Nonlinear mechanical modeling of electrical connectors using simple numerical methods and secant modulus data

Electrical connectors are often modeled for mechanical performance using simple linear cantilever beam equations which are not capable of accurately predicting behavior once the design stress exceeds the base metal elastic limit. A numerical method which predicts nonlinear behavior using base metal secant modulus data was investigated as an alternative to constructing more complex nonlinear finite element models (FEM). This numerical method is simple to solve and does not require extensive computer aided design (CAD) and structural modeling training. However, application of this technique is limited to simple geometry. Stress and force calculated using the secant modulus numerical method compared well to results obtained using nonlinear finite element techniques.