Heading of a small bi-metallic components for electric contacts

by

Heading of a small bi-metallic components for electric contacts

Wojciech Presz, Robert Cacko

Institute of Manufacturing Technologies, Warsaw University of Technology, Narbutta 85, 02-524 Warsaw, Poland.

DOI:

https://doi.org/10.7494/cmms.2018.2.0612

Abstract:

Electrical connectors mostly have silver contacts joined to the supplying and discharging electric current elements by riveting. In order to reduce costs, the rivet core of the contact can be replaced with a cheaper material such as copper. There is a wide range of commercially offered bi-metallic, silver-copper rivets available for the production of contacts. This generates a new situation in the riveting process, as the bi-metallic rivet is to be formed. In the analyzed example it is a small-sized object that places it near the limits of micro-forming. The riveting process was originally designed by classical upsetting. It was based on the results of FEM simulation taking into account the deformation of three materials included in the joint: two materials rivet and sheet material. The FEM results were verified by the results of experimental studies, obtaining good agreement. The method of elimination of the impact of elastic deformations of the load system on the process forces flow was elaborated and it was used for comparative analysis with the force flows obtained from FEM. A model simulating the working conditions of the connector was developed. Based on the joint load modeling results, it was shown that the resulting silver distribution in the connector head eliminates the risk of separation of both materials during exploitation.

Cite as:

Presz, W., Cacko, R. (2018). Heading of a small bi-metallic components for electric contacts. Computer Methods in Materials Science, 18(2), 41 – 48. https://doi.org/10.7494/cmms.2018.2.0612

Article (PDF):

Keywords:

Metal forming, Heading, Bi-metallic component

References:

Essaa, K., Kacmarcik, I., Hartley, P., Plancak, M., Vilotic, D.,2012, Upsetting of bi-metallic ring billets, Journal of MaterialsProcessing Technology 212, 817- 824.

Geiger, M., Kleiner, M., Eckstein, R., Tiesler, N., Engel, U.,2001, Microforming, CIRP Annals – Manufacturing Technology,50 (2), 445-462.Geiger, M., Messner, A., Engel,U., 1997, Production of microparts – Size effects in bulkmetal forming, similarity theory, Production Engineering,4, 55-58.

Green e-motion project, 2016, Paris Declaration on ElectroMobility and Climate Change & Call to Action;www.greenemotion-project.euKazanowski, P., Misiołek, W.Z., Epler, E.E., 2004, Bi-metal rodextrusion—process and product optimization, MaterialsScience and Engineering, A369, 170-180.

Kocanda, A, Presz, W., Mazurek, W., Adamczyk, G., 2001,Contact pressure distribution in upsetting of compoundmetals, Journal of Materials Processing Technology, 60,44-48.

Muster, A., Presz, W., 1999, Influence of initial surface roughnesson galling behavior of steel-steel couple, ScandinavianJournal of Metallurgy, 28 (1), 5-8.

Olejnik, L., Presz, W., Rosochowski, A., 2009, Backward Extrusionusing Micro-Blanked Aluminium Sheet, InternationalJournal of Material Forming, 2, 1, 617-620.

Paris Declaration on Electro Mobility and Climate Change &Call to Action, 2015, Lima – Paris.Politis, D.J., Lin, J., Dean, T.A., Balint, D.A., 2014, An investigationinto the forging of Bi-metal gears, Journal of MaterialsProcessing Technology, 214, 2248– 2260.

Presz, W., Cacko, R., 2011, Influence of Micro-Rivet ManufacturingProcess on Quality of Micro-Joint, Proc. 14th Int.Conf. on Material Forming, Esaform 2011, Belfast, AmericanInstitute of Physics Conf. Proc. 1353, 1, 541-546.

Presz, W., Cacko, R., 2017, Ultrasonic assisted microforming,26th Int. Conf. on Metallurgy and Materials, METAL,Brno, 2017, 521-526Presz, W., Cacko, R., 2018a, Bimetallic Micro-Punches forMicro-Blanking Processes, Archives of Metallurgy andMaterials, 63, 29-34.

Presz, W., Cacko, R., 2018b, Determination of material distributionin heading process of small bimetallic bar, AIP ConferenceProceedings, 1960, 050014.

Presz, W., Rosochowski, A., 2006, The influence of grain sizeon surface quality of microformed components, The 9thProc. Int. Conf. on Materials Forming, ESAFORM 2006,Glasgow, 587-590.

Presz, W., Rosochowski, M., 2017, Application of semiphysicalmodeling of interface surface roughness in designof pre-stressed microforming dies, Int. Conf. on the Technologyof Plasticity, ICTP 2017, Procedia Engineering,207, 1004-1009.

Presz, W., 2016, Scale effect in design of the pre-stressed microdiesfor microforming, Computer Methods in MaterialsScience, 16, 196-203.

Raulea, L.V., Goijaerts, A.M., Govaert, L.E., Baaijens, F.P.T.,2001, Size effect in the processing of thin metal sheets,Journal of Materials Processing Technology, 115, 44-48.

Stress-Strain Curves, 2002, Material Park, OH 44073-0002.

Tiesler N., 2002, Microforming – Size effects in friction andtheir influence on extrusion processes, Wire, 52, 1, 34-38.

Wang, Ch., Guo, B., Shan, D., Zhang, M., Bai, X., 2014, Tribologicalbehaviors in microforming considering microscopicallytrapped lubricant at contact interface, Journal of Advanced Manufacturing Technology, 71, 2083-2090.

Yueqing Hawin Electric Co., Ltd., https://hawin.en.alibaba.com/.Wenzhou

Saijin Electrical Alloy Co., Ltd., https://saijinele.en.alibaba.com/