Simulation numérique du procédé de sertissage de contacts électriques aéronautiques : optimisation des conditions d'assemblage pour la tenue mécanique

Abstract : This thesis focuses on the modeling of the aeronautical electrical contact crimping process for aircraft applications and the crimped contact mechanical holding. Electrical crimping is a plastic deformation process of a contact (component) on a multi-strand wire. Two types of crimping technologies are studied. The copper technology, widely used in the industry, is characterized by the assembly of a copper contact and a 19 strands copper cable. The aluminum technology, which has been recently developed to reduce the aircraft weight, is characterized by the assembly of a copper contact with a 7 strands cable through two electrical and sealing crimpings. At first, the elastoplastic parameters characterizations of the materials constitutive laws are made. The appropriate testing facilities determination, directly impacted by the small size (millimeter order) of our samples, is followed by a detailed results analysis. The non-standard tests inverse analysis use is preferred. The whole analyzes results are validated, regardless of the process itself. In a second step, the crimping simulation development steps are accurately performed. For this highly multi-model fields type, the study of the interactions influence is conducted. Determining the crimping indentation depth parameters is developed for each technology. The first simulation results are discussed to reduce computation time. Finally, the developed numerical model is used to simulate the contacts crimping and the mechanical holding over various configurations. The geometrical (strands diameter, contact diameter, twisting thread cables), rheological (standard copper having been insufficiently or excessively annealed) or mechanical (under-crimping, over-crimping) parameters study are made to check their influences on the crimping forces and the failure mechanisms while pulling. This study aims to validate the crimping efficiency. The manufacturers could be able to check in real time the crimping validity by comparing the experimental crimping force curves to validity curves integrated in an electronic crimping tool.
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  • HAL Id : tel-01102755, version 2

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Matthieu Petitprez. Simulation numérique du procédé de sertissage de contacts électriques aéronautiques : optimisation des conditions d'assemblage pour la tenue mécanique. Mécanique des matériaux [physics.class-ph]. Ecole Nationale Supérieure des Mines de Paris, 2013. Français. ⟨NNT : 2013ENMP0093⟩. ⟨tel-01102755v2⟩

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