To study the reliability problem of fatigue life of the electrical connector, the mechanical properties of the pin and jack of a military aviation electrical contact part in a single plugging-pulling process are calculated using the finite element analysis software ABAQUS. A physical model for the fatigue failure of the contact part is established according to the load case. Then, a simulation calculation model of fatigue life of the contact part is built by combining the fatigue analysis software FE-SAFE and the ABAQUS. The initial model is constructed utilizing the Monte Carlo sampling method while considering the randomness of the manufacture error of critical structural parameters of the jack and the mating error of the pin and the jack. In addition, the corresponding fatigue life is calculated by the simulation method, and then its distribution type and distributing parameters are obtained. Finally, the reliability analysis model for fatigue life of the contact part is established. Analysis result shows that the model established in this paper can realize reliability prediction of the electrical connector after arbitrary times of plugging-pulling when the fatigue life is less than the allowable life, and the two types of errors can be defined effectively utilizing the quantitative evaluation model of fatigue life of the electrical connector under the allowable life condition. The model proposed can provide some reference to reliability design, manufacture, and assembly of the electrical connector.
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