In this paper, an explicit dynamic finite element model is built to study the compressive forming technology used in the metal connector of transmission lines of power system. Additionally, to improve the calculation accuracy, an optimized reversed calculation method for determining the equivalent friction coefficients is designed and coupled into the dynamic finite element model. It is validated with a carefully designed experiment that the coupled dynamic finite element model is effective in describing the plastic flow and in determining the grip strength of the compressive forming structure. Finally, with the dynamic finite element model, an optimized compressive forming process window is obtained for controlling the formation of edge flaws while keeping sufficient grip strength.
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