1、 _ SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising ther
2、efrom, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be revised, reaffirmed, stabilized, or cancelled. SAE invites your written comments and suggestions. Copyright 2013 SAE International All rights reserved. No part of this
3、publication may be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) Tel: +1 724-776-49
4、70 (outside USA) Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.org SAE values your input. To provide feedback on this Technical Report, please visit http:/www.sae.org/technical/standards/AS5259 RATIONALE AS5259 has been reaffirmed to comply with the SAE five-year rev
5、iew policy. AEROSPACE STANDARD AS5259 Issued 2008-09 Reaffirmed 2013-07 Crimping Tool and Accessories, Electrical, Size 8 to 700 KCMIL, General Purpose Use, Die and Dieless FSC 5120 1. SCOPE This specification covers design requirements, performance requirements, and methods of procurement for tools
6、 and associated accessories used to crimp wire barrels of aircraft electrical wiring components including ferrules, terminals, splices and connector contacts on wire/cable sizes 8 to 700 KCMIL. 1.1 Intended Use The purpose of this specification is to define the tools design s performance, interchang
7、eability, repeatability and reliability, not the tools component crimp characteristics. The crimp characteristics are defined by the component specification which specifies the crimp tool. The ability of the tool to properly crimp a component is determined by the component specification or the engin
8、eering drawing which specifies the tool. Tools defined by this specification are recommended to be used only for those components which specifically call out the use of the tool in the component specification or engineering drawing (see 3.1.1). 1.2 Qualification Products procured from this specifica
9、tion require a supplier to be on a Qualified Product List at the time of request for purchase (see 6.4). 1.3 Part Number Structure The part number structure for the tool, related accessory (i.e., dies, release tool, etc.), and kit shall be M5259/1-0001A I I I_ Kit Designator (blank for no kit) I I_
10、Basic tool designation (-0001), each accessory (-0002, -0003, etc) I_ Detail Specification Designation 2. REFERENCES 2.1 Applicable Documents The following publications form a part of this document to the extent specified herein. Unless otherwise specified, the applicable issue of the publication sh
11、all be the issue in effect on the date of the purchase order. In the event of conflict between the text of this document and references cited herein, the text of this document takes precedence except as specified in the detail specification (see 3.1). Nothing in this document, however, supersedes ap
12、plicable laws and regulations unless a specific exemption has been obtained. 2.1.1 SAE Publications Available from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or 724-776-4970 (outside USA), www.sae.org. AS5259/1 Crimping Tool and Ac
13、cessories, Electrical, Size 8 to 0000, General Use Die Type 2.1.2 ASQ Publications Available from American Society for Quality, 600 North Plankinton Avenue, Milwaukee, WI 53203, Tel: 800-248-1946 (United States or Canada) or +1-414-272-8575 (International), www.asq.org. ASQC Z1.4 Sampling Procedures
14、 and Tables for Inspection by Attributes 2.1.3 NCSL Publications Available from National Conference of Standards Laboratories, 2995 Wilderness Place, Suite 107, Boulder, CO 80301-5404, Tel: 303-440-3339, www.ncsli.org. NCSL Z540-1 General Requirements for Calibration Laboratories and Measuring and T
15、est Equipment 2.1.4 U.S. Government Publications Available from the Document Automation and Production Service (DAPS), Building 4/D, 700 Robbins Avenue, Philadelphia, PA 19111-5094, Tel: 215-697-6257, http:/assist.daps.dla.mil/quicksearch/. MIL-STD-202 Test Methods for Electronic and Electrical Comp
16、onent Parts SD-6 Provisions Governing Qualification 2.2 Definitions 2.2.1 SAE PREPARING ACTIVITY SAE Preparing Activity is the SAE sub-committee responsible for preparing and maintaining the product specification and the required technical data. 2.2.2 QUALIFICATION INSPECTION Qualification Inspectio
17、n is a process that demonstrates that a component is capable of fully conforming to all the requirements defined in a specification. Qualification Inspection includes definition of the measurements, tests, analysis, and associated data which provides consistent rationale for acceptance of a particul
18、ar suppliers design as meeting the specification requirements typically prior to acquisition by the Purchaser. SAE INTERNATIONAL AS5259 Page 2 of 17_ 2.2.3 QUALIFIED PRODUCTS LIST A Qualified Products List is a list of suppliers whose products have been evaluated to a defined process and who are aut
19、horized to provide those products to a purchaser upon request. When a Qualified Products List is specified only approved suppliers are authorized to provide products under the part number defined in the component specification. A Qualified Products List is established and maintained by a Qualifying
20、Activity. 2.2.4 QUALIFYING ACTIVITY A Qualifying Activity is a function established by a Purchaser or group of Purchasers that has a defined process used to consistently evaluate all Suppliers products in accordance with the component specification (see Section 6). 2.2.5 QUALITY CONFORMANCE INSPECTI
21、ON Quality Conformance Inspection is a process which includes measurements, non-destructive tests, analysis, and associated data that will provide verification that a particular individual component continually conforms to the requirements defined in the specification. 2.2.6 QUALIFICATION BY SIMILAR
22、ITY An alternative Qualification Inspection process accomplished without completing all of the measurements, tests, and analysis requirements defined in the specification. Acceptance and the extent of similarity, is determined by the Qualifying Activity. Similarity is established through a rationale
23、 that certain designs, materials, and/or processes are identical to those already approved through qualification of the components. Verification testing for the new product is not required for designs, materials, and/or processes already approved. When a Qualified Products List is being established
24、the qualification by similarity rationale shall be approved by the Qualifying Activity prior to initiation of the remaining portions of the Qualification Inspection process. 2.2.7 PURCHASER A purchaser is an activity that can issue a purchase order or contract. 2.2.8 SUPPLIER A supplier is an origin
25、al component manufacturer or a value added component manufacturer which has design and production control of the processes used to produce the final component in accordance with the specification. 2.2.9 COMPONENT PREPARING ACTIVITY The component preparing activity is an activity that control a compo
26、nent specification or drawing that reference a crimping tool required to assemble a wire or cable to the component specified. 3. REQUIREMENTS 3.1 Detail Specifications The tool requirements shall be as specified herein and in accordance with the applicable detail specification. In the event of any c
27、onflict between the requirements of this specification and the detail specification, the latter shall govern. SAE INTERNATIONAL AS5259 Page 3 of 17_ 3.1.1 Criteria for Tool Inclusion The criteria for defining a tool in a detail specification is that a component document intended to reference the too
28、l must be controlled by a component preparing activity such as a user, government, or non-government standard body. It is the responsibility of the component specification preparer to determine if a specific tool can be used to crimp specific wire barrels. After the tool has been determined to be ac
29、ceptable for the component, the component preparing activity is recommended to request SAE to establish an AS5259/Y detail specification (slant sheet) which the activity can then reference in the component specification. Request for tools to be listed in AS5259 shall be made by the component prepari
30、ng activity to SAE preparing activity (see 6.7). 3.1.2 Detail Specification Requirements Die dimensions shall be definitive enough to insure that variation from multiple component supplier designs, as defined by the component detail specification, is not affected by the die. The basic tool dimension
31、s shall be definitive enough to insure replacement of the tool in a storage container without modification of the container. A detail configuration of a go/no-go gage or pressure gage shall be provided in the detail specification. Metric equivalents may be provided to the nearest 0.01 mm and shown a
32、s (x.xx). Metric equivalents are calculated based on 1 in equals 25.4 mm. The detail specification shall be formatted as shown in Appendix A. 3.2 Dimensions (see 5.1) Dimensions shall be in accordance with the detail specification. Dimensions in the detail specification are shown in inches and after
33、 plating (if specified). 3.3 Materials (see 5.1) All materials shall be suitable for the fabrication or maintenance of aerospace hardware when used on land or sea. Materials shall be specified in the detail specification. 3.4 Storage Container (see 5.2) When a storage container is specified by the d
34、etail specification the tool and related accessories shall be stored in a container specified by the supplier. The storage container shall have the case tool M5259/Y part number and the suppliers case part number permanently attached to top of the case. To insure ease of tracking individual parts, e
35、ach accessory (die, gage, etc.) designed to be separated from the tool shall have an individual labeled compartment in the container. All parts shall be individually separated to prevent damage during normal container storage or transportation to and from the work site. The total weight of the stora
36、ge container with tool and accessories included shall be 30.87 lb (14 kg) maximum. When the maximum weight is exceeded the case shall be equipped with self contain wheels and pull handle. The storage container shall be equipped with a carrying handle. The case shall stand without falling when stood
37、with handle in the up position. The case shall not tip over when tested as specified. 3.5 Tool Instructions (see 5.3) Each tool shall be provided with concise, clearly written individual instructions containing the following information outlined as shown. a. Title: (must include storage container na
38、me, AS5259/Y and suppliers part number) b. Detail Actuated Tool Pictorials: (must include M5259/Y-0001 and manufacturers part number) c. Detail Accessory Pictorials: (must include AS5259/Y dies, gages, and manufacturers part numbers) d. Safety Instructions e. Operation Instructions: (must include cr
39、imping, gauging, etc.) SAE INTERNATIONAL AS5259 Page 4 of 17_ f. Maintenance Instruction: (must be clear, precise, and include pictorial as needed) g. Replaceable Parts (must include suppliers designated part Numbers) h. List of Applicable Ferrules, Terminals, Splices, and Contacts, etc.: (must incl
40、ude specification or component part numbers) i. Supplier Information: (must include address and telephone Number of supplier) 3.6 Replaceable Parts Control (see 5.4) All replaceable parts shall be designated by a M5259/Y-XXXX or by supplier part number which is directly referenced on the tool and ac
41、cessory design drawings used to produce and control the tool configuration and provided in the tool instructions. 3.7 Parts Identification (see 5.5) The storage container, when specified, basic tool and accessories identifications shall be durable and withstand typical handling and usage. The identi
42、fication shall be clearly readable after all specified environmental tests. 3.8 Tool Assembly (see 5.6) The tool shall be easily assembled and disassembled (dies, handles, etc.) in accordance with the tool instruction without special tools (see tool instructions). Special tools shall be specified by
43、 part number in the detail specification. 3.9 Tool Operation Characteristics (see 5.7) 3.9.1 Nibs/Dies Gauging (see 5.7.1) The nibs/dies shall be constructed such that when the nibs/dies are in a fully closed position or final crimp position (end face-to-end face for dies), their wear characteristic
44、s may be determined by go/no-go gages or equivalent pressure gages as applicable. The gages general characteristic shall be depicted in the tool instructions. The tool instructions shall provide clear information on how and when to use gages for the applicable component being crimped. 3.9.2 Nibs/Die
45、s Visual Examination (see 5.7.2) The dies or nibs shall exhibit no cracks, broken parts, or jagged edges. 3.10 Crimp Operation 3.10.1 Partial Crimp (see 5.8.1) The tool shall be capable of deliberately aborting a partial crimp without completing the crimp cycle. 3.10.2 Completed Crimp (see 5.8.2) Th
46、e tool shall advance the nibs/dies with only human power to perform the crimp cycle. Once crimping action has begun, the tool shall operate in such a manner, that it insures the proper pressure is being continually applied regardless of the position of the handles and without release to the nibs/die
47、s. When a proper crimp is completed (end face-to-end face for dies), the tool shall release the pressure automatically and the handles will return to its normal position regardless of the orientation of the tool. The tool shall perform a crimp operation and return to a normal position within 5 s. SA
48、E INTERNATIONAL AS5259 Page 5 of 17_ 3.11 High Compression Force (see 5.9) Unless otherwise specified in the detail specification the force to actuate the tool shall meet the gauging requirements after the handle is subjected to a 253 lb (1124 N) actuation force. 3.12 Crimp Compression Force (see 5.10) Unless otherwise
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