Abstract: As a core component of the automotive electrical system, the reliability of the terminal crimping points in automotive wire harnesses directly relates to vehicle performance and driving safety. Conducting research on the fatigue strength of terminal crimping points holds significant engineering value for ensuring the stable and reliable operation of automotive wire harnesses during long-term service. This paper adopts a method combining vibration tests, fatigue strength tests, and working condition simulations. Targeting common typical scenarios in the process of vehicle driving, such as acceleration, deceleration, turning, and bumping, it constructs a terminal simulation model that conforms to actual operating conditions. With the help of ANSYS software, it simulates and analyzes the vehicle's movement process, focusing on studying the displacement changes, stress distribution, and fatigue strength characteristics of the terminal crimping points. The research reveals that under normal vehicle driving conditions, the stress level at the terminal crimping points is low, and the rate of fatigue damage accumulation is slow; however, under bumpy working conditions, the stress at the crimping points rises sharply, leading to a significant acceleration in the rate of fatigue damage accumulation. The research results can provide theoretical basis and technical support for the design optimization, processing technology improvement, and manufacturing quality control of automotive wire harnesses.

Key words: vibration test; fatigue strength test; simulation analys

摘要： 汽车线束作为汽车电气系统的核心组成部分，其端子压接处的可靠性直接关乎整车性 能与行驶安全。开展端子压接处疲劳强度研究，对保障汽车线束在长期服役过程中的稳定可 靠运行具有重要工程价值。文章通过振动试验、疲劳强度试验结合工况模拟的方法，针对汽 车行驶过程中常见的加速、减速、转弯、颠簸等典型场景，构建贴合实际运行状态的端子仿 真模型。借助 ANSYS 软件对汽车运动过程进行模拟分析，重点研究端子压接处的位移变化、 应力分布及疲劳强度特性。研究表明，在汽车正常行驶工况下，端子压接处应力水平较低， 疲劳损伤累积速率缓慢，而在颠簸工况下，压接处应力会急剧攀升，导致疲劳损伤累积速度 显著加快。研究成果可为汽车线束的设计优化、加工工艺改进及制造质量控制提供理论依据 与技术支撑。

关键词: 振动试验；疲劳强度试验；仿真分析