Simulation of Metal Flow During the Hydraulic Crimping Process of Strain Clamps

ZHOU Lulu; LIU Zihan; LI Chengrui; CHAI Jingxuan; GUO Junli; ZHAO Boyang

doi:10.3969/j.issn.1674-6457.2026.06.025

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Journal of Netshape Forming Engineering ›› 2026, Vol. 18 ›› Issue (6) : 291-303. DOI: 10.3969/j.issn.1674-6457.2026.06.025

Simulation of Metal Flow During the Hydraulic Crimping Process of Strain Clamps

ZHOU Lulu¹, LIU Zihan¹, LI Chengrui¹, CHAI Jingxuan^1,2,*, GUO Junli^1,2, ZHAO Boyang³

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Abstract

The work aims to fundamentally reveal the metal flow behavior and defect formation mechanism during the hydraulic crimping process of strain clamps, optimize crimping process parameters, prevent wire breakage accidents caused by strand loosening and insufficient filling of anti-slip grooves, and enhance the mechanical reliability and service safety of transmission line joints. Based on cold pressure welding theory, a three-dimensional finite element model of the strain clamp and JL1X/LHA1-800/550 conductor was established, and the crimping process was simulated with DEFORM software. By analyzing the deformation behavior of the strain sleeve against the anti-slip grooves of the steel anchor and the outer layer of the conductor, the competitive metal flow mechanism was systematically investigated. Die movement speed was set at 1 mm/s and 5 mm/s, and holding pressure at 20, 30, and 40 kN to compare the axial flow velocity of metal, filling status of anti-slip grooves, and the evolution of stress and damage in the conductor under different process parameters. The simulation results indicated that: (1) Strand loosening was related to the increase in the helical angle α of the conductor after crimping and inconsistent axial flow velocities between the steel core and aluminum strands, which was difficult to avoid completely under current process conditions; (2) The degree to which the strain sleeve embedded into the anti-slip grooves was closely related to the axial flow velocity of the metal. During the die-closing stage, the axial flow velocity of the metal reached up to five times the die movement speed, and such high-speed flow led to a decline in the filling quality of the anti-slip grooves, especially insufficient filling in the middle groove region; (3) As the holding pressure increased from 20 kN to 40 kN, the stress concentration areas expanded significantly, indicating that excessive holding pressure exacerbated internal material damage. Existing research has not yet sufficiently revealed the underlying mechanisms of metal flow competition and deformation mismatch in dissimilar materials. Based on the interface bonding theory of cold pressure welding, the competitive metal flow mechanisms underlying two typical defects are analyzed, including insufficient filling of anti-slip grooves and strand loosening and the strategy of coordinately regulating die movement speed and holding pressure is explored. The findings provide a theoretical basis for mechanism analysis and parameter optimization of strain clamp crimping processes.

Key words

strain clamp / hydraulic crimping / DEFORM / cold pressure welding / metal flow / aluminum conductor steel reinforced

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ZHOU Lulu, LIU Zihan, LI Chengrui, CHAI Jingxuan, GUO Junli, ZHAO Boyang. Simulation of Metal Flow During the Hydraulic Crimping Process of Strain Clamps[J]. Journal of Netshape Forming Engineering. 2026, 18(6): 291-303 https://doi.org/10.3969/j.issn.1674-6457.2026.06.025

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Funding

Ningxia Natural Science Foundation (2026AAC030150); Ningxia Natural Science Foundation (2026AAC030317); National Natural Science Foundation of China Young Scientists Fund (Category C) (52205387); Project Funded by the Special Fund of Liupan Mountain Laboratory under the Ningxia Key Research and Development Program (LPS-2026-KY-D-JC-0003)