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RISS 인기검색어
- 검색키워드
- 저자 : Ashish K Rajak (검색결과 3 건)
- 무료
- 기관 내 무료
- 유료
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Designing of field shaper for the electro-magnetic crimping process
Ashish K Rajak,Ramesh Kumar,Sachin D Kore 대한기계학회 2019 JOURNAL OF MECHANICAL SCIENCE AND TECHNOLOGY Vol.33 No.11
Design of a field shaper plays an essential role in the electromagnetic crimping process. It needs to be designed in such a manner that maximum magnetic field is concentrated at the active working zone. Simultaneously it is essential to take care of the mechanical strength of the field shaper so that the von Mises stress acting over the field shaper should always be lower than the strength of the material used for making field shaper. In this manuscript, numerical and experimental work is carried out in the variation of the effective height of the field shaper, to get the most suitable effective working zone height for maximum magnetic pressure acting over the workpiece. Research is carried out over the electrical interconnectors as an application, to achieve maximum crimping of the terminal over the wire strands. Results like the current density, Von-Mises stress, magnetic field, Lorentz force, terminal deformation, and contact length are discussed in detail. These results will help to design a field shaper for different industrial applications.
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Application of electromagnetic forming in terminal crimping using different types of field shapers
Ashish K. Rajak,Sachin D. Kore 대한기계학회 2018 JOURNAL OF MECHANICAL SCIENCE AND TECHNOLOGY Vol.32 No.9
Mechanical crimping is the most used method of pressure connection for permanent electrical contact in electrical and electronic equipment. Terminal plastic deformation on multi-wire strands is carried out to achieve mechanical strength and electrical conductivity. Electromagnetic (EM) is assumed to be an alternative method to overcome the challenges of spring back in the terminal on tool relaxation, cracks, non-uniform deformation, reduced strength, decreased the durability of joints in conventional crimping tool. Implementation of the field shaper (FS) has been proposed to enhance the magnetic field to concentrate the magnetic pressure at the required location for the effective terminal crimping over the wire strands. In this work, crimping was carried out using FS as a tool. Experiments were carried out utilizing tapered FS, single step FS and double step FS on aluminum terminal over seven strands aluminum wire strands that are commercially utilized for making interconnections. Results like contact length, contact resistance, terminal deformation, surface hardness, cross-section hardness and pull-out tests were found out and compared simultaneously. Also, the test results were compared with the samples crimped using a conventional crimping tool. From the results single step FS was found to be the most efficient FS than double step FS whereas the tapered FS was the least efficient. The results will be helpful in determining the geometry for the field shapers in similar applications.
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Ashish K. Rajak,Ramesh Kumar,Hirak Basumatary,Sachin D. Kore 한국정밀공학회 2018 International Journal of Precision Engineering and Vol.19 No.3
Electromagnetic terminal-wire crimping (EMTWC) is a type of mechanical joining process. In EMTWC, the terminal is deformed over the wire strands plastically to enhance the mechanical strength by increasing the contact area. A well-crimped electrical interconnection helps to avoid harmful configurations by reducing sparks, overheating, power losses etc. Subsequently, the challenge to minimize various disadvantages of conventional mechanical terminal-wire crimping process like non-uniform deformation, decreased durability, cracks, etc., can be overcome by the electromagnetic crimping process. In this work, application of the fieldshaper has been proposed to concentrate the magnetic pressure at the desired location for effective wire crimping. Numerical analysis was carried out using LS-DYNATM on three different types of field-shaper namely single-step, double-step and tapered. In all the three field-shaper, the total length, the outer diameter and the effective working length were constant. The samples used was an aluminum terminal and seven strands of aluminum wires which are commercially used for making electrical inter connections. Experiments were carried out based on the results obtained through numerical analysis. Experimental and numerical results were in agreement and the error was less than 10%. The efficiency of single-step field-shaper was found to be better compared to double-step and tapered fieldshaper.
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