Novel Electrical Joints Using Deformation Machining Technology Part I: Computer Modeling

This paper explores the use of deformation machining technology (DMT), originally developed at Bauman Moscow State Technical University, to make electrical joints and compare their performance to bolted and welded electrical joints. The DMT process is used to generate tooth-like profiles on two opposing surfaces that make the electrical joint, which are later joined by applying a mechanical load. To optimize the interfacing surface tooth-like profiles, a computational finite element model is developed. The model is used to simulate the mechanical joining of both Cu and Al DMT joints. The model is able to predict the most important parameters that contribute to enhancing the teeth interlocking and increasing the contact surface area. The model is successfully used in optimizing Cu-DMT joints; however, for Al-DMT joints the model predicted an unreliable electrical joint attributed to a spring-back effect that occurs after the mechanical load for making the joint is removed.