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WHERE FORM MEETS FUNCTION
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 increased friction. Tooling wear can be accelerated
due to higher crimp forces. Surface treatments that minimize this
material transfer are critical to extended tooling life.
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 minimize cracks
and imperfections that may be generated during the machining
and/or heat treat operations. It is important 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, pitting 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 finish 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 observed 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 insulation crimp.
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
APPLICATION TOOLING
/// WHERE FORM MEETS FUNCTION
Page 4
WHERE FORM MEETS FUNCTION
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 discussed 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 characteristics between tooling
sets will result in reduced process variation.
Friction of the crimp tooling surfaces is influenced by factors
similar to those that influence adhesive wear—hardness and
surface finish. Generally, harder materials exhibit lower
coefficients for sliding friction. Friction coefficients have also been
shown to be related to surface finish. Manufacturing processes
need to produce consistent results such that when tooling sets
need to be changed in production, minimum disruption in crimp
quality is achieved. It has been found that maintaining surface
hardness above Rc 55 as well as keeping surface finishes to 8
micro-inches or less is desirable to obtain consistent crimp results
and minimize adhesive wear.
Typical Effect of Friction on Crimp Force
APPLICATION TOOLING
/// WHERE FORM MEETS FUNCTION
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