Numerical approach to joule heating analysis for electrical parts using MSC Marc

In designing electrical products, the joule heating phenomenon caused by the resistance of volume and contact should be considered to avoid damages and fire caused by overheating. This study established a joule heating analysis technique that considers volumetric and contact resistances by comparing with experimental results. Equivalent resistance was introduced to predict the joule heating generation of wires. Finite element models, including wires with equivalent volumetric resistance, a contact area with measured electrical contact resistance, and a block with perfect electrical insulation, exhibit good agreement between the results of the experimental measurements and the finite element analysis using five different materials.