Quality Crimp Handbook
SECTION 1
INTRODUCTION TO CRIMP TECHNOLOGY
Developed to replace the need to solder terminations, crimping technology provides a high quality connection
between a terminal and a wire at a relatively low applied cost. The methods for applying crimp terminations
depend on the application and volume, and range from hand-held devices to fully automated systems.
The application methods include a basic hand tool, a press and die set, a stripper crimper, or a fully automatic
wire processing system. However, no matter what method is used, the setup of each tool is critical for
achieving a quality crimp.
Today, many OEM companies are using Statistical Process Control (SPC) to continuously improve their crimp
terminations. Crimp termination is a complex process and to ensure consistent quality it is necessary to
understand the variability and inter-relational interactions that the technology involves.
Without a thorough understanding of the crimping process, and all the factors that can affect it, the result may
not meet expectations. The three key elements in the crimping 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 stranding, and one insulation diameter (UL type). Most terminals accommodate
many wire sizes, stranding, and a range of insulation diameters, and the terminals are designed to meet
acceptable levels over this entire range.
Wire
The wire stranding and insulation type can vary widely within one wire size. For example, there is more than
18% more material in an 18 AWG by 19-strand wire than an 18 AWG by 16-strand wire. The insulation
diameter of an 18 AWG wire can range from 1.78mm (.070") to over 4.57mm (.180"). Wire strands can be
copper, tinned, over coated, or top coated. Wire insulation materials, thickness, and durometers vary from
application to application.
Tooling
What type of tooling does the application require? Does the application require hand stripping of the wire or
does the volume dictate an automatic wire-stripping machine? Does the application and volume require hand
tools, press and die, or fully automatic wire process machines? Crimping with a manual hand tool, semi-
automatic press and die, or fully automatic wire processor, all involve different levels of variability. The
terminal, wire, and type of application tooling all affect the quality of the completed terminations.
Order No: TM-638000029
Revision: D
Release Date: 09-04-03
Revision Date: 12-23-09
UNCONTROLLED COPY
Page 3 of 24
Quality Crimp Handbook
SECTION 2
PURPOSE
This handbook provides general guidelines and procedures for understanding and achieving acceptable crimp
terminations. A glossary in Section 4 lists common terms and definitions. Section 5 lists the tools that are
necessary to take accurate measurements and evaluate the crimp's acceptability.
The tooling setup is critical in determining the quality of the finished crimp. The attributes that need to be
considered include crimp height, conductor brush, bell mouth, and cut-off tab and strip length and insulation
position. Variability in one or more of these attributes can reduce the measured pull force. It can be difficult to
establish acceptable variability limits because the attributes all interact with one another.
For example, a track adjustment for bell mouth also will change the 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 slight change to the conductor crimp height measurement. It may be
necessary for the setup person to make multiple adjustments before establishing an optimal setup.
The order the setup is done may help reduce the number of repetitions required for an optimum setup.
Section 6 has a flowchart for a process setup while Section 9 is a troubleshooting guide for common problems.
Using Statistical Process Control (SPC) during the crimping process can help minimize the amount of defects.
Section 8 provides a general explanation of the benefits of using SPC.
This handbook is structured so that parts, or all, of its contents can be used as a procedural guide for ISO
requirements.
Order No: TM-638000029
Revision: D
Release Date: 09-04-03
Revision Date: 12-23-09
UNCONTROLLED COPY
Page 4 of 24
Quality Crimp Handbook
SECTION 3
SCOPE
This handbook is intended for Molex customers who are crimping Molex open barrel crimp terminals
and are using Molex tooling,
primarily in semiautomatic or automatic wire processing termination methods.
The handbook's contents may slightly differ from other connector manufacturers' guidelines or individual
company procedures.
This handbook provides a basic overview of what to look for in an acceptable crimp. It is not intended to
replace individual product and/or tooling specifications.
Individual terminals or applications may have special requirements. Tooling limitations also may not permit an
attribute to be adjusted to meet optimum requirements.
Order No: TM-638000029
Revision: D
Release Date: 09-04-03
Revision Date: 12-23-09
UNCONTROLLED COPY
Page 5 of 24
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