given design approach. In many respects FRP pultruded materials are anisotropic. The anisotropic of their elastic constants influences the distribution of stresses while the anisotropy of their mechanical properties (ultimate strengths) limits their load carrying capacity. Finally, the anisotropy of their failure modes governs the progression and the spread of the damage. Each level of anisotropy will be discussed distinctly. Geometrical considerations are also necessary to arrive at an efficient design. Namely, we will consider the frictional interactions between the end-fitting inner wall and the rod, then we will present our approach in selecting the appropriate L/D ratio (i.e., the ratio of the end-fitting length over the rod diameter), and finally we will discuss the influence of the compression profile, i.e., the permanent radial displacement imparted to the rod due to the action of the crimping force.