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Finite Element Codes are useful tools for predicting the structural performance of plastic components. Through the use of these tools conceptual designs can be assessed and mature designs can be optimized; thereby, shortening the costly build and test cycle. In the past predictions were most useful in predicting the load-displacement response of the component. This could be accurately done by accurately modeling the geometry and boundary conditions and by knowing the modulus of the material. As plastics have increasingly been used in more demanding applications such as load bearing automotive components, other nonlinear deformation processes and failure mechanisms become important. In plastics the yield stress is typically very strain rate sensitive and can also be pressure dependent as well.

The high costs of prototyping, revisions, and production tooling, with a higher emphasis on quality, concurrent with demands for miniaturization, higher-density packaging, stricter performance, and a shortened product development cycle, have led to the development of advanced analysis techniques that address the performance issues associated with failure prevention in automotive connectors. Because of the complex material and geometric nonlinearity demands in performance, traditional calculations are inadequate, and new methods, utilizing finite element analysis techniques were developed. These highly specialized analysis techniques will enable the designer and engineer to predict connector performance with a high degree of confidence. Concurrent with concept designs, structural analyses (in the areas of assembly, disassembly, and terminal retention) must be done prior to design release.