WIRE NEWS WN January 2018 - Page 5

Tooling setup To prevent excess wear, tooling must be mounted properly. Therefore, when tooling must be replaced, take extra precautions to ensure that mounting surfaces are clean and in good condition. Crimp tooling must sit flush with the base plate and applicator ram. The upper tooling, or crimp dies, must be centered over the lower crimp anvil. A simple method to ensure that the upper tooling is centered is as follows: 1. Install the lower and upper tooling and hardware but do not completely tighten the screws. 2. Gently install the applicator ram ensuring the upper tooling does not contact th e lower tooling. 3. Lay a thin strip of paper over the lower crimp anvil. 4. Gently but firmly push the upper tooling down over the anvil. While keeping downward pressure on the ram, tighten the screws to secure the upper and lower tooling. Once you are sure that the tooling is installed properly, ensure that the terminal feed adjustment provides accurate terminal placement. This applies for pneumatic, mechanical, or motorized feeds. However, when working with a mechanical feed applicator, consider the press it will go into. Depending on the quality of the terminal brake, the feed adjustment might differ between a slower press, such as an older bench press, or faster presses, which are common on automatic machines. Prevent tooling crashes Most applicators are shipped with ram collars. The ram collars (red piece shown in the photo) prevent collisions between the upper and lower tooling when the applicator is not installed in a press. Such collisions may damage the tooling prematurely. Tooling collision can be avoided by regularly checking presses for proper shut height and using ram collars when applicators are not in use Signs of tooling damage may be: 1. Scarring or marking inside the upper crimp die. This might also appear as consistent marking on the crimped terminal. 2. Rounded edges on the crimp anvil. This might reveal itself with excessive flash or burrs on the terminal. Whenever an applicator is installed into a press, it is recommended to either hand-cycle or cycle the press in jog mode two or three times to ensure the tooling closes properly without collisions. Presses should be checked regularly to confirm that they are set for the proper shut height. For most mini-style applicators, the standard shut height is 135.78mm ± 0.02 or 5.345” ± 0.0008. If the shut height on one press is set too low, this may cause the tooling to crash. Furthermore, when presses are properly adjusted for shut height, consistent results can be expected when applicators are moved between presses. Shut heights can be confirmed using simple shut height gauges or with press analyzers which are readily available on the market. » WIRE NEWS January 2018 5