Multi-physics Simulation of Electrical Contacts: Coupled Mechanical and Thermal Analysis Using ANSYS

This study presents a finite element analysis of an electrical contact using ANSYS, focusing on both mechanical and thermal behavior. A silver–copper contact model was analyzed under loading to assess stress, deformation, and strain energy distributions. Results show localized mechanical hotspots that may lead to fatigue. Thermal simulations, incorporating Joule heating, revealed temperature peaks up to 109.9°C, overlapping with mechanical stress zones. These critical areas indicate coupled failure risks. The analysis highlights the value of simulation for identifying design weaknesses and improving contact reliability.