Qual Crimp

QUALITY CRIMPING HANDBOOK
QUALITY CRIMPING
HANDBOOK
Bringing People & Technology Together, WorldwideSM
Corporate Headquarters : 2222 Wellington Court, Lisle, IL, 60532, U.S.A., Tel : 630-969-4550
Application Tooling Division : 1150 E. Diehl Rd., Naperville, IL 60563, Tel : 630-969-4550
European Headquarters : Munich, Germany, Tel : 49-89-413092-0
Far East North Headquarters : Kanagawa, Japan, Tel : 81-462-2336
Far East South Headquarters : Jurong Town, Singapore, Tel : 65-268-6868
Printed in U.S.A.
Order Number - 63800-0029
5M JI 6/96
1996, Molex Incorporated

Illustrations by Julie Theis-Pane
PRODUCED BY THE MOLEX

APPLICATION TOOLING GROUP
10.0 NOTES
Table of Contents
Introduction To Crimp Technology ........... 5
1.0
Purpose
............................................... 6
2.0
Scope
............................................... 7
3.0
Definitions
............................................... 9
4.0
Associated Materials ................................... 15
5.0
Procedure
5.1
Tool Setup
................................... 16
6.0
Measurement ............................................... 20
6.1
Pull Force
................................... 20
6.2
Crimp Height ................................... 23
7.0
Process Control
7.1
7.2
7.3
7.4
8.0
................................... 24
Process Capability
Production
Visual Inspection
Control Charting
Trouble Shooting
8.1
8.2
8.3
8.4
8.5
8.6
38
............................................... 16
....................... 24
.......................26
.......................26
.......................26
....................... 29
Wire Preparation
....................... 29
Bellmouth and Cut-Off Tab Length 29
Conductor Brush and Insulation Position 31
Insulation Crimp
....................... 33
Crimp Height ................................... 35
Pull Force
................................... 35
9.0
Wire Gauge Chart
10.0
Notes
................................... 36
............................................... 38
3
INTRODUCTION TO
CRIMP TECHNOLOGY
9.0 Wire Gauge Chart

AWG
WIRE AREA
STRANDING
WIRE DIAMETER CIRCULAR
WIRE BREAK
sq. inch
sq. mm
dia.
inch
mm
MILLS
lbs.
0.01287
8.302
0.1280
0.128
3.25
16384
489.0
2175.00
0.01212
7.820
19
0.0285
0.145
3.68
15433
460.6
2048.72
0.01233
7.955
49
0.0179
0.147
3.73
15700
468.6
2084.21
0.01334
8.605
133
0.0113
0.147
3.73
16983
506.9
2254.49
0.01319
8.513
168
0.0100
0.147
3.73
16800
501.4
2230.22
0.01306
8.424
665
0.0050
0.147
3.73
16625
496.2
2206.99
10
0.00816
5.261
0.1019
0.102
2.59
10384
309.9
1378.44
10
0.00735
4.740
37
0.0159
0.115
2.92
9354
279.2
1241.75
10
0.00776
5.006
49
0.0142
0.116
2.95
9880
294.9
1311.63
10
0.00825
5.320
105
0.0100
0.116
2.95
10500
313.4
1393.89
12
0.00513
3.308
0.0808
0.081
2.05
6529
194.8
866.69
12
0.00563
3.632
0.0320
0.096
2.44
7168
213.9
951.56
12
0.00478
3.085
19
0.0179
0.093
2.36
6088
181.7
808.16
12
0.00511
3.294
65
0.0100
0.095
2.41
6500
194.0
862.88
12
0.00514
3.3118
165
0.0063
0.095
2.41
6549
195.5
869.37
14
0.00323
2.082
0.0641
0.064
1.63
4109
122.6
545.45
14
0.00352
2.270
0.0253
0.073
1.85
4481
133.7
594.81
14
0.00301
1.941
19
0.0142
0.073
1.85
3831
114.3
508.59
14
0.00322
2.078
41
0.0100
0.073
1.85
4100
122.4
544.28
14
0.00327
2.112
105
0.0063
0.073
1.85
4167
124.4
553.24
16
0.00203
1.308
0.0508
0.051
1.30
2581
77.0
342.58
16
0.00222
1.433
0.0201
0.060
1.52
2828
84.4
375.43
16
0.00191
1.229
19
0.0113
0.058
1.47
2426
72.4
322.07
16
0.00204
1.317
26
0.0100
0.059
1.50
2600
77.6
345.15
16
0.00203
1.307
65
0.0063
0.059
1.50
2580
77.0
342.48
16
0.00206
1.330
105
0.0050
0.058
1.47
2625
78.3
348.47
18
0.00128
0.823
0.0403
0.040
1.02
1624
48.5
215.60
18
0.00139
0.897
0.0159
0.048
1.22
1770
52.8
234.93
18
0.00126
0.811
16
0.0100
0.047
1.19
1600
47.8
212.40
18
0.00149
0.963
19
0.0100
0.049
1.24
1900
56.7
252.23
36
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. But 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 end 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 so 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 x 19 strand
wire than an 18 AWG x 16 strand. The insulation diameter of an 18 AWG wire
can range from .070" (1,78 mm) to over .180" (4,57 mm). Wire strands can
be copper, tinned, overcoated, or topcoated. 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.
1.0 PURPOSE
8.0 TROUBLE SHOOTING

8.5 CRIMP HEIGHT
Problem
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, bellmouth, cut-off tab, 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 bellmouth 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. Chapter 5 has a flowchart for a process setup while
Chapter 7 is a trouble shooting guide for common problems. Using Statistical
Process Control (SPC) during the crimping process can help minimize the
Parts per Million (PPM) reject levels. Chapter 6 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.
Cause
Changed crimp tooling

Crimp height off target
(Fig. 42)
Changed crimp press

(shut height)
Changed press type
(manufacturer)
Changed terminal reel
(lot code)
Adjust tooling back to target
Changed tooling set-up

Damaged or worn tooling
Wire variability
Terminal variability
Crimp height variability to high

(Fig. 43)
Inspect incoming product.
Damaged, loose, or worn

tooling
Tooling replacement or
tightening
Measurement error
Gage capability analysis
Terminal spring back too great,

over crimping
Cut or missing wire strands
Crimp height adjustment

Stripping process adjustment
Cause
Solution
Cut or nicked strands
Check the stripping process
Crimp height too low
Adjust crimp height
8.6 PULL FORCE
Problem
Wire breaks before conductor
crimp - low pull force (Fig. 45)
Wire pulls out of conductor grip

- low pull force (Fig. 45)
Small or no bellmouth
Adjust tooling track
Insulation crimp through

insulation wall
Raise insulation crimp height
Crimp height too high
Adjust crimp height
Small or no conductor brush
Increase strip length
Conductor bellmouth too big
Gold terminal application

Terminal material thickness too
small
Light serrations on terminal
Solution
Changed wire type, vendor, or

stranding
Changed insulation color or
durometer
This handbook provides general guidelines and procedures for understanding

and achieving acceptable crimp terminations. A Glossary in Chapter 3 lists
common terms and definitions. Chapter 4 lists the tools that are necessary to
take accurate measurements and evaluate the crimp's acceptability.
35
Evaluate the terminal

application
Contact your local sales
engineer
2.0 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.
Figure 41 - Optimal Crimp Height Chart
Figure 42 - Crimp Height Off Target
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.
Figure 43 - Crimp Height Variability Too High
Figure 44 - Optimal Pull Force Chart
Figure 45 - Low Pull Force Chart
8.4 INSULATION CRIMP
Problem
Cause
Terminal surrounds less than

88% of a large diameter wire
(Fig. 37)
Crimp too loose, not enough

terminal insulation barrel
Terminal contacts less than

Too much terminal insulation
50% of a small diameter wire
barrel
(Fig. 38)
Solution
Tighten insulation crimp height
Evaluate terminal
Evaluate terminal
Insulation crimp barrels cut

through insulation into
conductor strands (Fig. 39)
Crimp too tight
Adjust insulation crimp

height*
Insulation not firmly gripping

insulation, fails bend test
(Fig. 40)
Crimp too loose
Adjust insulation crimp height

tighter
*Inexpensive hand tools provide no adjustment for the insulation crimp. A

hand tool is intended for low volume applications. Although you are not able
to adjust the insulation crimp on a hand tool, an insulation crimp which
pierces the insulation may still be considered acceptable for many applications. This criteria only applies to hand tools due to their low speed crimp
cycle. If the insulation crimp pierces the insulation, the wire strands tend to
move aside without damage.
Figure 1 - Terminal Anatomy

8
33
3.0 DEFINITIONS
(Anatomy of a Crimp Termination)
Figure 34 - Preferred Insulation Crimp
BEND TEST
One way to test the insulation crimp is by bending the wire several times and
then evaluating the movement of the insulation and wire strands. As a general
rule, the insulation crimp should withstand the wire being bent 60 to 90
degrees in any direction, several times. Use care when working with small
wire sizes so the wire at the back of the insulation crimp does not shear.
Figure 36 - Acceptable Insulation Crimp
CONDUCTOR BRUSH
The conductor brush is made up of the wire strands that extend past the conductor crimp on the contact side of the terminal. This helps ensure that
mechanical compression occurs over the full length of the conductor crimp.
The conductor brush should not extend into the contact area.
CONDUCTOR CRIMP
This is the metallurgical compression of a terminal around the wire's conductor. This connection creates a common electrical path with low resistance and
high current carrying capabilities.
Figure 38 - Marginal Insulation Crimp
BELLMOUTH (FLARE)
The flare that is formed on the edge of the conductor crimp acts as a funnel
for the wire strands. This funnel reduces the possibility that a sharp edge on
the conductor crimp will cut or nick the wire strands. As a general guideline,
the conductor bellmouth needs to be approximately 1 to 2x the thickness of
the terminal material *.
* Consult individual terminal specifications
32
CONDUCTOR CRIMP HEIGHT

The conductor crimp height is measured from the top surface of the formed
crimp to the bottom most radial surface. Do not include the extrusion points in
this measurement (See Figure 2, pg. 10). Measuring crimp height is a quick,
non-destructive way to help ensure the correct metallurgical compression of a
terminal around the wire's conductor and is an excellent attribute for process
control. The crimp height specification is typically set as a balance between
electrical and mechanical performance over the complete range of wire stranding and coatings, and terminal materials and platings. Although it is possible
to optimize a crimp height to individual wire strandings and terminal platings,
one crimp height specification is normally created.
CUT-OFF TAB LENGTH
This is the material that protrudes outside the insulation crimp after the terminal is separated from the carrier strip. As a general rule, the cut-off tab is
approximately 1.0 to 1.5x terminal material thickness *. A cut-off tab that is
too long may expose a terminal outside the housing or it may fail electrical
spacing requirements. In most situations, a tool is setup to provide a cut-off
tab that is flush to one material thickness.
* Consult individual terminal specifications requirements.
9

8.3 CONDUCTOR BRUSH AND INSULATION POSITION
Problem
Cause
Solution
Insulation under cond. crimp,

good conductor brush (Fig. 26)
Strip length too short
Check specification, adjust strip

length longer
Bench - Wire stop position

incorrect
Wire Processing - Press
position incorrect
Adjust wire stop to center of

transition area
Adjust press position away
from wire
Insulation under conductor

crimp, long conductor brush
length (Fig. 27)

crimp, short or no conductor
brush (Fig. 28)

length longer
Re-adjust wire stop position for
bench applications OR
Re-adjust press position for
wire processing applications

length shorter
Strip length too long
Insulation edge centered in tranbench applications OR
sition area, conductor brush too
long (Fig. 29)
Irregular wire cut-off or strands
Check for worn stripping
pulled from insulation bundle
tooling
Insulation edge centered in transition area, conductor brush too

short (Fig. 30)
Insulation edge under insulation

crimp, good or long conductor
brush (Fig. 31)

length longer

length shorter
Terminal Cross Section

brush (Fig. 32)
10

incorrect
position incorrect

transition area
from wire
Verify operators wire

placement ability
Operator training, reduce

crimping rate
31
Figure 26 - Insulation Under Conductor Crimp,

Good Conductor Brush
EXTRUSIONS (FLASH)
These are the small flares that form on the bottom of the conductor crimp
resulting from the clearance between the punch and anvil tooling. If the anvil
is worn or the terminal is over-crimped, excessive extrusion results. An
uneven extrusion may also result if the punch and anvil alignment is not correct, if the feed adjustment is off, or if there is insufficient/excessive terminal
drag.
INSULATION CRIMP (STRAIN RELIEF)
This is the part of the terminal that provides both wire support for insertion
into the housing and allows the terminal to withstand shock and vibration.
The terminal needs to hold the wire as firmly as possible without cutting
through to the conductor strands. The acceptability of an insulation crimp is
subjective and depends on the application. A bend test is recommended to
determine whether or not the strain relief is acceptable for each particular
application.
Figure 25 - Optimal Crimp

Short or No Conductor Brush

Conductor Brush Too Long
Figure 30 - Conductor Brush Too Short
INSULATION CRIMP HEIGHT

Molex does not specify insulation crimp heights because of the wide variety
of insulation thickness, material, and hardness. Most terminals are designed
to accommodate multiple wire ranges. Within the terminals range, an insulation diameter may not completely surround the wire or fully surround the
diameter of the wire. This condition will still provide an acceptable insulation
crimp for most applications.
A large insulation should firmly grip at least 88% of the wire.

A smaller insulation should firmly grip at least 50% of the wire
and firmly hold the top of the wire.
To evaluate the insulation section cut the wire flush with the back of the terminal. Once the optimum setting for the application is determined it is important to document the insulation crimp height. Then, as part of the setup procedure the operator can check the crimp height.
Figure 29 - Conductor Brush Too Long
Figure 32 - Insulation Under Insulation Crimp,

Conductor Brush Too Short

30
INSULATION POSITION
This is the location of the insulation in relation to the transition area between
the conductor and insulation crimps. Equal amounts of the conductor strands
and insulation needs to be visible in the transition area. The insulation position ensures that the insulation is crimped along the full length of the insulation crimp, and that no insulation gets crimped under the conductor crimp.
The insulation position is set by the wire stop and strip length for bench
applications. For automatic wire processing applications the insulation position is set by the in/out press adjustment.
11

8.1 WIRE PREPARATION
Problem
Irregular Insulation Cut (Fig. 16)
Figure 3 - Strip Length

Cut or nicked strands (Fig. 17)
Irregular conductor cut pulled strands (Fig. 18)
Figure 4 - Process
Wire length variability too high

(Fig. 19)
Wrong strip length (Fig. 19)
Cause
Solution
Worn tooling
Replace tooling
Cut depth too shallow
Adjust cut depth
Damaged tooling
Replace tooling
Cut depth too deep
Adjust cut depth
Conductor not on wire center
Contact wire supplier
Worn tooling
Replace tooling
Wire cut depth too shallow
Adjust cut depth
Wire drive rollers/belts worn
Replace belts/rollers
Insulation durometer too hard
Increase drive pressure
Wire straightener too loose or

tight
Adjust wire straightener
Incorrect setup
Re-setup tooling
Figure 5 - Pull Force Tester
8.2 BELLMOUTH AND CUT-OFF TAB LENGTH
Problem
Figure 7 - In Press Terminal Position
Figure 6 - Press Shut Height
12
Cause
Solution
Low pull force (Fig. 21 & 22)
Excessive bellmouth no cut-off Adjust track position for small

tab
cut-off tab
Excessive bellmouth, cut-off tab Check for worn or incorrect
punch tooling and replace
alright
No bellmouth and/or excessive

cut-off tab
Long cut-off tab (Fig. 24)
Good bellmouth and excessive

cut-off tab
29
Adjust track position

Check for camber in terminal
strip
Check for worn cut-off and

replace if necessary
Check for worn punch tooling,
replace, and re-adjust track
STRIP LENGTH
The strip length is determined by measuring the exposed conductor strands
after the insulation is removed. The strip length determines the conductor
brush length when the insulation position is centered.
Figure 17 - Cut Strands

Figure 16 - Irregular Insulation Cut
Figure 18 - Pulled Strands

Figure 19 - Wire Length Variability
or Wrong Strip Length
PROCESS
The combination of people, equipment, tooling, materials, methods and procedures needed to produce a crimp termination. Process Control is used to
track attributes over time to aid in the detection of change to the process.
Detecting a process change when it happens helps prevent many thousands of
bad crimps.
PULL FORCE TESTING

Pull Force Testing is a quick, destructive way to evaluate the mechanical
properties of a crimp termination. When making a crimp, enough pressure
must be applied to breakdown the oxides that may build up on the stripped
conductor and the tin plating on the inside of the terminal grip. This is necessary to provide a good metal-to-metal contact. If this does not occur, resistance can increase. Over crimping a crimp termination will reduce the circular area of the conductor and increase resistance.
Pull Force testing is also a good indicator of problems in the process. Cut or
nicked strands in the stripping operation, lack of bellmouth or conductor
brush, or incorrect crimp height or tooling will reduce pull force. Wire properties and stranding, and terminal design (material thickness and serration
design), also can increase or decrease pull force levels.
Figure 21 - Excessive Bellmouth
Figure 22 - Excessive Bellmouth, No Cut-off Tab
SHUT HEIGHT
The distance, at bottom dead center on a press, from the tooling mounting
base plate to the tooling connection point on the ram of the press.
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 determines conductor bellmouth, cut-off tab length, and terminal extrusions.
Figure 23 - No Bellmouth, Excessive Cut-off Tab
Figure 24 - Excessive Cut-off Tab, Good Bellmouth
28
13
It indicates that a process shift occurred between measurement 12 and 13. This
type of shift could occur due to a change in wire, a change in terminal lots, a
jam in the machine that damaged the tooling, a change in operators, or an
adjustment to the insulation crimp. Since the measurements are still within
specification, would you stop production to adjust crimp height?
A shift in the process due to a change in material may warrant a crimp height
adjustment. A shift after a jam would not indicate an adjustment, but a close
evaluation of the tooling. A shift in the process between operators would not
indicate an adjustment, but an evaluation of measurement capability. The purpose of a control chart is to identify what caused the shift in process to justify if
an adjustment to the process is needed.
Figure 8 - Caliper
Figure 9 - Eye Loop
Figure 11 - Pocket Ruler
Figure 10 - Crimp Micrometer
Figure 12 - Toolmakers Microscope
14
27
4.0 ASSOCIATED MATERIALS

7.2 PRODUCTION
Before the tool is ready for production, the level of capability needs to be
established. Many harness manufacturers run only a few hundred or few thousand wires at one time. In this case, it is not practical or economical to run a
twenty-five piece capability with every set-up.
7.3 VISUAL INSPECTION
It needs to be standard operating procedure for the operator to manually fan
each bundle of crimped wires and visually check bellmouth, conductor brush,
insulation position, cut-off tab length, and insulation crimp.
7.4 CONTROL CHARTING
Crimp height is typically control charted because it is a quick nondestructive
measurement and is critical for the termination's electrical and mechanical
reliability. There are three primary purposes for control charting. One, the number of setup samples is usually small, with limited statistical value. Two, since
special cause effects on a process are irregular and unpredictable, it is necessary to be able to catch changes in the process as soon as they occur. This prevents thousands of terminations from being scrapped after the run is over.
Three, and most important, this data is necessary to assess and improve the
crimp process.
Once the tooling process is setup and the wire size does not change, keep one
control chart for wire color changes, wire length changes, terminal material
changes, or setup adjustments. Record the data point on the chart before making a crimp height adjustment. If data is recorded after each adjustment, the
process is likely to assume control and provide little data for improving the
process. The operator needs to make as many notes as possible on the chart.
The only truly effective and economically sensible way to manage a manufacturing process is to understand, monitor and reduce sources of variability that
are inherent to the process itself. Every minute required for setup or adjustments is unproductive. What does this sample chart tell us?
CALIPER
A gage, consisting of two opposing blades, for measuring linear dimensional
attributes.
EYE LOOP
A magnification tool, normally 10x power or greater, which is used to aid
visual evaluation of a crimp termination.
CRIMP MICROMETER
This is a micrometer specifically designed to measure crimp height. The
measurement is taken in the center of the crimp so it is not influenced by the
conductor bellmouth. It has a thin blade that supports the top of the crimp
while a pointed section determines the bottom most radial surface.
RULER (POCKET SCALE)

This is used to estimate the five piece measurement of bellmouth, cut-off tab,
conductor brush, wire position, and strip length. The recommended maximum
resolution is .5 mm (.020 in).
PULL TESTER (Reference fig. 5, pg.12)

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 weights on the wire for a minimum of one minute.
TOOLMAKER'S MICROSCOPE
This is used for close visual evaluation and statistical measurement of bellmouth, cut-off tab, conductor brush, wire position, and strip length.
X & R Chart
Control Limit for sample of 5 = Avg (Avg of 5readings) + .577 x Avg (Ranges)
26
15
5.0 PROCEDURES
5.1 TOOL SETUP (Reference Procedures Flow Chart)
1.
Check that tooling is clean and not worn. If necessary, clean and
replace worn tooling.
2.
Disconnect power to the press and remove guarding devices.
3.
Install the appropriate tooling into the press.
4.
Load terminals into the tooling so that the first terminal is located
over the anvil.
5.
Manually cycle the press to help ensure a complete cycle can be

made without interference. If it cannot, remove tooling and check
press shut height. Go to procedure 3.
6.
Check that the tooling is aligned. Check the impression on the

bottom of the crimp that was made by the anvil tooling. Check that
the extrusions and crimp form are centered. If not, align tooling and
go to procedure 5.
7.
Check that the terminal feed locates the next terminal over the
center of the anvil tooling. If not, adjust terminal feed and feed
finger and go to procedure 5.
8.
Re-install all safety 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.
10. Evaluate cut-off tab length and conductor bellmouth. If adjustment is

necessary, disconnect power to the press and remove guarding.
Adjust track position. Manually cycle the press and check the feed
finger for feed location, go to procedure 7.
11. Evaluate conductor brush. If adjustment is necessary, disconnect
power to the press and remove guarding. Adjust wire stop for bench
applications, or press position on automatic wire processing
equipment. Go to procedure 8.
12. Evaluate insulation position. If necessary, adjust strip length, crimp
new samples, and go to procedure 11.
16
A 25 piece minimum sample needs to be taken from the crimping process.

Calculate the average and standard deviation for each specification. A capability index is defined by the formula below. Cp may range in value from 0 to
infinity, with a larger value indicating a more capable process. A value >1.33
is considered acceptable for most applications.
Tolerance
6*Standard Deviation
The CpK index indicates whether the process will produce units within the
tolerance limits. CpK has a value equal to Cp if the process is centered on the
mean of specification; if CpK is negative, the process mean is outside the
specification limits; if CpK is between 0 and 1 then some of the 6 sigma spread
falls outside the tolerance limits. If CpK is larger than 1, the 6 sigma spread is
completely within the tolerance limits. CpK is calculated with the lesser of the
following formulas:
(USL - MEAN)
(MEAN - LSL)
USL = Upper Specification Limit, LSL = Lower Specification Limit

Six sigma is a goal of many companies because it represents virtually zero
defects. The ability of a company to achieve a six sigma level depends on the
amount of common variability in its process. For example, hand stripping the
wire produces more variability than a stripping machine; a crimping hand tool
produces more variability than a press and die set and bench terminations produce more variability than a wire processing machine.
A part of the variability in crimping will result from the type of instruments
that are used to measure the parts and the operator's ability to repeat the measurement. A crimp micrometer will measure more accurately than a dial
caliper. An automatic pull force system will measure better than a hook type
scale. It is important that the measurement gage has enough resolution.
Two operators may measure the same part differently, or the same operator may
measure the part differently when using two types of gages. Molex recommends a gage capability study to identify what part of the variability is coming
from measurement error. Micro-terminals crimped to small wire sizes need a
tight crimp height range to maintain pull force. The variability from measurement error can keep CpK's low.
The capability of the crimping tools needs to be re-confirmed if the production
data is significantly different from the capability study.
25
7.0 CRIMP PROCESS

CONTROL
13. Loosen insulation crimp height.

14. Crimp sample terminals.
The crimp process is the interaction of a terminal, wire, tooling, personnel,

methods and procedures, and environmental attributes. When this process is
controlled it will produce a quality termination. Quality control is an important
part of quality crimping. It should not take excessive setup or inspection time to
do and can save a harness manufacturer thousands of dollars in potential
rework or re-manufacturing.
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.
Variability is the slight changes that occur from crimp to crimp. There are two
types of variability, common or special. Common causes of variation affect the
process uniformly and are the result of many small sources. Common variability are inherent tolerances within a reel of wire or terminals. Common variability also is created by the natural tolerances of the stripping and crimping
machines.
17. Adjust insulation crimp.
Reducing variability at the common level typically has to come from changes
at the wire, terminal, and tooling manufacturer.
Special causes of variation occur irregularly and unpredictably. Without checks
throughout a run, having a tool become loose after the first hundred crimps or a
jam result from a damaged tool may be undetected until thousands of crimps
are made.
7.1 PROCESS CAPABILITY
Before putting a new crimping tool in production, Molex recommends that
each customer do a capability study, using the specific wire that will be used in
its process. A capability study, which is based on the assumption of a normal
distribution (bell-type curve), estimates the probability of a measurement being
outside of specification.
CpK
+/- Sigma
% Yield
PPM*
0.67
95.45
45,500
99.73
2,699
1.33
99.99
63
1.67
99.99+
0.57
99.99++
16. Perform a pull force test. If it fails, refer to trouble shooting.

19. Evaluate insulation crimp. If necessary, disconnect power and
remove guarding. Adjust insulation crimp height, install guards,
connect power, and go to procedure 18.
20. Measure 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 18.
21. Document measurements.
Please Work Safely At All Times.
* PPM - Parts per million potential defects.
24
17
PROCEDURES
18
6.2 CRIMP HEIGHT TESTING

1.
Complete tool set-up procedure.
2.
Crimp a minimum of 5 samples.
3.
Place the flat blade of the crimp micrometer across the center of the
dual radii of the conductor crimp. Do not take the measurement
near the conductor bellmouth.
4.
Rotate the micrometer dial until the point contacts the bottom most
radial surface. If using a caliper, be certain not to measure the
extrusion points of the crimp.
5.
Record crimp height readings. A minimum of 5 crimp height

readings are necessary to confirm each set-up. A minimum of
25 readings are necessary to determine capability.
6.
Check crimp height every 250 to 500 parts throughout the run.
Note:
Crimp Height is usually control charted because it is a quick

nondestructive measurement and is critical for the termination's
electrical and mechanical reliability. There are three primary \
purposes for control charting. One, the number of setup samples is
normally small, and its statistical value is limited. Two, since
special cause/effects on a process are irregular and unpredictable, it
is necessary to have a means of catching changes in the process as
soon as they occur. This prevents having to scrap thousands of
terminations after the run is over. Three, and this is most important,
the data is necessary to assess and improve the crimp process.
23
FLOW CHART
22
Figure 15 - Caliper
19
6.0 MEASUREMENT
Note:
6.1 PULL FORCE TESTING
1.
Cut wire length approximately 6 inches (152 mm) long.
2.
Strip one end to 1/2 inch (13 mm) or long enough so no wire
insulation is under the insulation grip, or loosen the insulation crimp
so it has no grip on the insulation of the wire.
3.
Terminate the appropriate terminal to the wire to the nominal crimp

height.
4.
Visually inspect the termination for bellmouth, wire brush, and cut
strands.
5.
Set pull tester to 2" per minute (50 mm/min). For most applications, a
higher rate will not have a significant impact on the data. The slower
rate prevents a sudden application of force or jerking that snaps
strands. Verify higher pull rates with data taken at 2" per minute.
High variability and lower CpK's are common for double

wire applications. The variability is due to more variation in
conductor brush, conductor bellmouth and fewer strands of one wire
being in contact with the serrations on the terminal barrel. A double
crimp application is considered no better than the smallest wire
crimped. Higher pull force readings can be seen if both wires are
gripped and pulled exactly together. Pulling each wire individually
will result in a much lower pull force reading. If both wires are of the
same size, the top wire will normally result in a lower reading than the
bottom wire due to the effects of the terminal serrations.
Wire Chart
Test Values for Pullout Test
UL486A
Size of Conductor
Pullout Force*
AWG
LBS.
(N)
(mm2)
30
(0.05)
1.5
(6.7)
If necessary, knot the UN-terminated end of the wire (If insulation

slips on wire).
28
(0.08)
(8.9)
26
(0.13)
(13.4)
Regardless of pull tester type, both wire and terminated end must be
securely clamped. (Note: Clamp terminal contact interface, do not
clamp conductor crimp)
24
(0.20)
(22.3)
22
(0.324)
(35.6)
8.
Activate pull test.
20
(0.519)
13
(57.9)
9.
Record pull force readings. A minimum of 5 pull force measurements

should be done to confirm each set-up. A minimum of 25 readings
should be taken for capability.
18
(0.823)
20
(89.0)
16
(1.31)
30
(133.5)
14
(2.08)
50
(222.6)
12
(3.31)
70
(311.5)
10
(5.261)
80
(356.0)
(8.367)
90
(400.5)
6.
7.
10.
Compare lowest reading to minimum pull force specification.
* Consult individual specifications
Note:
20
Figure 13 - Pull Force Testing
Pull Force has only a minimum specification. For CpK calculations,

the average reading is assumed nominal and the upper specification
limit is set so CP and CpK are equal. High pull force readings that
increase the standard deviation can lower CpK even if the mean and
lowest reading are increased.
21
6.0 MEASUREMENT
Note:
6.1 PULL FORCE TESTING
1.
Cut wire length approximately 6 inches (152 mm) long.
2.
Strip one end to 1/2 inch (13 mm) or long enough so no wire
insulation is under the insulation grip, or loosen the insulation crimp
so it has no grip on the insulation of the wire.
3.
Terminate the appropriate terminal to the wire to the nominal crimp

height.
4.
Visually inspect the termination for bellmouth, wire brush, and cut
strands.
5.
Set pull tester to 2" per minute (50 mm/min). For most applications, a
higher rate will not have a significant impact on the data. The slower
rate prevents a sudden application of force or jerking that snaps
strands. Verify higher pull rates with data taken at 2" per minute.
High variability and lower CpK's are common for double

wire applications. The variability is due to more variation in
conductor brush, conductor bellmouth and fewer strands of one wire
being in contact with the serrations on the terminal barrel. A double
crimp application is considered no better than the smallest wire
crimped. Higher pull force readings can be seen if both wires are
gripped and pulled exactly together. Pulling each wire individually
will result in a much lower pull force reading. If both wires are of the
same size, the top wire will normally result in a lower reading than the
bottom wire due to the effects of the terminal serrations.
Wire Chart
Test Values for Pullout Test
UL486A
Size of Conductor
Pullout Force*
AWG
LBS.
(N)
(mm2)
30
(0.05)
1.5
(6.7)
If necessary, knot the UN-terminated end of the wire (If insulation

slips on wire).
28
(0.08)
(8.9)
26
(0.13)
(13.4)
Regardless of pull tester type, both wire and terminated end must be
securely clamped. (Note: Clamp terminal contact interface, do not
clamp conductor crimp)
24
(0.20)
(22.3)
22
(0.324)
(35.6)
8.
Activate pull test.
20
(0.519)
13
(57.9)
9.
Record pull force readings. A minimum of 5 pull force measurements

should be done to confirm each set-up. A minimum of 25 readings
should be taken for capability.
18
(0.823)
20
(89.0)
16
(1.31)
30
(133.5)
14
(2.08)
50
(222.6)
12
(3.31)
70
(311.5)
10
(5.261)
80
(356.0)
(8.367)
90
(400.5)
6.
7.
10.
Compare lowest reading to minimum pull force specification.
* Consult individual specifications
Note:
20
Figure 13 - Pull Force Testing
Pull Force has only a minimum specification. For CpK calculations,

the average reading is assumed nominal and the upper specification
limit is set so CP and CpK are equal. High pull force readings that
increase the standard deviation can lower CpK even if the mean and
lowest reading are increased.
21
FLOW CHART
22
Figure 15 - Caliper
19
PROCEDURES
18
6.2 CRIMP HEIGHT TESTING

1.
Complete tool set-up procedure.
2.
Crimp a minimum of 5 samples.
3.
Place the flat blade of the crimp micrometer across the center of the
dual radii of the conductor crimp. Do not take the measurement
near the conductor bellmouth.
4.
Rotate the micrometer dial until the point contacts the bottom most
radial surface. If using a caliper, be certain not to measure the
extrusion points of the crimp.
5.
Record crimp height readings. A minimum of 5 crimp height

readings are necessary to confirm each set-up. A minimum of
25 readings are necessary to determine capability.
6.
Check crimp height every 250 to 500 parts throughout the run.
Note:
Crimp Height is usually control charted because it is a quick

nondestructive measurement and is critical for the termination's
electrical and mechanical reliability. There are three primary \
purposes for control charting. One, the number of setup samples is
normally small, and its statistical value is limited. Two, since
special cause/effects on a process are irregular and unpredictable, it
is necessary to have a means of catching changes in the process as
soon as they occur. This prevents having to scrap thousands of
terminations after the run is over. Three, and this is most important,
the data is necessary to assess and improve the crimp process.
23
7.0 CRIMP PROCESS

CONTROL
13. Loosen insulation crimp height.

The crimp process is the interaction of a terminal, wire, tooling, personnel,

methods and procedures, and environmental attributes. When this process is
controlled it will produce a quality termination. Quality control is an important
part of quality crimping. It should not take excessive setup or inspection time to
do and can save a harness manufacturer thousands of dollars in potential
rework or re-manufacturing.
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.
Variability is the slight changes that occur from crimp to crimp. There are two
types of variability, common or special. Common causes of variation affect the
process uniformly and are the result of many small sources. Common variability are inherent tolerances within a reel of wire or terminals. Common variability also is created by the natural tolerances of the stripping and crimping
machines.
17. Adjust insulation crimp.
Reducing variability at the common level typically has to come from changes
at the wire, terminal, and tooling manufacturer.
Special causes of variation occur irregularly and unpredictably. Without checks
throughout a run, having a tool become loose after the first hundred crimps or a
jam result from a damaged tool may be undetected until thousands of crimps
are made.
7.1 PROCESS CAPABILITY
Before putting a new crimping tool in production, Molex recommends that
each customer do a capability study, using the specific wire that will be used in
its process. A capability study, which is based on the assumption of a normal
distribution (bell-type curve), estimates the probability of a measurement being
outside of specification.
CpK
+/- Sigma
% Yield
PPM*
0.67
95.45
45,500
99.73
2,699
1.33
99.99
63
1.67
99.99+
0.57
99.99++
16. Perform a pull force test. If it fails, refer to trouble shooting.

19. Evaluate insulation crimp. If necessary, disconnect power and
remove guarding. Adjust insulation crimp height, install guards,
connect power, and go to procedure 18.
20. Measure 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 18.
21. Document measurements.
Please Work Safely At All Times.
* PPM - Parts per million potential defects.
24
17
5.0 PROCEDURES
5.1 TOOL SETUP (Reference Procedures Flow Chart)
1.
Check that tooling is clean and not worn. If necessary, clean and
replace worn tooling.
2.
Disconnect power to the press and remove guarding devices.
3.
Install the appropriate tooling into the press.
4.
Load terminals into the tooling so that the first terminal is located
over the anvil.
5.
Manually cycle the press to help ensure a complete cycle can be

made without interference. If it cannot, remove tooling and check
press shut height. Go to procedure 3.
6.
Check that the tooling is aligned. Check the impression on the

bottom of the crimp that was made by the anvil tooling. Check that
the extrusions and crimp form are centered. If not, align tooling and
go to procedure 5.
7.
Check that the terminal feed locates the next terminal over the
center of the anvil tooling. If not, adjust terminal feed and feed
finger and go to procedure 5.
8.
Re-install all safety 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.
10. Evaluate cut-off tab length and conductor bellmouth. If adjustment is

necessary, disconnect power to the press and remove guarding.
Adjust track position. Manually cycle the press and check the feed
finger for feed location, go to procedure 7.
11. Evaluate conductor brush. If adjustment is necessary, disconnect
power to the press and remove guarding. Adjust wire stop for bench
applications, or press position on automatic wire processing
equipment. Go to procedure 8.
12. Evaluate insulation position. If necessary, adjust strip length, crimp
new samples, and go to procedure 11.
16
A 25 piece minimum sample needs to be taken from the crimping process.

Calculate the average and standard deviation for each specification. A capability index is defined by the formula below. Cp may range in value from 0 to
infinity, with a larger value indicating a more capable process. A value >1.33
is considered acceptable for most applications.
Tolerance
The CpK index indicates whether the process will produce units within the
tolerance limits. CpK has a value equal to Cp if the process is centered on the
mean of specification; if CpK is negative, the process mean is outside the
specification limits; if CpK is between 0 and 1 then some of the 6 sigma spread
falls outside the tolerance limits. If CpK is larger than 1, the 6 sigma spread is
completely within the tolerance limits. CpK is calculated with the lesser of the
following formulas:
(USL - MEAN)
(MEAN - LSL)
USL = Upper Specification Limit, LSL = Lower Specification Limit

Six sigma is a goal of many companies because it represents virtually zero
defects. The ability of a company to achieve a six sigma level depends on the
amount of common variability in its process. For example, hand stripping the
wire produces more variability than a stripping machine; a crimping hand tool
produces more variability than a press and die set and bench terminations produce more variability than a wire processing machine.
A part of the variability in crimping will result from the type of instruments
that are used to measure the parts and the operator's ability to repeat the measurement. A crimp micrometer will measure more accurately than a dial
caliper. An automatic pull force system will measure better than a hook type
scale. It is important that the measurement gage has enough resolution.
Two operators may measure the same part differently, or the same operator may
measure the part differently when using two types of gages. Molex recommends a gage capability study to identify what part of the variability is coming
from measurement error. Micro-terminals crimped to small wire sizes need a
tight crimp height range to maintain pull force. The variability from measurement error can keep CpK's low.
The capability of the crimping tools needs to be re-confirmed if the production
data is significantly different from the capability study.
25
4.0 ASSOCIATED MATERIALS

7.2 PRODUCTION
Before the tool is ready for production, the level of capability needs to be
established. Many harness manufacturers run only a few hundred or few thousand wires at one time. In this case, it is not practical or economical to run a
twenty-five piece capability with every set-up.
7.3 VISUAL INSPECTION
It needs to be standard operating procedure for the operator to manually fan
each bundle of crimped wires and visually check bellmouth, conductor brush,
insulation position, cut-off tab length, and insulation crimp.
7.4 CONTROL CHARTING
Crimp height is typically control charted because it is a quick nondestructive
measurement and is critical for the termination's electrical and mechanical
reliability. There are three primary purposes for control charting. One, the number of setup samples is usually small, with limited statistical value. Two, since
special cause effects on a process are irregular and unpredictable, it is necessary to be able to catch changes in the process as soon as they occur. This prevents thousands of terminations from being scrapped after the run is over.
Three, and most important, this data is necessary to assess and improve the
crimp process.
Once the tooling process is setup and the wire size does not change, keep one
control chart for wire color changes, wire length changes, terminal material
changes, or setup adjustments. Record the data point on the chart before making a crimp height adjustment. If data is recorded after each adjustment, the
process is likely to assume control and provide little data for improving the
process. The operator needs to make as many notes as possible on the chart.
The only truly effective and economically sensible way to manage a manufacturing process is to understand, monitor and reduce sources of variability that
are inherent to the process itself. Every minute required for setup or adjustments is unproductive. What does this sample chart tell us?
CALIPER
A gage, consisting of two opposing blades, for measuring linear dimensional
attributes.
EYE LOOP
A magnification tool, normally 10x power or greater, which is used to aid
visual evaluation of a crimp termination.
CRIMP MICROMETER
This is a micrometer specifically designed to measure crimp height. The
measurement is taken in the center of the crimp so it is not influenced by the
conductor bellmouth. It has a thin blade that supports the top of the crimp
while a pointed section determines the bottom most radial surface.
RULER (POCKET SCALE)

This is used to estimate the five piece measurement of bellmouth, cut-off tab,
conductor brush, wire position, and strip length. The recommended maximum
resolution is .5 mm (.020 in).
PULL TESTER (Reference fig. 5, pg.12)

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 weights on the wire for a minimum of one minute.
TOOLMAKER'S MICROSCOPE
This is used for close visual evaluation and statistical measurement of bellmouth, cut-off tab, conductor brush, wire position, and strip length.
X & R Chart
Control Limit for sample of 5 = Avg (Avg of 5readings) + .577 x Avg (Ranges)
26
15
It indicates that a process shift occurred between measurement 12 and 13. This
type of shift could occur due to a change in wire, a change in terminal lots, a
jam in the machine that damaged the tooling, a change in operators, or an
adjustment to the insulation crimp. Since the measurements are still within
specification, would you stop production to adjust crimp height?
A shift in the process due to a change in material may warrant a crimp height
adjustment. A shift after a jam would not indicate an adjustment, but a close
evaluation of the tooling. A shift in the process between operators would not
indicate an adjustment, but an evaluation of measurement capability. The purpose of a control chart is to identify what caused the shift in process to justify if
an adjustment to the process is needed.
Figure 8 - Caliper
Figure 9 - Eye Loop
Figure 11 - Pocket Ruler
Figure 12 - Toolmakers Microscope
14
27
STRIP LENGTH
The strip length is determined by measuring the exposed conductor strands
after the insulation is removed. The strip length determines the conductor
brush length when the insulation position is centered.
Figure 17 - Cut Strands

Figure 16 - Irregular Insulation Cut
Figure 18 - Pulled Strands

Figure 19 - Wire Length Variability
or Wrong Strip Length
PROCESS
The combination of people, equipment, tooling, materials, methods and procedures needed to produce a crimp termination. Process Control is used to
track attributes over time to aid in the detection of change to the process.
Detecting a process change when it happens helps prevent many thousands of
bad crimps.
PULL FORCE TESTING

Pull Force Testing is a quick, destructive way to evaluate the mechanical
properties of a crimp termination. When making a crimp, enough pressure
must be applied to breakdown the oxides that may build up on the stripped
conductor and the tin plating on the inside of the terminal grip. This is necessary to provide a good metal-to-metal contact. If this does not occur, resistance can increase. Over crimping a crimp termination will reduce the circular area of the conductor and increase resistance.
Pull Force testing is also a good indicator of problems in the process. Cut or
nicked strands in the stripping operation, lack of bellmouth or conductor
brush, or incorrect crimp height or tooling will reduce pull force. Wire properties and stranding, and terminal design (material thickness and serration
design), also can increase or decrease pull force levels.
Figure 21 - Excessive Bellmouth
Figure 22 - Excessive Bellmouth, No Cut-off Tab
SHUT HEIGHT
The distance, at bottom dead center on a press, from the tooling mounting
base plate to the tooling connection point on the ram of the press.
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 determines conductor bellmouth, cut-off tab length, and terminal extrusions.
Figure 23 - No Bellmouth, Excessive Cut-off Tab
Figure 24 - Excessive Cut-off Tab, Good Bellmouth
28
13

8.1 WIRE PREPARATION
Problem
Irregular Insulation Cut (Fig. 16)
Figure 3 - Strip Length

Irregular conductor cut pulled strands (Fig. 18)
Figure 4 - Process
Wire length variability too high

(Fig. 19)
Wrong strip length (Fig. 19)
Cause
Solution
Worn tooling
Replace tooling
Cut depth too shallow
Adjust cut depth
Damaged tooling
Replace tooling
Cut depth too deep
Adjust cut depth
Conductor not on wire center
Contact wire supplier
Worn tooling
Replace tooling
Wire cut depth too shallow
Adjust cut depth
Wire drive rollers/belts worn
Replace belts/rollers
Insulation durometer too hard
Increase drive pressure
Wire straightener too loose or

tight
Adjust wire straightener
Incorrect setup
Re-setup tooling
Figure 5 - Pull Force Tester
8.2 BELLMOUTH AND CUT-OFF TAB LENGTH
Problem
Figure 7 - In Press Terminal Position
Figure 6 - Press Shut Height
12
Cause
Solution
Low pull force (Fig. 21 & 22)
Excessive bellmouth no cut-off Adjust track position for small

tab
cut-off tab
Excessive bellmouth, cut-off tab Check for worn or incorrect
punch tooling and replace
alright
No bellmouth and/or excessive

cut-off tab
Long cut-off tab (Fig. 24)
Good bellmouth and excessive

cut-off tab
29
Adjust track position

Check for camber in terminal
strip
Check for worn cut-off and

replace if necessary
Check for worn punch tooling,
replace, and re-adjust track

Good Conductor Brush
EXTRUSIONS (FLASH)
These are the small flares that form on the bottom of the conductor crimp
resulting from the clearance between the punch and anvil tooling. If the anvil
is worn or the terminal is over-crimped, excessive extrusion results. An
uneven extrusion may also result if the punch and anvil alignment is not correct, if the feed adjustment is off, or if there is insufficient/excessive terminal
drag.
INSULATION CRIMP (STRAIN RELIEF)
This is the part of the terminal that provides both wire support for insertion
into the housing and allows the terminal to withstand shock and vibration.
The terminal needs to hold the wire as firmly as possible without cutting
through to the conductor strands. The acceptability of an insulation crimp is
subjective and depends on the application. A bend test is recommended to
determine whether or not the strain relief is acceptable for each particular
application.

Short or No Conductor Brush

Figure 30 - Conductor Brush Too Short
INSULATION CRIMP HEIGHT

Molex does not specify insulation crimp heights because of the wide variety
of insulation thickness, material, and hardness. Most terminals are designed
to accommodate multiple wire ranges. Within the terminals range, an insulation diameter may not completely surround the wire or fully surround the
diameter of the wire. This condition will still provide an acceptable insulation
crimp for most applications.
A large insulation should firmly grip at least 88% of the wire.

A smaller insulation should firmly grip at least 50% of the wire
and firmly hold the top of the wire.
To evaluate the insulation section cut the wire flush with the back of the terminal. Once the optimum setting for the application is determined it is important to document the insulation crimp height. Then, as part of the setup procedure the operator can check the crimp height.
Figure 29 - Conductor Brush Too Long

Conductor Brush Too Short

30
INSULATION POSITION
This is the location of the insulation in relation to the transition area between
the conductor and insulation crimps. Equal amounts of the conductor strands
and insulation needs to be visible in the transition area. The insulation position ensures that the insulation is crimped along the full length of the insulation crimp, and that no insulation gets crimped under the conductor crimp.
The insulation position is set by the wire stop and strip length for bench
applications. For automatic wire processing applications the insulation position is set by the in/out press adjustment.
11

8.3 CONDUCTOR BRUSH AND INSULATION POSITION
Problem
Cause
Solution
Insulation under cond. crimp,

good conductor brush (Fig. 26)

length longer

incorrect
position incorrect

transition area
from wire

crimp, long conductor brush
length (Fig. 27)

brush (Fig. 28)

length longer

length shorter
Insulation edge centered in tranbench applications OR
sition area, conductor brush too
long (Fig. 29)
Irregular wire cut-off or strands
Check for worn stripping
pulled from insulation bundle
tooling
Insulation edge centered in transition area, conductor brush too

short (Fig. 30)

crimp, good or long conductor
brush (Fig. 31)

length longer

length shorter
Terminal Cross Section

brush (Fig. 32)
10

incorrect
position incorrect

transition area
from wire
Verify operators wire

placement ability
Operator training, reduce

crimping rate
31
3.0 DEFINITIONS
(Anatomy of a Crimp Termination)
BEND TEST
One way to test the insulation crimp is by bending the wire several times and
then evaluating the movement of the insulation and wire strands. As a general
rule, the insulation crimp should withstand the wire being bent 60 to 90
degrees in any direction, several times. Use care when working with small
wire sizes so the wire at the back of the insulation crimp does not shear.
CONDUCTOR BRUSH
The conductor brush is made up of the wire strands that extend past the conductor crimp on the contact side of the terminal. This helps ensure that
mechanical compression occurs over the full length of the conductor crimp.
The conductor brush should not extend into the contact area.
CONDUCTOR CRIMP
This is the metallurgical compression of a terminal around the wire's conductor. This connection creates a common electrical path with low resistance and
high current carrying capabilities.
BELLMOUTH (FLARE)
The flare that is formed on the edge of the conductor crimp acts as a funnel
for the wire strands. This funnel reduces the possibility that a sharp edge on
the conductor crimp will cut or nick the wire strands. As a general guideline,
the conductor bellmouth needs to be approximately 1 to 2x the thickness of
the terminal material *.
* Consult individual terminal specifications
32
CONDUCTOR CRIMP HEIGHT

The conductor crimp height is measured from the top surface of the formed
crimp to the bottom most radial surface. Do not include the extrusion points in
this measurement (See Figure 2, pg. 10). Measuring crimp height is a quick,
non-destructive way to help ensure the correct metallurgical compression of a
terminal around the wire's conductor and is an excellent attribute for process
control. The crimp height specification is typically set as a balance between
electrical and mechanical performance over the complete range of wire stranding and coatings, and terminal materials and platings. Although it is possible
to optimize a crimp height to individual wire strandings and terminal platings,
one crimp height specification is normally created.
CUT-OFF TAB LENGTH
This is the material that protrudes outside the insulation crimp after the terminal is separated from the carrier strip. As a general rule, the cut-off tab is
approximately 1.0 to 1.5x terminal material thickness *. A cut-off tab that is
too long may expose a terminal outside the housing or it may fail electrical
spacing requirements. In most situations, a tool is setup to provide a cut-off
tab that is flush to one material thickness.
* Consult individual terminal specifications requirements.
9
8.4 INSULATION CRIMP
Problem
Cause
Terminal surrounds less than

88% of a large diameter wire
(Fig. 37)
Crimp too loose, not enough

terminal insulation barrel
Terminal contacts less than

Too much terminal insulation
50% of a small diameter wire
barrel
(Fig. 38)
Solution
Tighten insulation crimp height
Evaluate terminal
Evaluate terminal
Insulation crimp barrels cut

through insulation into
conductor strands (Fig. 39)
Crimp too tight
Adjust insulation crimp

height*
Insulation not firmly gripping

insulation, fails bend test
(Fig. 40)
Crimp too loose
Adjust insulation crimp height

tighter
*Inexpensive hand tools provide no adjustment for the insulation crimp. A

hand tool is intended for low volume applications. Although you are not able
to adjust the insulation crimp on a hand tool, an insulation crimp which
pierces the insulation may still be considered acceptable for many applications. This criteria only applies to hand tools due to their low speed crimp
cycle. If the insulation crimp pierces the insulation, the wire strands tend to
move aside without damage.

8
33
2.0 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.
Figure 41 - Optimal Crimp Height Chart
Figure 42 - Crimp Height Off Target
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.
Figure 43 - Crimp Height Variability Too High
Figure 44 - Optimal Pull Force Chart
Figure 45 - Low Pull Force Chart
1.0 PURPOSE

8.5 CRIMP HEIGHT
Problem
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, bellmouth, cut-off tab, 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 bellmouth 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. Chapter 5 has a flowchart for a process setup while
Chapter 7 is a trouble shooting guide for common problems. Using Statistical
Process Control (SPC) during the crimping process can help minimize the
Parts per Million (PPM) reject levels. Chapter 6 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.
Cause
Changed crimp tooling

Crimp height off target
(Fig. 42)
Changed crimp press

(shut height)
Changed press type
(manufacturer)
Changed terminal reel
(lot code)
Adjust tooling back to target
Changed tooling set-up

Damaged or worn tooling
Wire variability
Terminal variability
Crimp height variability to high

(Fig. 43)
Inspect incoming product.
Damaged, loose, or worn

tooling
Tooling replacement or
tightening
Measurement error
Gage capability analysis
Terminal spring back too great,

over crimping
Cut or missing wire strands
Crimp height adjustment

Stripping process adjustment
Cause
Solution
Cut or nicked strands
Check the stripping process
Crimp height too low
Adjust crimp height
8.6 PULL FORCE
Problem
Wire breaks before conductor
crimp - low pull force (Fig. 45)
Wire pulls out of conductor grip

- low pull force (Fig. 45)
Small or no bellmouth
Insulation crimp through

insulation wall
Raise insulation crimp height
Crimp height too high
Adjust crimp height
Small or no conductor brush
Increase strip length
Conductor bellmouth too big
Gold terminal application

Terminal material thickness too
small
Light serrations on terminal
Solution
Changed wire type, vendor, or

stranding
Changed insulation color or
durometer
This handbook provides general guidelines and procedures for understanding

and achieving acceptable crimp terminations. A Glossary in Chapter 3 lists
common terms and definitions. Chapter 4 lists the tools that are necessary to
take accurate measurements and evaluate the crimp's acceptability.
35
Evaluate the terminal

application
Contact your local sales
engineer
INTRODUCTION TO
CRIMP TECHNOLOGY

AWG
WIRE AREA
STRANDING
WIRE BREAK
sq. inch
sq. mm
dia.
inch
mm
MILLS
lbs.
0.01287
8.302
0.1280
0.128
3.25
16384
489.0
2175.00
0.01212
7.820
19
0.0285
0.145
3.68
15433
460.6
2048.72
0.01233
7.955
49
0.0179
0.147
3.73
15700
468.6
2084.21
0.01334
8.605
133
0.0113
0.147
3.73
16983
506.9
2254.49
0.01319
8.513
168
0.0100
0.147
3.73
16800
501.4
2230.22
0.01306
8.424
665
0.0050
0.147
3.73
16625
496.2
2206.99
10
0.00816
5.261
0.1019
0.102
2.59
10384
309.9
1378.44
10
0.00735
4.740
37
0.0159
0.115
2.92
9354
279.2
1241.75
10
0.00776
5.006
49
0.0142
0.116
2.95
9880
294.9
1311.63
10
0.00825
5.320
105
0.0100
0.116
2.95
10500
313.4
1393.89
12
0.00513
3.308
0.0808
0.081
2.05
6529
194.8
866.69
12
0.00563
3.632
0.0320
0.096
2.44
7168
213.9
951.56
12
0.00478
3.085
19
0.0179
0.093
2.36
6088
181.7
808.16
12
0.00511
3.294
65
0.0100
0.095
2.41
6500
194.0
862.88
12
0.00514
3.3118
165
0.0063
0.095
2.41
6549
195.5
869.37
14
0.00323
2.082
0.0641
0.064
1.63
4109
122.6
545.45
14
0.00352
2.270
0.0253
0.073
1.85
4481
133.7
594.81
14
0.00301
1.941
19
0.0142
0.073
1.85
3831
114.3
508.59
14
0.00322
2.078
41
0.0100
0.073
1.85
4100
122.4
544.28
14
0.00327
2.112
105
0.0063
0.073
1.85
4167
124.4
553.24
16
0.00203
1.308
0.0508
0.051
1.30
2581
77.0
342.58
16
0.00222
1.433
0.0201
0.060
1.52
2828
84.4
375.43
16
0.00191
1.229
19
0.0113
0.058
1.47
2426
72.4
322.07
16
0.00204
1.317
26
0.0100
0.059
1.50
2600
77.6
345.15
16
0.00203
1.307
65
0.0063
0.059
1.50
2580
77.0
342.48
16
0.00206
1.330
105
0.0050
0.058
1.47
2625
78.3
348.47
18
0.00128
0.823
0.0403
0.040
1.02
1624
48.5
215.60
18
0.00139
0.897
0.0159
0.048
1.22
1770
52.8
234.93
18
0.00126
0.811
16
0.0100
0.047
1.19
1600
47.8
212.40
18
0.00149
0.963
19
0.0100
0.049
1.24
1900
56.7
252.23
36
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. But 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 end 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 so 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 x 19 strand
wire than an 18 AWG x 16 strand. The insulation diameter of an 18 AWG wire
can range from .070" (1,78 mm) to over .180" (4,57 mm). Wire strands can
be copper, tinned, overcoated, or topcoated. 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.

AWG
WIRE AREA
STRANDING
WIRE BREAK
sq. inch
sq. mm
dia.
inch
mm
MILLS
lbs.
18
0.00128
0.825
41
0.0063
0.047
1.19
1627
48.6
216.03
18
0.00128
0.823
65
0.0050
0.047
1.19
1625
48.5
215.72
20
0.00080
0.519
0.0320
0.032
0.81
1024
30.6
135.94
20
0.00087
0.563
0.0126
0.038
0.97
1111
33.2
147.53
20
0.00079
0.507
10
0.0100
0.035
0.89
1000
29.8
132.75
20
0.00096
0.616
19
0.0080
0.037
0.94
1216
36.3
161.43
20
0.00081
0.523
26
0.0063
0.036
0.91
1032
30.8
136.99
20
0.00081
0.519
41
0.0050
0.036
0.91
1025
30.6
136.07
22
0.00050
0.324
0.0253
0.025
0.64
640
19.1
84.97
22
0.00055
0.355
0.0100
0.030
0.76
700
20.9
92.93
22
0.00059
0.382
19
0.0063
0.031
0.79
754
22.5
100.11
22
0.00051
0.329
26
0.0050
0.030
0.76
650
19.4
86.29
24
0.00032
0.205
0.0201
0.024
0.61
404
12.1
53.63
24
0.00035
0.227
0.0080
0.023
0.58
448
13.4
59.47
24
0.00031
0.201
10
0.0063
0.024
0.61
397
11.8
52.69
24
0.00037
0.241
19
0.0050
0.023
0.58
475
14.2
63.06
24
0.00031
0.200
41
0.0031
0.023
0.58
394
11.8
52.31
.26
0.00020
0.128
0.0159
0.016
0.40
253
7.5
33.56
26
0.00022
0.141
0.0063
0.021
0.53
278
8.3
36.88
26
0.00020
0.127
10
0.0050
0.020
0.51
250
7.5
33.19
26
0.00024
0.154
19
0.0040
0.019
0.48
304
9.1
40.36
28
0.00012
0.080
0.0126
0.013
0.32
159
4.7
21.08
28
0.00014
0.089
0.0050
0.015
0.38
175
5.2
23.23
28
0.00014
0.093
19
0.0031
0.016
0.41
183
5.4
24.24
30
0.00008
0.051
0.0100
0.010
0.25
100
3.0
13.28
30
0.00009
0.057
0.0040
0.012
0.30
112
3.3
14.87
30
0.00009
0.060
19
0.0025
0.012
0.30
118
3.5
15.64
32
0.00005
0.032
0.0080
0.008
0.20
64
1.9
8.50
32
0.00005
0.034
0.0031
0.008
0.20
67
2.0
8.93
32
0.00006
0.039
19
0.0020
0.009
0.23
76
2.3
10.09
37
10.0 NOTES
Table of Contents
Introduction To Crimp Technology ........... 5
1.0
Purpose
............................................... 6
2.0
Scope
............................................... 7
3.0
Definitions
............................................... 9
4.0
Associated Materials ................................... 15
5.0
Procedure
5.1
Tool Setup
................................... 16
6.0
Measurement ............................................... 20
6.1
Pull Force
................................... 20
6.2
Crimp Height ................................... 23
7.0
Process Control
7.1
7.2
7.3
7.4
8.0
................................... 24
Process Capability
Production
Visual Inspection
Control Charting
Trouble Shooting
8.1
8.2
8.3
8.4
8.5
8.6
38
............................................... 16
....................... 24
.......................26
.......................26
.......................26
....................... 29
Wire Preparation
....................... 29
Bellmouth and Cut-Off Tab Length 29
Conductor Brush and Insulation Position 31
Insulation Crimp
....................... 33
Crimp Height ................................... 35
Pull Force
................................... 35
9.0
Wire Gauge Chart
10.0
Notes
................................... 36
............................................... 38
3
10.0 NOTES
39
QUALITY CRIMPING HANDBOOK
QUALITY CRIMPING
HANDBOOK
Bringing People & Technology Together, WorldwideSM
Corporate Headquarters : 2222 Wellington Court, Lisle, IL, 60532, U.S.A., Tel : 630-969-4550
Application Tooling Division : 1150 E. Diehl Rd., Naperville, IL 60563, Tel : 630-969-4550
European Headquarters : Munich, Germany, Tel : 49-89-413092-0
Far East North Headquarters : Kanagawa, Japan, Tel : 81-462-2336
Far East South Headquarters : Jurong Town, Singapore, Tel : 65-268-6868
Printed in U.S.A.
Order Number - 63800-0029
5M JI 6/96
1996, Molex Incorporated

Illustrations by Julie Theis-Pane
PRODUCED BY THE MOLEX

APPLICATION TOOLING GROUP

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QUALITY CRIMPING HANDBOOK

1996, Molex Incorporated

PRODUCED BY THE MOLEX

Associated Materials ................................... 15

Wire Gauge Chart

9.0 Wire Gauge Chart

WIRE DIAMETER CIRCULAR

Developed to replace the need to solder terminations, crimping technology

8.0 TROUBLE SHOOTING

Changed crimp tooling

Changed crimp press

Adjust tooling back to target

Changed tooling set-up

Crimp height variability to high

Inspect incoming product.

Damaged, loose, or worn

Gage capability analysis

Terminal spring back too great,

Crimp height adjustment

Cut or nicked strands

Check the stripping process

Crimp height too low

Adjust crimp height

8.6 PULL FORCE

Wire pulls out of conductor grip

Adjust tooling track

Insulation crimp through

Raise insulation crimp height

Crimp height too high

Adjust crimp height

Small or no conductor brush

Increase strip length

Conductor bellmouth too big

Adjust tooling track

Gold terminal application

Changed wire type, vendor, or

This handbook provides general guidelines and procedures for understanding

Evaluate the terminal

Figure 42 - Crimp Height Off Target

This handbook provides a basic overview of what to look for in an acceptable

Figure 43 - Crimp Height Variability Too High

Figure 44 - Optimal Pull Force Chart

Figure 45 - Low Pull Force Chart

8.0 TROUBLE SHOOTING

8.4 INSULATION CRIMP

Terminal surrounds less than

Crimp too loose, not enough

Terminal contacts less than

Insulation crimp barrels cut

Crimp too tight

Adjust insulation crimp

Insulation not firmly gripping

Crimp too loose

Adjust insulation crimp height

*Inexpensive hand tools provide no adjustment for the insulation crimp. A

Figure 1 - Terminal Anatomy

Figure 34 - Preferred Insulation Crimp

Figure 33 - Preferred Insulation Crimp

Figure 36 - Acceptable Insulation Crimp

Figure 35 - Acceptable Insulation Crimp