Crimping Die Guide
This guide helps you understand crimping dies: what they are, how to select the right series, match dies to cables and tools, and how to maintain them for safe, reliable crimps.
1. What Are Crimping Dies?
Crimping dies are shaped inserts used with compatible crimping tools to compress terminals or lugs onto cables. They ensure strong electrical and mechanical contact. The die profile must match the terminal type and tool.
2. Die Series & Compatibility
Manufacturers offer multiple die series (e.g., Series 4, 5, 15, 18) for different tool families. Always ensure the die series matches your tool. Mismatched dies can result in poor connections or tool damage.
3. Profile Types: Hex, Indent, and More
Common die profiles include hexagonal, indent, and semi-circular. Each is suited to different terminal types, standards, and applications. Choose based on the connection’s mechanical strength, environment, and regulatory requirements.
4. Selecting the Correct Size
The die size must match both the cable cross-section and the terminal barrel. A die that's too large leads to a loose crimp; too small can damage the terminal or conductor. Always refer to size charts or technical data.
5. Tool & Die Maintenance
Keep dies clean and free from corrosion. Inspect for wear or chipping, and ensure proper lubrication where required. Store in a dry, protected space. Damaged dies should be replaced immediately to avoid compromised crimps.
6. Testing & Verification of Crimps
After crimping, check for correct deformation and cable retention. Perform pull tests or resistance checks where appropriate. Regular testing ensures ongoing electrical and mechanical reliability.
7. Safety & Standards
Always use certified dies, terminals, and tools. Follow manufacturer specifications and safety guidelines. Ensure crimped connections comply with relevant standards (e.g. BS, UL, IEC) based on your project or industry.
