Abstract: A structural optimization method was proposed for composite prefabricated cable terminals that accounted for nonlinear deformation of rubber stress cones caused by interference fit during installation, which could adversely affect interface pressure distribution. Based on elastoplastic mechanics theory, deformation and displacement equations during expansion process were derived to obtain actual dimensions after deformation. The Yeoh model was then introduced into finite element simulations to calculate interface pressure for rubber components with complex geometry, large deformation, and incompressibility. Considering the influence of spring axial compensation force and nonlinear deformation on interface pressure distribution, the analysis revealed a distribution characterized by high pressure peaks at both ends and low pressure in the middle. An optimized structural design was developed and validated, achieving a more uniform pressure distribution and effectively mitigating local stress concentration, providing a reference for the design and application of composite prefabricated cable terminals.