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Traditional electric transmission line fittings, which are always manufactured from thick metal slabs, possess the disadvantage of heavy weight. In this study, a new type of electrical-connection-fitting, clevis-clevis component made of high-strength steel is developed to reduce weight, and a new hot-stamping process for multilayered sheets is proposed to manufacture the component efficiently. First, the structure of the new clevis-clevis component is designed, and the corresponding tool is developed. Second, a flat-tool heat transfer experiment is conducted. The influence of the number of layers and contact pressure on the cooling rate of each sheet is investigated. The optimizing number of layers and contact pressure for the multilayered-sheet, hot-stamping process are obtained. The optimal number of layers is two, and the optimal contact pressure is more than 20 MPa. The final microstructure of each sheet is fully martensitic, and the strength is about 1500 MPa. Finally, U-shaped, double-layer-sheet hot stamping is implemented to produce a typical electrical-connection-fitting, clevis-clevis component. The bearing capacity of a four-layered clevis-clevis is tested through numerical and experimental methods. The new connection-fitting clevis-clevis component exhibits a high load capacity of 280 kN. Compared with that of the traditional component, the weight of the new component is reduced by 60%.

Multilayered-Sheet Hot Stamping and Application in Electric-Power-Fitting Products