Mechanical performance of physical-contact, multi-fiber optical connectors: Finite element analysis and semi-analytical model

• Accurate 3D finite element (FE) model of multi-fiber connector is presented.
• An analytical approach based on FE results allows for fast Monte Carlo analysis of connector performance.
• Recommendations for optimization of connector geometry are given.

Three-dimensional finite element analysis of physical-contact, multi-fiber optical connector was used to characterize fiber-to-fiber contact and support the development and validation of a semi-analytical model (SAM) for the contact force. This contact behavior is determined by the elastic deformation of the system components (ferrule, fibers, and bonding adhesive) and the classical Hertzian contact at the fiber tips – effects that ultimately define the axial compliance of the system. Two 3-D finite element models for a 12-fiber connector are constructed to study the contact of two connectors, and the specific numerical simulations are carried out to generate input data to SAM, confirm the main assumptions made in its development, and numerically validate the predictions for the contact force. These simulations mainly consider non-uniform fiber height profiles and different end-face fiber tip geometries characterized by their radius of curvature. The numerically validated SAM is then used to study some performance aspects of multi-fiber connectors as related to the required contact force, namely, finding fiber height profiles that require minimum contact force and evaluating the throughput of polishing processes assuming a target contact force. Predictions are supported by Monte Carlo simulations and associated with current profile geometry metrics.