Why Is Secondary Crimping Strictly Prohibited With Cold-pressed Needle Crimpers?

When a cold-pressed needle crimping device delivers a faulty or failed termination, the only acceptable solution is to immediately cut off the damaged terminal. Attempting a second press on a failed connection compromises mechanical integrity and electrical safety. Rework of the same crimping cylinder must be avoided to ensure reliable wire connection and prevent costly equipment downtime.

The Physical Dangers of Second Crimping

Re-crimping a failed joint introduces severe micro-fractures in the terminal metal. This unsafe practice reduces the overall holding force and alters the electrical resistance of the connection.

Why Rework Fails

• Metal over-hardening leads to sudden structural cracking under vibration.

• Altered internal dimensions cause high-resistance electrical hotspots.

• Improper contact crimping profiles result in loose, hazardous wire strands.

Corrective Action Procedure

To maintain strict quality standards after a failed cycle with a specialized contact crimper, professionals follow a precise three-step replacement procedure.

1. Cut the wire cleanly right behind the damaged terminal insulation.

2. Strip the wire to the exact gauge specification using calibrated blades.

3. Insert a brand-new terminal into the d sub contact crimper for re-termination.

Pull Force Requirements for Standard Wire Gauges

The following technical data outlines the minimum tensile strength requirements that initial crimps must meet to ensure long-term operational stability.

Adhering to this strict clean-cut policy eliminates the risks of intermittent power losses, overheating, or catastrophic equipment failures caused by deformed barrels. Cutting away the defect and restarting ensures that every final terminal meets precise engineering standards, protecting system longevity and maintaining code compliance.