TBO-Quality Crimp Handbook

INDUSTRIAL CRIMP QUALITY

HANDBOOK
Order No. 64016-0065

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Table of Contents

SECTION

1 Introduction

2 Purpose and Scope

3 Definitions and Terms

4 Associated Materials

5 Terminal Description
5.1. Features of Solderless Terminals
5.2. Barrel Serration/Dimples
5.3. Barrel Styles
5.4. Slices

6 Procedure
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. Setup and Operation of a Air Powered Crimp Tool

7 Quality Crimps
7.1. Visual Inspection of OPEN BARREL Crimps
7.2. Visual Inspection of CLOSED BARREL Crimp

8 Importance of Proper Crimping

8.1. Conditions
8.2. Testing
8.3. Tensile Value
8.4. Electrical Resistance
8.5. Crimp joints

9 Miscellaneous

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SECTION1
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, 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) as well as Mil Specification. 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.

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SECTION 2
PURPOSE

This handbook provides general guidelines and procedures for understanding and achieving acceptable crimp
terminations. A glossary in Section 3 lists common terms and definitions. Section 4 lists the tools that are
necessary to take accurate measurements and evaluate the crimp's acceptability.

For open barrel only, 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, 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 to establishing an optimal setup.

The order in which a setup is done may help reduce the number of repetitions required for an optimum setup.

This handbook is structured so that parts, or all, of its contents can be used as a procedural guide for ISO
requirements.

SCOPE

This handbook is intended for Molex customers who are crimping Molex open and closed barrel crimp
terminals and are using Molex tooling.

The handbook's contents may slightly differ from other connector manufacturers' or individual company guidelines
and 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.

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SECTION 3
Contact Area

It is the area in contact between two conductors, or a
DEFINITIONS conductor and a connector permitting the flow of
electricity.

AWG
American Wire Gauge. It is the standard system for
Conductor Brush
designating wire diameter. The conductor brush is made up of the wire strands
that extend past the conductor barrel on the contact

Barrel side of the terminal. This helps ensure that
It is the back end portion of a terminal or contact. It mechanical compression occurs over the full length
is crimped to the conductor, insulation, or both. of the conductor crimp. The conductor brush should
When designed to receive the conductor, it is called not extend into the contact area.
the conductor barrel. When designed to support or
grip the insulation, it is called the insulation barrel. BRUSH

Bell Mouth
This is the undisturbed portion of the conductor
barrel nearest the insulation crimp. It is the result CONDUCTOR
from the actual crimping, which acts as a funnel for BARREL
the wires and reduces the possibility of a sharp edge
on the barrel cutting or nicking the wires.
Conductor Crimp
This is the metallurgical compression of a terminal

Bend Test around the wire's conductor. This connection
One way to test the insulation crimp is by bending creates a common electrical path with low
the wire several times and then evaluating the resistance and high current carrying capabilities.
movement of the insulation and wire strands. As a
rule, the insulation crimp should withstand the wire
Conductor Crimp Height (Open Barrel Crimps)
being bent 60 to 90 degrees in any direction, several The conductor crimp height is measured from the
times. Use care when working with small wire sizes top surface of the formed crimp to the bottom radial
so the wire at the back of the insulation crimp does surface. Do not include the extrusion points in this
not shear. measurement. Measuring crimp height is a quick,
non-destructive way to help ensure the correct

Butt Splice metallurgical compression of a terminal around the
It is a device to join two conductors, end-to-end, wire's conductor and is an excellent attribute for
rather than overlapping. process control. The crimp height specification is
typically set as a balance between electrical and

Chamfer mechanical performance over the complete range of
An angle on the inside edge of the barrel entrance of wire stranding and coatings, and terminal materials
a terminal that permits easier insertion of the wires and plating. Although it is possible to optimize a
into the barrel. crimp height to individual wire stranding and
terminal plating, one crimp height specification is
normally created.

Circular Mil Area (CMA)
A unit of area used to indicate wire size. It is the
*Consult individual terminal specification
computed total cross sectional area of conductors.
requirements
One circular mil equals cross-sectional area of a
wire one mil (0.001 inches) in diameter.

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Ferrule

Crimp A short tube used to mate solderless connectors to
It is the act of physically compressing (forming) a shielded or coaxial cable. It is used as an insulation
connector or contact barrel around a cable in order grip sleeve on solderless terminals.
to make an electrical connection. On a crimped
terminal, a second crimp is often added to the
Flash
insulation area for added strain relief. It is an abnormal protrusion on the wire barrel,
(either insulation material or metal), which indicates

CSA that the crimping tool is either misaligned or worn
Canadian Standards Association is an independent and thus should not be used.
Canadian testing laboratory similar to UL
(Underwriters Laboratories Inc.).
Funnel Entry
It is a crimped terminal or splice barrel, which opens

Cut-off Tab Length to facilitate quick and easy wire insertion.
This material protrudes outside the end of the
terminal after the terminal is separated from the
Gas Tight Seal
carrier strip. As a rule, the cut-off tab should be A contact system that utilizes soft metals at high
flush or .254mm (.010”) protruding outside the contact pressures so that upon mating, metal is
housing sleeve. A cut-off tab, which is too long, upset and the resultant joint prevents contaminant
may expose a terminal outside the housing or it may gases from entering the contact area.
fail electrical spacing requirements. In most
situations, a tool is setup to provide a cut-off tab that
Gauge
is flush to one material thickness. A method of measurement, often using “go” and “no-
go” pins or shapes to determine whether a device is
within tolerance.

Harness
A group of wires or cables joined to form a circuit
network for electronic or electrical equipment. A
harness is usually an assembly of cables cut to the
CARRIER STRIP
CUT-OFF TAB proper length, terminated, and tied together prior to
LENGTH being assembled in a piece of equipment.

Dielectric Test
Tests that consist of the application of a voltage
Insulation Crimp (Strain Relief)
higher than the rated voltage for a specific time for It is a crimp encompassing both the wire and
the purpose of determining the adequacy against insulation. This helps to prevent the conductor
breakdown of insulation materials and spacing under from being exposed due to the insulation receding
normal conditions. This test is used to ensure the and offers additional resistance to vibration.
crimping procedure did not puncture or destroy the
insulation material on the terminal.
Insulation Crimp Height
Molex does not specify insulation crimp heights

Extrusions (Flash) because of the wide variety of insulation thickness,
These small flares form on the bottom wire barrel material, and hardness. Most terminals are
resulting from the clearance between the punch designed to accommodate multiple wire ranges.
and anvil tooling. If the anvil is worn or if the Within the terminal’s range, an insulation diameter
terminal is over-crimped an excessive extrusion may not completely surround the wire or fully
results. An uneven extrusion may also result if the surround the diameter of the wire. This condition
punch and anvil being misaligned. will still provide an acceptable insulation crimp for
most applications.

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 A large insulation should firmly grip at least
Nest

88% of the wire. The portion of a crimping die, which supports or
 A smaller insulation should firmly grip at least reshapes the barrel during crimping.
50% of the wire and firmly hold the top of the
wire.
PSI
(Pounds per Square Inch) Used to denote pressure
To evaluate the insulation section, cut the wire flush of air or other gas, e.g. 75 psi.
with the back of the terminal. Once the optimum
setting for the application is determined, it is
Pull Force Testing
important to document the insulation crimp height. Pull force testing is a quick, destructive method to
Then, as part of the setup procedure, the operator evaluate the mechanical properties of a crimp
can check the insulation crimp height. termination. When making a crimp, enough
pressure must be applied to break down the oxides

Locator that may build up on the stripped conductor and the
A device for positioning terminals, splices, or tin-plating on the inside of the terminal grip. This is
contacts in crimping dies. necessary to provide a good metal-to-metal contact.
If this does not occur, resistance can increase.

MCM Over-crimping a crimp termination will reduce the
Equal one thousand circular mils. Used above 4/0 circular area of the conductor and increase
CMA (rather than AWG). resistance.

Mega Pull force testing is also a

Prefix denoting one million, e.g., one Mega volt = good indicator of problems
one million volts. in the process. Cut or
nicked strands in the

Micro stripping operation, lack of
Prefix denotes one millionth, e.g., one Milivolt = bell mouth or conductor
one thousandth of a volt. brush, or incorrect crimp
height or tooling will reduce

Mil Spec pull force. Wire properties
Military Specification. A specification used for and stranding, and terminal
qualification of products for acceptability as required design (material thickness
for U.S. Government applications (usually for a and serration design), also
military branch), e.g. Mil-T-7928 covers terminals, can increase or decrease pull force levels.
lugs, splices, conductors, crimp style.

Serrations

Mechanical Strength It is the saw-toothed grooves on the surface of a
To insure how strong the connection is or how much terminal, which ensures firm gripping of the
the wire and terminal must be squeezed to get a gas conductor. Also provides additional contact area.
tight seal. It’s important to crimp the wires tight
enough to keep them from slipping out of the
Solderless
connector, but not so tight as to crush the wires in This means without solder – in our case, denoting
the terminal, causing them to break off. The the use of a crimping tool.
connection is weakened if the wires are cut or
nicked.
Splice
A device used to join two or more conductors
together.

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determines conductor, cut-off tab length, and

Strip Length terminal extrusions.
The strip length is determined by measuring the PUNCHES
exposed conductor strands after the insulation is
removed. The strip length determines the
conductor brush length when the insulation position TERMINAL
WIRE
is centered.

*Consult individual terminal specification

requirements

STRIP
LENGTH
ANVILS

UL
Underwriters’ Laboratories, Inc., founded in 1894,
is chartered as a not-for-profit organization under

Tab the laws of Delaware, to establish, maintain, and
Flat rectangular male connection tabs on electrical operate laboratories for the investigation of
components; various sizes to fit female quick materials, devices, products, equipment,
disconnects. construction methods, and systems with respect to
hazards affecting life and property.

Tensile Test
This is a pull test to determine the mechanical
Voltage Drop Test
strength of the crimped wire. They are specific A test of the voltage developed across a component
minimum values set for each wire size. See Section or conductor by the current in the resistance or
8. impedance of the component or conductor. It is the
test of the electrical integrity of the crimp.

Terminal
A device designed to terminate a conductor that is to
Wire
be affixed to a wire or cable to establish an electrical They are a group of conductors that has a low
connection. It is a synonym for contact. There are resistance to current flow, together with any
two main types, which include the open barrel and associated insulation. There are two kinds: a solid
the closed barrel. Parts of the terminal are: wire, which is one single strand of material, or
stranded group of wire, which is a bundle of wires
Insulation barrel Where the wire’s insulation will be twisted together to act as one.
crimped or supported so that it is
firmly gripped.
Wire Size
Wire barrel Where the bare wire will be Wires have varying sizes or gauges that carry
crimped. different amounts of electrical current with each wire
Contact area Where the terminal will be attached used for a separate purpose. The size is called out
to the mating part. with a number, such as 8 or 10, followed by the
letters AWG, which stand for American Wire Gauge.

Terminal Position
The terminal position is set by the alignment of the
terminal to the forming punch and anvils, and the
carrier-strip cut-off tooling. The tool set-up

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Wire Stop
It is a stop at the end of a terminal wire barrel. It
WIRES
prevents wire from passing completely through the
barrel so the wire will not interfere with the function
of the contact.

WIRE STOP

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SECTION 4

ASSOCIATED MATERIALS

Caliper
It is a gauge, consisting of two opposing blades, for
measuring linear dimensional attributes.

Pull Tester
A device used to determine the mechanical strength
of a crimp termination. Most pull testing is done
with a device that clamps
the wire, pulls at a set
speed, and measures force
by means of a load cell. A
pull tester also can be as
simple as hanging fixed

Eye Loop weights on the wire for a
It is a magnification tool, minimum of one minute.
normally 10 times power or
greater, which is used to aid
Toolmaker’s Microscope
visual evaluation of a crimp This is used for close
termination. visual evaluation and
statistical measurement of bell mouth, cut-off tab,
conductor brush, wire position, and strip length.

Crimp Micrometer
This is a micrometer
specifically designed to
measure crimp height. The
measurement is taken in the
center of the crimp so the
conductor bell mouth does
not influence it. It has a thin
blade that supports the top of
the crimp while a pointed
section determines the
bottom radial surface.

Ruler (Pocket Scale)

This is used to estimate the five-piece
measurement of bell mouth, cut-off tab, conductor
brush, wire position, and strip length. The
recommended maximum resolution is 0.50mm
(.020”).

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SECTION 5
5.1 Features of Solderless Terminals
The quality of the base material must be evaluated. The material (metal) is either copper or brass depending on the
product.

Molex base metals are purchased, inspected, and received to Military specifications.

Most of these terminals use the guidelines of UL; Underwriters Laboratories is a US organization that sets certain
standards for connector testing.

Some terminals use the guidelines of Mil-T-7928, set by the United States Government.
The following charts show the UL and US Government specifications (MIL-T-7928) for various wire sizes. The
tensile strength is shown in pounds. It indicates the minimum acceptable force to break or separate the terminal
from the conductor.

Color Code Wire Size (AWG) *UL - 486 A *UL – 486 C *UL – 310 *Military Class 2
Yellow 26 3 N/A N/A 7
Yellow 24 5 N/A N/A 10
Red 22 8 8 8 15
Red 20 13 10 13 19
Red 18 20 10 20 38
Blue 16 30 15 30 50
Blue 14 50 25 50 70
Yellow 12 70 35 70 110
Yellow 10 80 40 80 150
Red 8 90 45 N/A 225
Blue 6 100 50 N/A 300
*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 Terminals only as listed

5.2 Barrel Serration/Dimples

Plain Insulation
1. When quality solderless terminals are stamped, the inside of the barrel is
scored with serrations or dimples. Plastic Insulation
Sleeve
2. When the crimp is made and the metal terminal barrel is drastically deformed,
the tin plating on the inside of the barrel is fractured at the serrations, thus
causing bare copper-to-copper contact between the wire and the terminal
barrel. This greatly enhances electrical conductivity. Terminal
3. If properly designed, the serrations, or dimples, have angled grooves that, Funnel Entry
during the crimping operation, will bite into the wire, which will greatly increase
the mechanical integrity of the crimp. Insulation with
Support Sleeve
4. A quality solderless terminal has features built into the barrel that insures a Tin-Plated
quality crimp. Brass Sleeve
5. The non-insulated terminal will have a chamfer at the wire insertion end so the
individual strands will not bump against the end of the metal.
6. An insulated terminal, the insulation should have a funnel entry. This acts as a
Nylon Sleeve
slide for the wires to enter the barrel smoothly.
7. There are two styles of insulated barrels. Both have a funnel feature.

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5.3 Barrel Styles 4. The Avikrimp™ has a color-coded sleeve, which

provides insulation as well as an insulation grip.
The barrel is the part of the terminal that is crimped The insulation is made of Nylon, and has a
around the wire. Molex offers different styles listed secondary tin-plated brass sleeve added. This
below. brass support sleeve is crimped around the wire
insulation providing a strain relief, so the wire does
not vibrate, TIN-PLATE
1. The Krimptite™ is the basic Molex barrel style. It is loosen, fray, or BRASS SLEEVE
non-insulated and is a one- break. It is
TONGUE (STYLE VARIES)
piece design. This available in 10
terminal is the most SEAM to 26 AWG
economical and has the (0.10 to NYLON SLEEVE
greatest variety of uses 6.60mm ).2
AVIKRIMP™
where special features are
not required. It is available TRANSITION
in 10 to 26 AWG (0.10 to BARREL OR THROAT 5. The Open Barrel product is used in manufacturing
6.60mm2). operations where quantity of work is needed. The
KRIMPTITE™
open barrel allows the wire to be crimped faster and
easier and is the barrel style preferred when using
2. The Versakrimp™ is the same as the Krimptite™, automated wire processing equipment.
except the seam is brazed (welded) closed. This
brazed-seam barrel terminal will not open under INSULATION
conditions of stress or wire pull. This allows for SUPPORT
CARRIER
crimping from any direction without the barrel STRIP
opening up, and TONGUE (STYLE VARIES)
provides greater
NO SEAM
tensile strength. This QUICK
terminal is ideal for DISCONNECTS
hard to crimp solid and AND RING
OPEN BARREL TERMINALS
stranded wires. It is STRIP
TRANSITION
available in wire range
BARREL OR THROAT
4/0 to 22 AWG (0.10 to
117.00mm2). VERSAKRIMP™ 6. The Nylakrimp™ is specifically designed for large
wire applications. The color-coded barrel is affix
with a permanent rigid color-coded nylon insulated
3. The Insulkrimp™ has a rigid insulation sleeve made sleeve. It has a funnel entrance that eliminates wire
of PVC (polyvinyl chloride), which protection to the strand fold back. It is available in wire range 4/0 to 8
Krimptite barrel area in wire sizes of 10-22 AWG or AWG (8.50 to 117.00mm2).
the brazed seam of the Versakrimp barrel of 4/0 to
22 AWG. It is available in wire range 4/0 to 22 NYLON SLEEVE
AWG (0.10 to 117.00mm2).

BARREL
HEAVY DUTY
TERMINALS
INSULATION FUNNEL
SLEEVE ENTRANCE NYLAKRIMP™

INSULKRIMP™

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STAR RINGS
MULTI STUDS
7. The Perma-Seal ™is specifically designed for water
resistant applications. The color-coded barrel has a
permanent rigid color-coded nylon insulated sleeve.
It has a funnel entrance that eliminates wire strand
fold back. It is available in wire range 10 to 22 AWG
(0.10 to 6.60 mm2). NYLON SHRINK
TUBING FEMALE QUICK
MALE QUICK
DISCONNECTS
DISCONNECTS
8. The Eyelet can be
used in place of
PERMA-SEAL™
standard compression
terminals because it
SEAMLESS BARREL
is deep drawn from
CDA-110
electrolytic pitch
Barrel Lengths
copper and then tin- EYELET In wire sizes 26-16 AWG, the industry has two
plated for corrosion standard barrel lengths
resistance. It has a FLARED BARREL for the metal barrel.
seamless barrel ENTRY The lengths are 6.35
with a flared barrel BARREL
mm (.25”) and 4.36 mm
LENGTH
entry. It is available in wire range 8 to 500 MCM. (11/64”). The 4.36 mm
barrel is the OEM
(Original Equipment Manufacturer) standard barrel

Tongue Styles length. The 6.35 mm barrel is more commonly used
The “Tongue” is the end of the terminal that attaches in the maintenance and aftermarket segments of
to other components (switch, stud, transformer, etc.). industry.
These tongue configurations vary. The following are The purpose of the longer barrel is simply to give the
some examples: user a bigger target area to crimp. These barrel
lengths are not so important if you use a terminal
RINGS HOOKS with the molded step construction on the insulation,
or if a precision ratchet tool with terminal locator is
used. OEM tooling is usually designed for only short
barrel terminals.

SPADES FLANGED
Step Construction Insulation for Tool Location

SPADES The “step” on the insulation of molded terminals is
used to position (locate) the crimping tool. The tool
should rest on the step and crimp made just above
it. This insures that the entire width of the crimping
tool is hitting on the barrel below. This step
construction is very important when using a non-
SNAP SPADES FLAG RINGS ratchet maintenance tool without a locator.

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Step Down Butt Slices

The Step Down Butt Splice is the perfect solution
when two wires need
to be inserted in one
end of a splice and a
single wire in the
other end.
LOCATE
TOOL HERE

STEP  Butt Splice

Avikrimp
CONSTRUCTION With the extra metal sleeve and nylon insulation,

Insulation Barrel Colors these splices should be used when heavy vibration
The colors on the insulation barrel (red, blue, and is anticipated and a
yellow) are used to indicate the wire range. The strong strain relief is
colors repeat themselves and are an industry needed.
standard color-coding. See the Chart below.

Color Code Wire Range (AWG)

Yellow 24-26
Red 18-22

Nylon Closed –End Connector
Blue 14-16 Used in a wide variety of
Yellow 10-12 situations to “pigtail” or tie
Red 8 together two or more wires.
Blue 6
Yellow 4

There are different kinds of barrels with different
Funnel Entry Butt Splice
shades of the same color, which are used for In the past, the crimping of machine terminated butt
different barrel styles. PVC and Nylon take the color splices has been difficult and nearly impossible if
differently. In the 14-16 AWG range (blue) for attempted on a piece of robotic equipment. Now,
example, the PVC barrels will be dark blue. The with our new Funnel Entry Butt Splice, the end that
nylon barrels will be a lighter, translucent blue. will be crimped by the crimping press is funneled to
When using the lighter blue terminals, the secondary allow quick and easy
sleeve will be crimped in addition to the wire barrel wire insertion.
crimp. The actual shade of color has nothing to do
with quality of the insulation.

Perma-Seal Splices™
5.4 Splices The tough sleeve of Perma-Seal splices resist
abrasion and cutting. This protective helps to
Molex-offers standard and special splices for nearly maintain the insulation and sealing properties even
every type of wiring need. in hostile
environments, not

Butt Slices to mention
On this connector, the unbeatable strain
stripped wires are relief.
inserted from each end
and they "butt" in the
center. Then a crimp at
each end secures the
connection.

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Wire Tap
Parallel Splice

The Wire Tap makes tapping into an existing wire This connector has stripped wires that lie side-by-
quick, easy, and reliable. This Tap-and-Run splice side in the splice. They are secured by a single
is actually a fully insulated female quick disconnect crimp in the
that can be spliced onto a wire and then mated with middle.
a .250 x .032 fully insulated, partially insulated, or
non-insulated male quick disconnect all without
stripping, twisting, soldering, or the need for special
tools. The Wire Tap is actually a female quick
Window Butt
disconnect. Splice
This connector has military approval (Mil-T-7928/5)

Multi-Lock to withstand the harshest environments. The
These color-coded connectors make quick, reliable, window guarantees proper wire insertion and crimp
and pre-insulated splices without stripping, twisting, tool alignment. They are nylon insulated and have
soldering, or the need for an insulation grip that provides superior strain relief.
special tools.

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SECTION 6
ACCEPT REJECT
PROCEDURES
Improper Stripping
“Nicked” Strands
6.1 Preparing the Wire

Check the stranded wire to see if any strands have

loosened and expanded to be larger than the wire and
the insulation together. If this has occurred, twist the Proper Stripping
wires to the size they were before they were stripped. Be Undamaged
Strands
sure that the stranded wire is within the outside diameter
of the insulation after you have twisted them.
Improper Stripping
ACCEPT REJECT
Cut Strands
Expanded Strands
Loose Wire 6.2 Setup and Operation of a Press

1. Check that tooling is clean and not worn. If

necessary, clean and replace worn tooling.
Wire within Exceeds
Outside Diameter
2. Disconnect power to the press and remove
Outside Diameter
guarding devices.
3. Install the appropriate tooling into the press.
Check the insulation to ensure that there has been 4. Load terminals into the tooling so that the first
a nice clean cut. Wires with damaged insulation terminal is located over the anvil.
should not be used. 5. Manually cycle the press to help ensure a complete
cycle can be made without interference. If it
ACCEPT REJECT cannot, remove tooling and check press shut
Insulation
height. Go to procedure 3.
Whiskers 6. Check that the tooling is aligned. Check the
impression on the bottom of the crimp that was
Insulation
Thickness made by the anvil tooling. Check that the
extrusions and crimp form are centered. If not,
Damage Less
Damage 1/2 of
align tooling and go to
Than 1/2 of procedure 5.
Insulation Thickness
Insulation Thickness 7. Check that the terminal
or Greater
feed locates the next
Split terminal over the center
Cut of the anvil tooling. If
not, adjust terminal
feed and the feed finger
and go to procedure 5.
8. Re-install all safety
Burred or Charred devices that were removed during the set-up.
(Follow all safety requirements listed in
individual press and/or tooling manuals.)
9. Crimp sample terminals under power.
Check to see if the stripping tool or machine has cut or 10. Evaluate cut-off tab length and conductor bell
nicked any of the wires. If you see nicked wire you must mouth. If adjustment is necessary, disconnect
cut and re-strip the wire before crimping to be sure that power to the press and remove guarding. Adjust
the amount of current that can be carried is not reduced.

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TBO-Quality Crimp Handbook
track position. Manually cycle the press and check 3. Place the terminal in the tool. Select the proper
the feed finger for feed location, go to procedure 7. color-coded crimp nest.
11. Evaluate conductor brush. If adjustment is 4. If using a locator, lift the locator and insert the
necessary, disconnect power to the press and terminal in the proper nest with the barrel up and
remove guarding. Adjust wire stop for bench against the locator bar. Release the locator blade to
applications or press position on automatic wire hold the terminal in position. See Figure 1. Locator
processing equipment. Go to procedure 8. may be raised or lowered so terminal sits flat and
12. Evaluate insulation position. If necessary, adjust straight in tool. The locator must be removed to run
strip length, crimp new samples, and go to splices.
procedure 11. 5. Insert the wire. See Figure 2.
13. Loosen insulation crimp height.
14. Crimp sample terminals.
15. Measure conductor crimp height and compare to
specification. If necessary, disconnect power and
remove guarding. Adjust conductor crimp height,
install guards, connect power, and go to procedure
14.
16. Perform a pull force test. Refer to troubleshooting
(Section 9) if this test fails.
17. Adjust insulation crimp. TERMINAL
18. Crimp sample terminals. Figure 2 WIRE
19. Evaluate insulation crimp. If necessary,
disconnect power and remove guarding. Adjust 6. Squeeze the handle. All production hand tools
insulation crimp height, install guards, connect should have a built in full-cycle ratchet mechanism.
power, and go to procedure 18. 7. Inspect for proper crimp location. Check the Hand
20. Measure crimp height and compare to Crimp Tool Specification sheet that you are using for
specification. If necessary, disconnect power and correct conductor crimp height.
remove guarding. Adjust conductor crimp height,
install guards, connect power, and go to procedure 6.4 Setup and Operation of a Air Powered Crimp
18. Tool
21. Document measurements.
1. Insure the Air Crimp Tool is designed to crimp the
6.3 Setup and Operation of a Hand Crimp Tool size wire and the proper terminal shown on the Air
Crimp Tool Specification Sheet.
1. Insure the hand tool is designed to crimp the size 2. Strip the wire and make sure it is clear of any nicks
wire and the proper terminal shown on the Hand or cuts. See Section above Preparing the Wire.
Crimp Tool Specification sheet. 3. Place the wire into the terminal. Select the proper
color-coded crimp nest.

SAFETY
SHEILD

LOCATOR TERMINAL
Figure 1 TERMINAL
2. Strip the wire and make sure it is clear of any nicks LOCATOR
Figure 3
or cuts. See Section above Preparing the Wire.

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TBO-Quality Crimp Handbook
Four piece F TYPE CRIMP, VibraKrimp™
4. If using a locator, lift the locator and insert the Four piece CONFINED CRIMP, InsulKrimp™ and
terminal with the wire in the proper nest with the AviKrimp™.
barrel up and against the locator bar. Release the Bottom INDENTOR CRIMP, 8 and 6 AWG
locator blade to hold the terminal in position. See VersaKrimp™.
Figure 3. Locator may be raised or lowered so
terminal sits flat and straight in tool. The locator
The Indentor crimp consists of a holding nest and
must be removed to run splices. indentor ram to deform the barrel. The advantage of
5. Push on the wire to assure it is still fully seated in the this configuration is that while it covers a broad
terminal. Cycle the tool. See Figure 4. range of wire sizes, it is still easy to design and
inexpensive to manufacture.

WIRE
TERMINAL
Figure 4
The F crimp is used to close the barrel and confine
the individual strands. The overall quality is
6. Inspect for proper crimp location. Check the Air excellent.
Powered Crimp Hand Tool Specification Sheet that
you are using for correct conductor crimp height

Caution:
Never operate this tool without the supplied
safety shield in place. Never place fingers in
the tool nests.

Note:
Whenever crimping without the locator, make sure
The Confined crimp gives the best overall crimp. It
the seam of the terminal is oriented up or down in is in the shape of a hexagon, an enclosed “C”, or a
the tool if using unbrazed product, as this will confined quad. The advantages of all three crimps
provide higher pull force values. are uniformity and compression of individual strands
and uniform outer appearance.

6.5 Crimping Dies

The Molex product line includes seven types of dies:

Two piece INDENTOR CRIMP, VersaKrimp™

Two piece CONFINED CRIMP, Krimptite™ and
VersaKrimp™
Two piece CONFINED CRIMP, InsulKrimp™ and
AviKrimp™
Two piece F TYPE CRIMP, Krimptite™ and
VersaKrimp™

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TBO-Quality Crimp Handbook
Molex provides a complete line of fully automatic you are not tied to a single source of supply for
wire processing machines. Each system is tailored components. This Manual shows the basics of Hand
to our individual customer’s needs by using support Held and Semi-Automatic equipment.
equipment, such as ARTOS, KOMAX, and others.
Using Molex application tooling experience and
machinery, built by non-component manufacturers,

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TBO-Quality Crimp Handbook
SECTION 7
ACCEPT REJECT
Quality Crimps
Quality is something that must be measured by some
Insulation Insulation
set of criteria. Four major agencies give test criteria for Slightly Pierced or
solderless terminals. They are: Damaged Crushed

U.L. (Underwriters Laboratories)
Insulation Support Crimp

CSA (Canadian Standard Association)
ACCEPT REJECT

NEMA (National Electronic Manufacturers
Association)

Federal Government Spec - Mil-T-7928 Metal Insulation Insulation
Tabs Formed Wire Tab Bent
In all of the above standards specific reference is made Is Held Snugly
to the following areas:
1. Be sure that the insulation barrel tabs are not
bent.

Copper or brass quality specifications
2. Form the tabs properly.

Tin-plating specs type and thickness 3. If one of the tabs is bent, the insulation crimp

Smoothness of edges and lack of burrs will not be strong enough to provide the

Firmness of fit between metal and insulation needed stress relief.

Then there is a whole series of tests to be performed
Wire Visible

on the crimp area after the crimp is made:
ACCEPT
1. Be sure that both the

Tensile test wire and the insulation

Dielectric withstand are visible in the window.
Window

Salt spray 2. If only the insulation is

Vibration visible, you may have

Heat rise crimp insulation in the conductor barrel. (Reject)
3. If only the bare wire is visible, you cannot assume
The most widely used field test for testing the quality of that the insulation has been properly crimped.
the crimp is the pull test, or tensile test. REJECT
REJECT

The two most widely used measurements are the U.L.

and Military Tensile values. See Section 8. Note that Insulation Wire Not
the Military is higher than the U.L. Not Visible Visible

7.1 Visual Inspection of OPEN BARREL Crimps 4. If there is no insulation support crimp, be sure that
wire visible behind the conductor crimp does not

Insulation Not Damaged extend the diameter of the insulation. If the visible
wire exceeds the diameter of the insulation, the
1. Crimp the insulation just enough (may have a terminal could cause a short.
ACCEPT REJECT
slight indentation to hold the wire in place). If Insulation
the insulation has been pierced or crushed, the Diameter
wires inside may have been damaged also.
2. Be sure that the conductor insulation has not Wire Visible Exceeds
been pierced or crushed by the crimp. Insulation Diameter

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TBO-Quality Crimp Handbook

Good Bell Mouth Present

ACCEPT REJECT
ACCEPT REJECT

Slight Wire Wire

Bell Mouth Crimped Protrudes
Wire No Bell Mouth
Crimp

Wire Extension
1. Be sure that a good bell mouth is present in the 1. Be sure that the wires extend not more than
wire barrel. 1/32” (.032”) past the end of the barrel. If the
2. If no bell is present, the sharp edge of the wire wires are not flush or greater, you will not be
barrel may cut or nick the wires. able to see if the crimp is complete and correct.
ACCEPT REJECT

No Wire Strands in the Contact Area
ACCEPT REJECT Wire
Wire Flush or Not Flush
Greater
Up to 1/32” (.032)
Wire in
Contact Area
Contact Area

No Damage to the Contact Area
ACCEPT REJECT

Wire in
Contact Area Contact Area
Slight Scratch or Scrape Contact Area
but No Visual Dents Damaged
No Wire Stop
Wire Stop Do Not Use
1. Be sure that the contact area is not dented or
crushed.
2. If it is dented or crushed (slight scratch or scrape
is permissible), the connection between the
1. Be sure that no wire strands extend into the terminal and another component cannot be
contact area of the lug or terminal. made properly.
2. If the wire strands are in the contact area, they
will interfere when the terminal is connected. 7.2 Visual Inspection of CLOSED BARREL Crimp

No Strands Sticking Out (Strand Turn Back)
Wire Visible

1. Be sure that all of the wire strands are twisted
ACCEPT
together, and are equal to the size they were Insulation
before being stripped. Crimp Wire Stop REJECT
2. If the strands are not together, or if one is left
sticking out, your wire mass is reduced and can
cause both electrical and mechanical problems.
Wire Brush
Wire Crimp is Visible Wire not Visible

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TBO-Quality Crimp Handbook
1. Be sure that the wire is visible in the inspection 2. This “brush” extension should be approximately
window so that there is evidence of a good 1/32” (.032”).
crimp. See Butt Connector below. 3. If the wires are not flush or greater, you will not
be able to see if the crimp is complete.

Crimp to be Centered
1. On all crimped terminals, the conductor crimp
Wire Size (AWG) Requirements
should be centered on the conductor barrel. This 1. To achieve a quality crimp be sure to follow the
insures even pressure on the entire length of the proper insulation crimp for different the size
barrel. wires.
ACCEPT REJECT
Wire sizes of 8AWG and larger do not require an
insulation crimp.
ACCEPT
Centered Not Centered
Too Far Forward
No Insulation Crimp

Good Bell Mouth Present
ACCEPT REJECT Wire sizes 18 thru 10 AWG require an insulation
crimp and the wire to be held securely in the
insulation crimp.

Bell Mouth Bell Mouth PLASTIC INSULATION CRIMP

1. Be sure that a good bell mouth is present on the REJECT REJECT

wire barrel.

No Wire Strands in the Contact Area Insulation Deformed No Insulation

Wire Can Move Crimp
In Insulation Crimp
REJECT
ACCEPT
METAL INSULATION
ACCEPT CRIMP REJECT
Wire in
Contact Area Contact Area

1. Be sure that wire strands do not exceed into the No Insulation

Insulation Deformed
tongue area of the lug or terminal. Crimp
Wire Should Not Move
2. If the wire strands are in the contact area, they In Insulation Crimp
will interfere when the terminal is connected.
METAL INSULATION

Wire Flush or Greater ACCEPT CRIMP REJECT

ACCEPT REJECT

Insulation Indent Insulation Indent

Wire Flush or Wire Formed-Wire Secure Formed-Wire Moves
Greater (Brush) Not Flush In Insulation Crimp In Insulation Crimp

1. Be sure that the wires are either flush with the

wire barrel crimp or extend or beyond.

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TBO-Quality Crimp Handbook

Insulation Support Crimp Quality of the Conductive Material

ACCEPT REJECT
The material should be 99.9% pure electrolytic tough
pitch copper wire. If you are dealing with terminals
that are approved for use by the Federal
Government under MIL-T-7958, then you are
Metal Sleeve Snug Metal Sleeve
assured the highest grades of copper are being
Not Snug
used.

1. On closed barrel terminals that have a

secondary metal sleeve (AviKrimp™), the metal
sleeve should be formed snugly around the wire.

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TBO-Quality Crimp Handbook
SECTION 8 8.2 Testing

Importance of Proper Crimping Mechanical

Once the correct terminal is selected, proper The tensile test or pull test is a means of evaluating the
attachment to the wire is critical. One indication of the mechanical properties of the crimped connection. The
importance of proper crimping is evidenced in a study chart on the existing page shows the UL and US
for the Space Shuttle Program that traced 28% of all Government Specifications (MIL-T-7928) for various wire
defects to improperly assembled wiring and connectors. sizes. The tensile strength is shown in pounds, it
Mechanical As Well As Electrical Connections Are indicates the minimum acceptable force to break or
Important - The result of a properly crimped joint is a separate a terminal from the conductor.
reliable mechanical and electrical connection.
When the crimp is made, there must be enough pressure
The mechanical connection is the crimping of the applied so that the oxides that may build up on the
terminal to the conductor. The desired result is stripped conductor and the tin plating on the inside of the
sufficient force on the outside of the barrel to tightly terminal barrel are broken down and there is good metal-
form it around the conductor. It must be secure enough to-metal contact. If this situation does not occur,
not to vibrate loose or to be pulled off through normal resistance can again build in the crimps.
use.
Just as important are the electrical characteristics. The Tensile Strength in Pounds
*Military
major concern is the amount of electrical resistance Wire Size *UL-486A *UL-486-C *UL-310
Class 2
caused by the mechanical joint. The electrical 26 3 N/A N/A 7
resistance will determine the crimped joint’s ability to 24 5 N/A N/A 10
conduct current. If you buy a quality product, you will 22 8 8 8 15
find that in many cases the mass of the metal barrel 20 13 10 13 19
after crimping actually aids the conduction. The extra 18 20 10 20 38
mass allows for little or no resistance over the crimp - 16 30 15 30 50
14 50 25 50 70
as long as the crimp is made properly. 12 70 35 70 110
10 80 40 80 150
8.1 Conditions 8 90 45 N/A 225
6 100 50 N/A 300
To achieve a positive relationship between the 4 140 N/A N/A 400
mechanical and electrical connection in the crimped 2 180 N/A N/A 550
1 200 N/A N/A 650
joint, the following conditions are required:
1/0 250 N/A N/A 700
1. The terminal must be of sufficient cross section 2/0 300 N/A N/A 750
size and conductive material that it is as good an 3/0 350 N/A N/A 825
electrical conductor as the wire. 4/0 450 N/A N/A 875
2. The surfaces of the wire and terminal that will be 250 MCM 500 N/A N/A 1000
pressed into contact in the crimp must be clean and 300 MCM 550 N/A N/A 1120
free of heavy, non-conductive films such as oxides, 350 MCM 600 N/A N/A 1125
sulfides, and similar substances.
*UL - 486 A - Terminals (Copper conductors only)
Some reasons for failure of crimped joints to meet *UL - 486 C - Butt Splices, Parallel Splices, Closed
minimum tensile requirements include nicked wires, End Connectors, and Wire Nuts
nicked or ruptured strands, strand turn back at crimp *UL - 310 - Quick Disconnects, Flag and Couplers
joint, and ruptured wires outside of the crimped *Military Class 2- Military Approved Terminals only as
terminal. To avoid these problems, use the correct size listed
wire for the barrel, prepare your wire carefully, and use
the proper crimping tool.

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Dielectric Testing If the die presses too tightly the individual strands can
(The term “dielectric” refers to an insulator.) be squeezed and elongated. This can cause a weak
point in the conductor. This can cause the wire to
Some terminals are covered with insulation so that break at a lower than allowable tensile strength,
electrical contact can be made only where it is and/or create a heat rise across the joint because of
desirable. The crimp is made through (on) this increased resistance.
insulation, which is compressed and extruded due to Causing Potential Wire is deformed
the pressure of the crimping dies. Obviously, not all Failure Mode or Future Excessive
Or Compressed Beyond
insulation materials can withstand this treatment and Break or Fracture Point Crimp Depth
Normal Yield Point
even with the strongest materials, the crimp must be
correctly designed so as not to rupture the insulation. Single
Strand Wire
Dielectric tests are made on insulated terminals after Terminal
Excessive
crimping to determine that the crimp process is not Bell Mouth
Wire Barrel
rupturing the insulation or thinning it out so that it will
not withstand impressed voltages. The test is made Another way to cause tensile failure is not
by impressing a voltage between the wire to which the compressing the barrel enough to hold the conductor
terminal is crimped and conductive materials securely. Molex crimp tools are designed to eliminate
contacting the terminal insulation. these problems.

8.4 Electrical Resistance

The electrical resistance across the crimp is compared

to the resistance of an equal length of wire, and
expressed as relative resistance for a particular wire
size.

The voltage is gradually increased until the Relative resistance of the crimp to the wire:
requirements are reached or until a breakdown occurs RC RC = Resistance over crimp
which means the insulation breaks. Depending on the RW RW = Resistance of wire
use and the specifying agency, dielectric withstanding
requirements normally range from 1500 to 8000 volts,
resulting in a 300 to 600 volt rating.

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 Relative resistance values of less than 1.0 denote a
enough, a void may be created in the compression crimped joint with less resistance than the wire;
joint permitting the individual strands to shift, thus values more than 1.0 indicate greater resistance than
loosening the connection. Further, the air space the wire. Usually it is easier to measure the voltage
(void) acts as an electrical resistor. drop across the crimped joint. Many specifications
state the requirements in terms of voltage drop at a
specified current. Voltage drop is the more
commonly used term in the industry. If the resistance
value is desired, it may be calculated from Ohms
Law:

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TBO-Quality Crimp Handbook
Annealing
R (ohms) = E (volts)
I (amps) When the metal part of a solderless terminal is
stamped on a stamping press; the strip of metal
Crimp voltage drop and resistance values are quite material is repeatedly hit in the stamping process.
small and are expressed in terms of mili-volts (.001
volts) and mili ohms (.001 ohms). These terminals are made on progressive dies

The indication of a poor crimp joint could be caused by

several factors. The resistance will increase or mili-
volt will drop.
This repeated hitting causes, the metal (usually
The presence of air pockets or voids in the crimped copper) to become WORK hardened. Copper gives
joint will cause a higher resistance. its best mechanical and electrical characteristics
These same voids cause higher resistance and will when it is in its original (not work hardened) state.
cause a temperature rise, which in turn increases the
corrosion rate and further increases the resistance. In order to return the work hardened copper to its
A crimped joint that has been over-crimped and the normal soft and malleable state, it must be annealed.
conductor (wire) elongated out of shape could cut the Annealing is accomplished by heating the metal
circular area of the conductor and cause a greater (copper) terminal in a furnace, and then cooling it
resistance at this weakened point. slowly. This process restores the copper to its
original state.
8.5 Crimp Joints
ACCEPT REJECT
A finely stranded wire (large number of small diameter
strands) usually improves crimped joint performance.
A wire composed of a few strands of larger size will Wire
tend to act as a solid wire in the crimp. Some Wire Flush or Not Flush
Greater Up to
stranded wire crimp configurations are not satisfactory 1/32” (.032”)
for solid wire. More deformation must be imposed in
order to form wire and barrel into a solid mass. On the How does annealing (or lack of) affect the crimp
other hand, finer strands will more readily fill the inside barrel and quality of a solderless terminal?
corner of the crimp shape and more evenly distribute
strand formation. When a work-hardened terminal is crimped, it does
not form around the wire in a uniform fashion, thus
Brazed barrel terminals usually give higher tensile test giving sharp angles, which allows for voids. The
than the non-brazed (for specific values, tensile tests annealed barrel can be easily formed, giving uniform
must be performed on each terminal). pressure on the wire and thus a superior crimp.

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TBO-Quality Crimp Handbook

SECTION 9
Miscellaneous
AWG-CMA Table
Terminal Size CMA Range
26-22 202-810
24-20 320-1,020
22-18 509-2,600
22-16 509-3,260
16-14 2,050-5,180
14-12 3,260-8,213
12-10 5,180-13,100
8 13,100-20,800
6 20,800-33,100
4 33,100-52,600
2 52,600-83,700
1/0 83,700-119,500
2/0 119,500-150,500
3/0 150,500-190,000
4/0 190,000-231,000

Technical Wire Information

CMA — Circular Mil Area is a unit of area equal to that of a circle whose diameter is
one Mil.
MIL — One mil equals .001 inches.
.001 = 1 mil
.030 = 30 mils
.125 = 125 mils
Changing Inches to Mils
1. Multiply inches by 1000
2. Move decimal point 3 places to right
3. Change terminology, i.e. .032 in. = 32 thousandths or 32 mils.

Computation of CMA
Round Solid Conductor:
Change diameter from inches to mils, and then multiply the diameter in mils by itself.
CMA = D mils x D mils
Stranded Conductor:
Find CMA of a single strand and multiply the result by the total number of strands.
CMA = (D x D) x Number of Strands of one Strand

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