BOTTOMING DIES
A GUARANTEE OF PROPER CRIMP FORCE
Introduction
Tool Considerations
Design, maintenance, and certification of crimp tooling are all essential
To confirm the repeatability
of a crimp configuration, the
standardized fixed point are the
bottoming surfaces of the wire
crimp components of the tool. It
is necessary that the tool’s wire
crimp components bottom, or
close, within 0.025 mm [0.001
in]. Handle force is a key factor
to confirm that any specific combination of hand tool, terminal,
and wire can be crimped. This requires considering the force
required to achieve optimum compression over the entire range
of terminals and wire applicable to a given tool. The wire crimp
jaws will be calibrated to bottom at the maximum crimp force
requirement for each specific tool.
elements in crimping production. Long-term consistency depends on
these elements to confirm that proper crimp force is applied to the
terminal, resulting in the specified tensile strength, mechanical stability,
and electrical conductivity.
Bottoming Dies and Handle Pressure
- Keys to effective Crimping
Before being able to discuss the importance of crimp repeatability,
it is critical to understand basic crimp theory. Engineers at
AMP Incorporated (acquired by Tyco Electronics in 1999, now
TE Connectivity) originally developed basic crimp theory and
technology as we know it today.
The principal parameters for crimping are based on a terminal’s
stock thickness and the Circular Mil Area (cross sectional area) of
the wire to be crimped. The compression and reduction of the cross
sectional area (wire and terminal), when correctly calculated, will
provide an optimum combination of tensile strength, mechanical
stability, and electrical conductivity.
As long as a consistent “window” of compression is attained,
a similarly consistent, repeatable level of performance can be
predicted for the products being crimped. For this reason, the
repeatability of the tooling being used is critical.
Ensuring Consistent Crimp Results
The first critical component in ensuring consistency involves the crimp itself.
Generally, two methods are utilized for verification of the crimp areas—by
measuring the crimp or by gauging the tooling.
In the case of open barrel terminals, the method of verification is to measure
the wire barrel of the crimped terminals (i.e., terminal crimp height), using
a micrometer with suitably modified jaws. The method for closed barrel
(insulated or uninsulated) or coaxial products utilizes gauges to check the
crimp tool itself. The second critical requirement is the ability of the tool
to consistently repeat the crimp profile. Hand tools must be capable of
consistently repeating the cross sectional reduction of the wire and terminal.
The tool design and maintenance are both components of this consistency.
Crimp performance is standardized in the tool by relating the crimp
configuration to a fixed point (setting) of tool operation.
APPLICATION TOOLING /// BOTTOMING DIES WHITE PAPER
CERTI-CRIMP hand tools are set to the desired
handle force for the tightest conformance
with specifications. This is done at the factory
and is not user-adjustable.
Ensuring Consistent Crimp Results
TE CERTI-CRIMP premium hand tools are set to a specific
handle force at our factory, based on bottoming the dies at their
maximum terminal and wire requirements. All CERTI-CRIMP
tools include a Certificate of Certification without charge to the
customer. This documents that the tool was certified at our plant
on a given date. This allows the customer to track and predict
requirements for future verification of tool performance.
The high crimping precision of CERTI-CRIMP tools is further
enhanced with a ratchet which aids the operator by ensuring
that the die bottoms before the tool can be opened. This ratchet
mechanism, however, is an aid to operation and subsidiary in
terms of crimp force to the actual tool and die design. In fact, with
extended use, wear and friction throughout the tool mechanism
can change the tool performance, calling for factory adjustment
and recertification to ensure proper operation.
When specifications call for use of TE terminals, the repeatable
handle pressure and bottoming dies of the CERTI-CRIMP tool
ensure a repeatable crimp.
Maintaining Consistent Crimp Performance
Proper crimp tooling design, based on bottoming dies, is essential to
consistent crimping that meets specifications. A ratchet system helps the
operator use the tool according to the terminal designer’s intent. Regular
maintenance and certification, on a cycle based on actual usage, ensure that
the process continues to produce the crimp quality demanded in today’s
market.
TE FIELD SERVICE
SERVICES
Standard Service
•
Includes
troubleshooting and
making repairs
Equipment Installation
•
Providing installation,
set-up and training
at time of equipment
delivery
Training
•
Basic Crimp Theory
•
Hand tool, applicator
and equipment set-up,
operation and
maintenance
CERTI-CRIMP tools are furnished with documentation of the
critical crimp area dimensions and the handle pressure setting,
reported on a Certificate of Certification.
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TE Connectivity, TE Connectivity (logo) and Every Connection Counts are trademarks. All other logos, products
and/or company names referred to herein might be trademarks of their respective owners.
VALUE-ADDED
SERVICES
Preventive
Maintenance and/
or Inspection
Certification
•
Provides service for
periodic visits to
perform Preventive
Maintenance and/or
Inspection Certification
Service on hand tools,
applicators and bench
equipment. Inspection
of the finished product
is made to confirm it
meets TE application
specifications.
Documentation is
available upon request
for traceability to
support your facilities’
quality system
requirements.
Contact us today to learn more
North America (US, Mexico and Canada)
The information given herein, including drawings, illustrations and schematics which are intended for illustration
purposes only, is believed to be reliable. However, TE Connectivity makes no warranties as to its accuracy or
completeness and disclaims any liability in connection with its use. TE Connectivity‘s obligations shall only be
as set forth in TE Connectivity‘s Standard Terms and Conditions of Sale for this product and in no case will TE
Connectivity be liable for any incidental, indirect or consequential damages arising out of the sale, resale, use
or misuse of the product. Users of TE Connectivity products should make their own evaluation to determine the
suitability of each such product for the specific application.
• Web: www.te.com/fieldservice
© 2019 TE Connectivity Ltd. family of companies All Rights Reserved.
For locations outside North America visit tooling.te.com
2365082-1
www.te.com/fieldservice
11/19
Rev. A
APPLICATION TOOLING /// BOTTOMING DIES WHITE PAPER
• Wire processing equipment:
800-722-1111 or 717-810-3434
• Board processing equipment:
888-782-3349 or 610-893-9680
E-mail: fieldservicesnorthamerica@te.com