Industrial Crimp Quality Handbook
Doc No: TM-640160065
Release Date: 00-00-02
UNCONTROLLED COPY
Page 1 of 27
Revision: C
Revision Date: 12-23-09
INDUSTRIAL CRIMP QUALITY
HANDBOOK
Order No. 64016-0065
Page 1: ...Industrial Crimp Quality Handbook Doc No TM 640160065 Release Date 00 00 02 UNCONTROLLED COPY Page 1 of 27 Revision C Revision Date 12 23 09 INDUSTRIAL CRIMP QUALITY HANDBOOK Order No 64016 0065...
Page 2: ...derless Terminals 5 2 Barrel Serration Dimples 5 3 Barrel Styles 5 4 Splices 6 Procedures 6 1 Preparing the Wire 6 2 Setup and Operation of a Press 6 3 Setup and Operation of a Hand Crimp Tool 6 4 Set...
Page 3: ...g process are the terminal the wire and the tooling Terminal For most applications it is not economically practical for connector manufacturers to design a terminal to accept one wire size one wire st...
Page 4: ...cut off tab length and the insulation wire position while strip length and wire locations affect the conductor brush and insulation position Adjusting the insulation crimp height may result in a slig...
Page 5: ...verlapping Chamfer An angle on the inside edge of the barrel entrance of a terminal that permits easier insertion of the wires into the barrel Circular Mil CM A unit of area used to indicate wire size...
Page 6: ...on the bottom wire barrel resulting from the clearance between the punch and anvil tooling If the anvil is worn or if the terminal is over crimped an excessive extrusion results An uneven extrusion ma...
Page 7: ...d terminal must be squeezed to get a gas tight seal It s important to crimp the wires tight enough to keep them from slipping out of the connector but not so tight as to crush the wires in the termina...
Page 8: ...8 Terminal A device designed to terminate a conductor that is to be affixed to a wire or cable to establish an electrical connection It is a synonym for contact There are two main types which include...
Page 9: ...dle of wires twisted together to act as one Wire Size Wires have varying sizes or gauges that carry different amounts of electrical current with each wire used for a separate purpose The size in AWG i...
Page 10: ...ce it It has a thin blade that supports the top of the crimp while a pointed section determines the bottom radial curved surface Ruler Pocket Scale This is used to measure the length of bell mouth cut...
Page 11: ...UL 486 A Terminals Copper conductors only UL 486 C Butt Splices Parallel Splices Closed End Connectors and Wire Nuts UL 310 Quick Disconnects Flag and Couplers Military Class 2 Military Approved Term...
Page 12: ...mm2 3 The Insulkrimp has a rigid insulation sleeve made of PVC polyvinyl chloride which protection to the Krimptite barrel area in wire sizes of 10 22 AWG or the brazed seam of the Versakrimp barrel o...
Page 13: ...ations vary The following are some examples Barrel Lengths In wire sizes 26 16 AWG the industry has two standard barrel lengths for the metal barrel The lengths are 6 35 mm 25 and 4 36 mm 11 64 The 4...
Page 14: ...pecial splices for nearly every type of wiring need Butt Splices On this connector the stripped wires are inserted from each end and they butt in the center Then a crimp at each end secures the connec...
Page 15: ...has stripped wires that lie side by side in the splice They are secured by a single crimp in the middle Window Butt Splice This connector has military approval Mil T 7928 5 to withstand the harshest...
Page 16: ...ou must cut and re strip the wire before crimping to be sure that the amount of current that can be carried is not reduced 6 2 Setup and Operation of a Press 1 Check that tooling is clean and not worn...
Page 17: ...ower and remove guarding Adjust conductor crimp height install guards connect power and go to procedure 18 21 Document measurements 6 3 Setup and Operation of a Hand Crimp Tool 1 Insure that the hand...
Page 18: ...cator make sure the seam of the barrel is oriented up or down in the tool as this will provide higher pull force values 6 5 Crimping Dies The Molex product line includes seven types of dies for differ...
Page 19: ...omplete line of fully automatic wire processing machines semi automatic and manual wire crimping tools Each system is tailored to our customer s individual needs by using support equipment and can be...
Page 20: ...and Military Tensile values See Section 8 Note that the Military pull force is higher than the U L 7 1 Visual Inspection of OPEN BARREL Crimps Insulation Not Damaged 1 Crimp the insulation just enough...
Page 21: ...contact area of the lug or terminal 2 If the wire strands are in the contact area they will interfere when the terminal is connected No Strands Sticking Out Strand Fold Back 1 Be sure that all of the...
Page 22: ...On all crimped terminals the conductor crimp should be centered on the conductor barrel This insures even pressure on the entire length of the barrel Good Bell Mouth Present 1 Be sure that a good bell...
Page 23: ...UNCONTROLLED COPY Page 23 of 27 Revision C Revision Date 12 23 09 Insulation Support Crimp 1 On closed barrel terminals that have a secondary metal sleeve AviKrimp the metal sleeve should be formed s...
Page 24: ...d similar substances Some reasons for failure of crimped joints to meet minimum tensile requirements include nicked wires nicked or ruptured strands strand turn back at crimp joint and ruptured wires...
Page 25: ...lt rating of the terminal 8 3 Final Tensile Value The type of die affects the final tensile value in several ways See Crimping Dies Section 6 5 If the die as in the indentor type does not indent far e...
Page 26: ...mp Some stranded wire crimp configurations are not satisfactory for solid wire More deformation must be imposed in order to form wire and barrel into a solid mass On the other hand finer strands will...
Page 27: ...e strand and multiply the result by the total number of strands CMA D x D x Number of Strands of one Strand SECTION 9 MISCELLANEOUS AWG CMA Table Terminal Size AWG CMA Range 26 22 202 810 24 20 320 1...
