Cuq-Lelandais, J. P.Innocenti, N.Gage, W.Huteau, C:Daulhac, G.Mrozowski, N.2025-09-212025-09-212025-08-26http://hdl.handle.net/2003/4392110.17877/DE290R-25689Magnetic Pulse Crimping (MPC) represents an interesting alternative to mechanical crimping. This solution is a contactless process using dynamic Lorentz forces induced by high pulse power electrical discharge through a coil. MPC has proven to be effective for cables terminals with both high electrical and mechanical performances. This solution differs from conventional methods for cables with large cross-sections for high voltages especially those manufactured for electric vehicles. The challenge lies in the high thickness of the terminal and the cable to be crimped together while maintaining the performance of the connection during use and ageing, that can be hard to hold with traditional processes. The aim of this work is to characterize the electrical resistance of 120 mm² power cables terminals that are assembled by MPC, with the goal of reducing the process width and potentially reduce the lug mass. First, a numerical study of the process is performed in order to design and characterize the crimping level depending on main process parameters, in particular through the compaction level of the assembly. Then, an experimental study has been carried out by testing assemblies with different crimping widths and generator energies, in order to reduce the crimped length without degrading the performance and repeatability. For each case, the electrical resistance of the cable/lug interface is measured, before and after exposure to thermal and humidity cycling representative of real-life conditions. The results are compared with samples produced using mechanical crimping to compare the performances and repeatability of each process respectively.enHigh Pulse Power (HPP)Multiphysics SimulationPower CableMagnetic Pulse Crimping (MPC)620670ConferencePaperCrimpenElektromagnetisches VerfahrenElektrisches KabelMultiphysicsSimulationExperiment