Analysis and Prediction of Vibration-Induced Fretting Motion in a Blade/Receptacle Connector Pair

Connector fretting propensity is generally evaluated through an exhaustive series of experimental tests, making the connector design and validation process time consuming and costly. Thus, a method using modeling and simulation techniques to predict the influence of various design factors on vibration-induced fretting propensity in electrical connectors would be very beneficial to those responsible for connector design and application. One approach is to use detailed finite element models for the connector system to relate the actual dynamics of the contact interface to the threshold vibration levels required for the onset of fretting and the relative motion transfer function. The present study describes one such model for a single tin-plated blade/receptacle connector pair. Concurrent simulation and experimental studies were performed to evaluate the threshold vibration levels as a function of excitation frequency, interface friction coefficient, and normal force. Good correlation between the experimentally observed results and those predicted by the models were obtained. Some insights and observations with regard to the effectiveness of such a modeling approach are also presented.