RESUMO
This study aims to enhance the productivity of high-voltage transmission line insulators and their operational safety by investigating their failure mechanisms under ultimate load conditions. Destructive tests were conducted on a specific type of insulator under ultimate load conditions. A high-speed camera was used to document the insulator's failure process and collect strain data from designated points. A simulation model of the insulator was established to predict the effects of ultimate loads. The simulation results identified a maximum first principal stress of 94.549 MPa in the porcelain shell, with stress distribution characteristics resembling a cantilever beam subjected to bending. This implied that the insulator failure occurred when the stress reached the bending strength of the porcelain shell. To validate the simulation's accuracy, bending and tensile strength tests were conducted on the ceramic materials constituting the insulator. The bending strength of the porcelain shell was 100.52 MPa, showing a 5.6% variation from the simulation results, which indicated the reliability of the simulation model. Finally, optimization designs on the design parameters P1 and P2 of the insulator were conducted. The results indicated that setting P1 to 8° and P2 to 90.062 mm decreased the first principal stress of the porcelain shell by 47.6% and Von Mises stress by 31.6% under ultimate load conditions, significantly enhancing the load-bearing capacity. This research contributed to improving the production yield and safety performance of insulators.