3-Dimensional Numerical Simulation of Open-Barrel Crimping Process

A study of an open-barrel crimping process of 7-stranded wire has been conducted using a full 3-dimensional non-linear explicit dynamic finite element model. 3D dynamic simulation of the crimping process allowed capturing parameters not available in commonly used 2D models, such as barrel and wire extrusion, effect of serrations, and effect of crimper geometry. The model was validated using experimental results. Numerical results indicate that elastic springback of the crimp, upon release of the tool pressure after crimping, is an essential design parameter engineered into a reliable crimped termination. The springback behavior was confirmed experimentally using metallurgical cross sections of terminals treated to reduce adhesion between the wire and the terminal.