Abstract:he aluminum alloy terminal board in a substation cracked during the service. The failure simulation and structure optimization are carried out combined with the on-site conditions in this work. The finite element simulation software is used to analyze the stress status of terminal board, and it is inferred that its failure is related to the stress concentration and deformation caused by the corrosion and thinning of the bottom plate. On this basis, the structure of terminal board is optimized, and the influence of chamfering treatment and the number and layout of bolt holes on the load and deformation of terminal board are investigated. The results show that the reasonable chamfering treatment and the reasonable number and layout of bolt hole can effectively reduce the stress and deformation at the breaking point of terminal board. Optimal structure can beachieved by integrating the advantages of chamfering with bolt hole layout in terms of dual suppression of stress and deformation.