航空电连接器接触件疲劳寿命的可靠性分析

为研究电连接器接触件疲劳寿命的可靠性问题，以某型军用航空电连接器通用接触件插针插孔为研究对象，应用有限元软件ABAQUS计算了接触件单次插拔过程中的接触性能。基于断裂力学理论，根据受力状况建立了接触件疲劳失效物理模型，进而联合疲劳分析软件FE-SAFE建立了接触件疲劳寿命的仿真计算模型。考虑插孔关键结构尺寸制造误差和插孔插针配合误差的随机性，利用蒙特卡罗抽样法随机构造初始装配模型并仿真计算对应的疲劳寿命，进而统计得出了接触件疲劳寿命的分布类型和分布参数，建立了电连接器接触件疲劳寿命的可靠性分析模型。结果表明：所建模型可实现电连接器任意次插拔后疲劳寿命小于许用寿命的可靠度预测，能对电连接器在许用寿命条件下2种误差的许用极限进行有效限定，可为电连接器接触件的可靠性设计、制造和装配提供理论参考。

Reliability analysis of fatigue life of aviation electrical connector contact parts

To study the reliability problem of fatigue life of the electrical connector, the mechanical properties of the pin and jack of a military aviation electrical contact part in a single plugging-pulling process are calculated using the finite element analysis software ABAQUS. A physical model for the fatigue failure of the contact part is established according to the load case. Then, a simulation calculation model of fatigue life of the contact part is built by combining the fatigue analysis software FE-SAFE and the ABAQUS. The initial model is constructed utilizing the Monte Carlo sampling method while considering the randomness of the manufacture error of critical structural parameters of the jack and the mating error of the pin and the jack. In addition, the corresponding fatigue life is calculated by the simulation method, and then its distribution type and distributing parameters are obtained. Finally, the reliability analysis model for fatigue life of the contact part is established. Analysis result shows that the model established in this paper can realize reliability prediction of the electrical connector after arbitrary times of plugging-pulling when the fatigue life is less than the allowable life, and the two types of errors can be defined effectively utilizing the quantitative evaluation model of fatigue life of the electrical connector under the allowable life condition. The model proposed can provide some reference to reliability design, manufacture, and assembly of the electrical connector.