User Manual

Quality Crimp Handbook
Order No: ATS-638000029 Release Date: 09-04-03 UNCONTROLLED COPY Page 6 of 23
Revision: C Revision Date: 09-12-06
INSULATION
CRIMP
BRUSH
STRIP
LENGTH
BELL
MOUTH
CRIMP
HEIGHT
CONDU
CTOR
CRIMP
CUT-OFF
TAB
SEAM
EXTRUSIONS
EXTRUSION
EXTRUSION
TERMINAL CROSS-
SECTION VIEW
Figure 4-1
BEND
DOWN
BEND UP
ROLLING
TWISTING
SECTION 4
DEFINITIONS
Anatomy of a Crimp Termination (Figure 4-1)
 Bell Mouth (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
bell mouth needs to be approximately 1 to 2 times the
thickness of the terminal material. *
 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 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.
 Conductor Crimp Height
The conductor crimp height is measured from the top surface of
the formed crimp to the bottom radial surface. Do not include the
extrusion points in this measurement, (See Figure 4-1).
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
plating. Although it is possible to optimize a crimp height to
individual wire stranding and terminal plating, one crimp height
specification is normally created.
*Consult individual terminal specification requirements
 Cut-off Tab Length
This material protrudes outside the insulation crimp after the
terminal is separated from the carrier strip. As a rule, the cut-off
tab is approximately 1.0 to 1.5 times 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