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产品型号654223-1的Datasheet PDF文件预览

Crimp Tooling —  
Where Form Meets Function  
Quality, cost, and throughput are key attributes for any production process. The  
crimp termination process is no exception. Many variables contribute to the results.  
Crimp tooling, defined here as crimpers and anvils, is one of those variables.  
This paper will focus on defining key characteristics of crimp tooling and the effects  
those characteristics may have on the production process.  
Introduction  
Quality, cost, and throughput are associated with specific measurements and linked to process variables. Crimp  
height, pull test values, leads per hour, and crimp symmetry are some of the measures used to monitor production  
termination processes.  
Many variables affect the process such as wire and terminal quality, machine repeatability, setup parameters, and  
operator skill.  
Crimp tooling is a significant contributor to the overall crimp termination process. The condition of crimp tooling is  
constantly monitored in production by various means. These means are often indirect measures. Crimp Quality  
Monitors and crimp cross sections are methodologies that infer the condition of the crimp tooling. Visual inspec-  
tion of the crimp tooling can be used  
to check for gross failures such as tool breakage or tooling deformation which occurred as a result of a machine  
crash. Continuous monitoring of production will help determine when  
the process needs to be adjusted and the replacement of crimp tooling can be one of the adjustments that is  
made.  
Crimp tooling can a have positive effect on the quality, cost, and throughput of the termination process. High qual-  
ity crimp tooling can produce high quality crimps with less in-process variation over a greater number of termina-  
tions.  
It is difficult to distinguish critical tooling attributes with visual inspection only. Some attributes cannot be in-  
spected even by running crimp samples. This paper will present the reader with information that identifies key  
crimp tooling attributes and the effect of those attributes on the crimping process.  
Key Crimp Tooling Characteristics  
There are four major categories of key characteristics for crimp tooling. These are:  
• Geometry and associated tolerances  
• Materials  
• Surface condition  
• Surface treatment  
Each of these categories contributes to the overall performance of the production termination process.  
tooling.te.com  
Geometry and Associated Tolerances  
Terminals are designed to perform to specification only when the final crimp form is within a narrow range of  
dimensions. Controlling critical crimp dimensions is influenced by many factors including:  
• Wire size and material variation  
Terminal size and material variation  
• Equipment condition  
The final quality and consistency of a crimp can never be any better than the  
quality and consistency of the tooling that is used. If other variations could  
be eliminated, tooling can and should be able to produce crimp forms that  
are well within specified tolerances. In addition, variation from one tooling  
set to another should be held to a minimum. Crimp tooling features that are  
well controlled and exhibit excellent consistency from tooling set to tooling  
set can result in shorter setup time as well as more consistent production re-  
sults.  
Some critical crimp characteristics are directly defined by the tooling form  
and are obvious. These include:  
Cross Section Defining Crimp Width,  
Crimp Height, and Flash  
• Crimp width  
• Crimp length  
Other critical crimp characteristics can be related to several tooling form fea-  
tures and/or other system factors. These may  
be less obvious and include:  
• Flash  
• Roll, twist, and side-to-side bend  
• Up/down bend  
• Crimp symmetry  
• Bellmouth  
The following discussion focuses on two characteristics, crimp width and flash, as examples of how tooling can  
affect crimp form. Similar arguments can be applied to the others.  
Crimp Width  
Crimp width is a good example of a feature that should be consistent and in control between different  
crimpers of the same part number. The reason for this is quite straightforward. For a given terminal and wire  
combination, it is necessary to achieve an area index, AI, which is determined by the terminal designer for op-  
timal mechanical and electrical performance. Crimp height, CH, and crimp width, CW, directly affect achieving  
proper AI. Area index, AI(as a percentage), is defined as:  
where At is the total area of the wire and barrel after crimping. AW and AB are, respectively, the initial cross-  
sectional areas of the wire and barrel before crimping.  
A typical design point for AI is 80%. In order to maintain  
the same AI, the crimp height, CH, needs to change in-  
versely to the change of crimp width, CW, in approxi-  
mately the same proportion. Thus, if the CW increases  
+2%, the CH needs to change approximately -2% in order  
to achieve the same AI design point. At first glance that  
may not seem significant, but in reality it can be very  
significant. Using another general industry design rule of  
the ratio of CH to CW of approximately 65%, a typical  
set of dimensions used as an example may be: CW = 0.110 in, CH = 0.068 in  
Cross Sections Showing Min-  
imum (a) and Maximum (b)  
Area Index perTerminal  
Specification—aVariation of  
3.5%  
(a)  
(b)  
Therefore, varying the CW by 2% would result in a CH variation of 2%, or 0.0014 in.  
At a CH tolerance of 0.002 in, 35% of the total CH tolerance would be used by a  
2% variation in CW. Thus, the importance of crimp width control is obvious when  
tooling is changed during a production run.  
Flash  
Most crimp terminations have a requirement to limit flash. Flash is defined as the material which protrudes to the  
sides of the terminal down and along the anvil. Flash is normal in the crimping process but excessive flash is very  
undesirable. Controlling flash requires a balance of several geometric factors. Other factors influencing flash are  
related to surface finish and friction, which will be discussed later in this paper.  
A dominant factor in controlling flash is controlling the clearance between the crimper and anvil during the crimp  
process. Defining the ideal clearance could in itself be a simple matter were it not for two facts:  
• In order to minimize terminals’ sticking in the crimper, the sides  
of the crimper are tapered. Thus the clearance between the  
anvil and crimper varies throughout the stroke.  
• Crimper and anvil sets are typically designed to terminate two  
to four wire sizes. This creates multiple crimp heights. Since the  
sides of the crimper are tapered to minimize terminal sticking,  
the maximum clearance permitted without creating flash must  
be assigned to the maximum crimp height specified for the  
tooling set. In addition, a minimal clearance must be maintained  
for the smallest crimp height specified by the tooling set to  
Crimper-to-Anvil Clearance = X +Y  
at the Final Crimp Height  
prohibit contact between the anvil and crimper.  
Crimper to anvil clearance is thus a combination of crimp width, crimper leg taper,  
anvil width, and crimp height. The critical design point is at the largest crimp  
height. This contribution to the gap is directly dependent on dimensional control.  
The following is offered as an example:  
Nominal condition: CH = 0.073 in, CW = 0.110 in  
Crimper leg taper = 3.0 degree  
Anvil Width = 0.109 in  
Nominal anvil to crimper total clearance = 0.005 in  
The clearance can grow rapidly with small changes to  
the nominal dimensions:  
(a)  
Significant flash can be generated  
with excessive anvil to crimper  
clearance, as shown by nominal  
design condition (a) and +0.003 in  
over nominal condition (b)  
CH remains unchanged = 0.073 in  
Increase in crimp width, CW, = 0.0008 in  
Increase in crimper leg taper = 0.8 degree  
Decrease in anvil width = 0.0008 in  
(b)  
The total increase in total clearance is this case =  
0.0026 in  
This more than a 50% increase in the nominal design  
clearance, which can result in unacceptable flash (see right).  
Dimensional control is clearly critical.  
Materials  
The material selection for tooling is critical. The material must  
be able to meet the in-service demands placed on the tooling components. The two critical tooling components  
to be reviewed are the wire crimper and the anvil.  
The wire crimper and the anvil have different functional demands. Both have the need to withstand high loads and  
moderate shock. However, the wire crimper is in fact an aggressive forming tool. It must withstand high shear  
loading that is a result of frictional loads generated as the terminal barrel slides along the crimper surfaces in the  
forming process, and then as the terminal barrel is plastically deformed and extruded to complete the termination.  
The anvil experiences some of the same conditions but to a much lower level of severity.  
The wire crimper and the anvil can be likened to a punch and die in the world of metalworking. The materials used  
in punch and die applications have been well documented, along with the material selection process. The added  
severity of the aggressive forming and the terminal and wire extrusion during crimping add complexity  
to the material selection. The material selection process involves:  
• Strength of materials with emphasis on toughness needed to  
withstand the moderate shocks generated during crimping  
Wear resistance to maintain form  
In addition to the above design considerations, there exists another phenomenon that occurs during crimping that  
can significantly shorten the useable life of a wire crimper. Material can be transferred from the terminal barrel to  
the wire crimper. This material buildup can result in unacceptable terminations. The crimped terminal surfaces can  
actually be deformed by the indentations of the deposited material. Crimp deformation may result due to in-  
creased friction. Tooling wear can be accelerated due to higher crimp forces. Surface treatments that minimize  
this material transfer are critical to extended tooling life.  
Strength of Materials  
Crimpers and anvils are designed to be able to withstand stresses that are typically encountered during crimping.  
The basic design of tooling with reference to size and geometry has been well analyzed and generally stresses  
generated during crimping are able to be accommodated. However, there are always demanding applications that  
will tax the design to its stress limits. In those cases, geometry and material may depart from the standard design.  
These exceptions are dealt with on a one-by-one basis and will not  
be discussed here.  
It is the unique requirement of stress and shock that needs to be discussed. Peak crimp loads go from zero to  
maximum in less than 40 ms. Tooling needs to withstand this load cycle at a rate of greater than once per second.  
Several classes of tool steels are suitable and are well described in the material handbooks. It is the processing of  
these materials that can make a significant performance difference.  
In order to withstand the rapid loading to a high stress on a repeated basis, the surface of the material must mini-  
mize cracks and imperfections that may be generated during the machining and/or heat treat operations. It is im-  
portant that grain structure be controlled in size and orientation to achieve maximum and consistent service life.  
Decarburization of the surface during heat treating must be controlled. Heat treating process controls are critical  
to reproducing the optimal surface. Machining processes must also be controlled to avoid surface cracking due to  
excessive heat generation during overly aggressive material removal. Likewise, localized tempering may occur,  
which can soften material beyond the effective range.  
These variations in final material and surface conditions are not readily detectable with a visual inspection. They  
can manifest themselves during service and result in unacceptable tooling performance.  
Wear Resistance  
Wear is generally described as the gradual deterioration of a surface through use. Several types of wear exist and  
include adhesive, abrasive, and pitting. By design, the tooling is able to withstand normal surface loads. Thus, pit-  
ting is typically not an issue.  
The primary wear mode experienced by crimp tooling is adhesive wear. Adhesive wear occurs as two surfaces  
slide across each other. Under load, adhesion, sometimes referred to as cold welding, can occur. Wear takes place  
at the localized points of adhesion due to shear and deformation. Adhesion is highest at the peaks of surface fin-  
ish because that is where the load is greatest. During crimping, the ideal conditions exist for adhesive wear. That is,  
• High loading due to crimp force  
• Sliding surfaces due to crimp formation, and terminal and  
wire extrusion  
Wear will generally manifest itself more significantly at edges of a surface. However, adhesive wear is often ob-  
served over substantial areas of the tooling. It is important to note here that the wire crimper is the component  
most susceptible to adhesive wear. Generally, adhesive wear will be directly related to load and to the amount of  
relative movement between the two materials. Although the anvil may have equal loading, the amount of relative  
movement between the terminal and tooling is many times more at the crimper than at the anvil. The insulation  
crimper typically experiences lower adhesive wear because the load is reduced compared to the wire crimp and  
the relative movement is less than that of the wire crimper, since there is no terminal and wire extrusion at the in-  
sulation crimp.  
Adhesive wear can be controlled in the selection of the material. Different alloys exhibit better or worse wear properties.  
These properties can be measured and are well documented. Adhesive wear  
is inversely proportional to the hardness of the material. Thus, the harder the material, the less adhesive wear. In crimp  
tooling, there is often a tradeoff that is made. In order to achieve higher wear resistance, the material often exhibits  
lower toughness by composition, hardness, or both. The final material selection is often based on years of experience.  
One material may have high wear characteristics and lower toughness, and be suitable for a small terminal since the  
margin of safety on stress is high. Another terminal may be large and the toughness could be of more importance due a  
lower stress design margin. The ability to design and manufacture crimpers from several materials will enable optimal  
material selection for a specific application.  
The final property that affects adhesive wear is surface finish. As stated earlier, adhesion is highest at the peaks of the  
surface. Thus, the smoother the finish, the less significant the peaks and the less significant the adhesion. Adhesive wear  
can be reduced with a lower surface finish. Surface finish affects other crimping performance parameters. These are dis-  
cussed in the next section.  
Abrasion can occur depending on terminal surfaces. If a terminal is plated with an abrasive substance, the tooling  
could suffer from abrasive wear. This would be an atypical condition  
and would be handled by special design.  
Other applications where abrasive wear is the primary wear mode involve terminals made of steel and stainless steel.  
Extensive testing has shown chromium plating is the best surface treatment that can be used on crimpers designed for  
these abrasive terminals. However, in these applications, crimpers will not last as long as those crimpers used to crimp  
terminals made of other, less abrasive base materials. Using a lubricant (in those applications where this is acceptable)  
has shown to increase the life of the crimper. However, even when lubricated the crimper life can be expected to be  
shorter when crimping steel or stainless steel terminals.  
Once abrasive wear has taken place to the point where the chromium plating has been removed from the base tool steel  
of the crimper, as successive crimp cycles occur, further wear will happen very quickly. Without the protective  
chromium plating, the underlying surface will then be subject to either further abrasive wear, or adhesive wear. For this  
reason, care should be taken to replace the crimper as soon as wear is visible on the surface of the crimper.  
Surface Condition  
Surface condition can affect the performance of the crimp tooling as well as the longevity of service. As noted in  
the previous section, a hard, smooth surface has improved adhesive wear properties and, thus, longer service life.  
The other attribute that needs to be considered is friction.  
Friction is a contributing factor in determining the final  
crimp form and process characteristics. Low tooling friction  
results in lower crimping force and thus can influence crimp  
form as well as tooling life. Consistent frictional characteris-  
tics between tooling sets will result in reduced process  
variation.  
Friction of the crimp tooling surfaces is influenced by fac-  
tors similar to those that influence adhesive wear—hard-  
ness and surface finish. Generally, harder materials exhibit  
lower coefficients for sliding friction. Friction coefficients  
have also been shown to be related to surface finish. Manu-  
facturing processes need to produce consistent results  
such that when tooling sets need to be changed in produc-  
tion, minimum disruption in crimp quality is achieved. It has  
been found that maintaining surface hardness above Rc 55 as  
Typical Effect of Friction on Crimp Force  
well as keeping surface finishes to 8 micro-inches or less is  
desirable to obtain consistent crimp results and minimize  
adhesive wear.  
Surface Treatment  
Surface condition can affect the performance of the crimp tooling as well as the longevity of service. As noted in the  
previous section, a hard, smooth surface has improved adhesive wear properties and, thus, longer service life. The  
other attribute that needs to be considered is friction.  
A commonly accepted approach to improved crimp tooling performance and life has been to apply a surface treat-  
ment to the crimp area. The wire crimper has been defined in previous discussions as tooling component that is sub-  
jected to the severest duty cycle. Thus, applying an appropriate surface treatment to the wire crimper will have the  
most benefit to crimp performance and tooling life. These treatments can include hard metal plating or ceramic  
coating.  
An example of a treatment that has been successful in achieving significant level of performance and life improvements  
is hard chromium plating. There are several valid reasons for this success.  
First, chromium plating has a very low coefficient of friction. As noted, friction has a significant effect on crimp form.  
The static and sliding coefficients of friction for steel on steel are typically 0.30 and 0.20 respectively. Chromium plated  
steel on steel can reduce the static and sliding coefficients to 0.17 and 0.16.  
The second area that is greatly improved with  
chromium plating is wear resistance. Adhesive wear  
resistance is improved as surface hardness improves.  
Chromium plating typically exhibits a hardness Rc  
65+. This hardness level greatly enhances resistance  
to adhesive wear. Also, this now frees up the designer  
to consider more base metal options. A base material  
of reduced wear resistance but greater toughness can  
be selected and its wear resistance improved with  
chromium plating. Thus, chromium plating can enable  
a better tooling solution for the crimp production  
process.  
Chromium Plated Crimper  
Surface after 100,000Termina-  
tions. Note there is no visible  
build up of material.  
Unplated Crimper Surface  
after 60,000Terminations.  
Note Significant buildup of  
material.  
Third, and perhaps one of the most significant effects  
of chromium plating, is its resistance to adhesion and  
cold welding. A side effect of adhesive wear is the  
transfer of material from the terminal to the wire  
crimper. By definition, adhesive wear is caused by ma-  
terial adhering to localized points on the surface.  
Some of the adhesion results in the surface material  
being worn away and some in the transfer of material  
from the terminal to the crimper. As more cycles  
occur, more material is transferred. Thus there a re-  
sultant buildup of terminal material on the crimper.  
This buildup will result in two potentially catastrophic  
failures:  
Gross Deformation of Crimped  
Terminal Resulting from Mate-  
rial Buildup in Crimper  
Visible Deformation of Outer  
Crimp Surface as a result of In-  
dentation from Material Buildup  
on Crimper  
• The built-up material will create deformations in  
the terminal surface, resulting in unacceptable  
crimps.  
• Crimps will be greatly distorted due to significant changes in the friction factor and result in the terminals not  
conforming to the desired form. Unacceptable crimp forms, such as unsymmetrical cross-section, excessive  
flash, and open barrels can result.  
Chromium plating has the ability to be applied uniformly and consistently and exhibits excellent adhesion to the  
base metals. The unique benefits of chromium plating, such as ease of application, consistency of plating, adhe-  
sion to base metal, extremely low coefficient of friction, very high hardness, and resistance to adhesion, make it  
truly difficult to match in crimp performance and durability. However many alternative coatings are being at-  
tempted, and some show excellent promise in specific applications.  
Summary  
This paper has explored four categories of characteristics that are key to high performance tooling. Several exam-  
ples have been discussed which demonstrate how minor variations in those characteristics can have measurable  
and sometimes significant effects on the resultant crimp form and its compliance to specifications. These same  
characteristics can affect tooling service life. It is also a logical extension of these discussions to conclude that  
variations of these characteristics from one tooling set to another tooling set can affect process control when  
tooling changes are required in production. Maintaining process control may require additional setup time. Quality  
tooling that addresses the key characteristics of geometry, materials, surface condition, and surface treatment is  
an important component of your total quality control program.  
Tooling Solutions from  
TE Connectivity  
Keeping up with changes and trends in  
manufacturing is critical for your survival.  
With our exposure in the global industry, we  
are in a position to develop systems and  
tooling that respond to these trends.  
Stay in touch with TE Connectivity for the  
latest innovations in the industry.  
tooling.te.com  
tooling.te.com/china  
tooling.te.com/europe  
© 2011 Tyco Electronics Corp. All Rights Reserved.  
The Icons of Quality, TE Connectivity (Logo) and TE Connectivity are trademarks.  
Tyco Electronics Corp, Harrisburg, PA 17105, Phone: 717-564-0100; Fax 717-986-3316  
配单直通车
654223-3产品参数
型号:654223-3
Brand Name:AMP
生命周期:Active
IHS 制造商:TE CONNECTIVITY LTD
Reach Compliance Code:unknown
风险等级:5.63
连接器支架类型:TOOL AND MACHINERY
制造商序列号:654223
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