Optimization of the Field Shaper Parameters in Electromagnetic Pulse Crimping of Cable

Crimping of wires to achieve a secure connection is one of the most critical challenges in fabrication of electronic circuit boards, automobiles, aviation, satellite and communication components. The electromagnetic pulse crimping process offers great potential to successfully address these challenges. In this paper, ANSYS/Multi physical software was used to first determine the electromagnetic force distribution on the terminal lug by analyzing the magnetic field in the electromagnetic pulse crimping process. The electromagnetic force was then imported into the ABAQUS/Explicit software as the boundary condition to calculate the deformation behavior of the terminal lug barrel and cable according to the stress-strain curve of the terminal material under high strain rate. The calculated deformation result was subsequently verified by experimental data. Three main parameters of the field shaper were analyzed to determine their influence on the crimping result; slit position, the inner diameter vertical dimension and the position relationship between the terminal lug and field shaper. Then using the empirical formula we calculated and verified the inner diameter vertical dimension of the field shaper. The model proved to be reliable. Deformation of the terminal was determined to be uneven along the circumference in the crimping area. For the type of terminal lug studied, an inner diameter vertical dimension of 10 mm proved to be optimum for increased strength of the crimped terminal connection. Allowing the terminal to protrude 1 mm from the field shaper resulted in a flatter crimped area and significant improvement in the quality of the crimped barrel surface. The empirical formula for calculating the inner diameter vertical dimension of the field shaper is reasonable and reliable, and the calculated measurement resulted in improved connection strength. The results of this research can be used to guide the electromagnetic pulse crimping of other terminal lug and cable types.