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 there
2、from, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be reaffirmed, revised, or cancelled. SAE invites your written comments and suggestions. Copyright 2011 SAE International All rights reserved. No part of this publication m
3、ay 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: +1 724-776-4970 (outside U
4、SA) 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/AS22520 AEROSPACE STANDARD AS22520 Issued 2011-10 Crimping Tools, Wire Termination, General S
5、pecification For FSC 5120 RATIONALE The document is written to permit the cancellation and supersession of MIL-DTL-22520 with this document. It includes qualifying activity requirements. Technical changes previously approved by military Preparing Activity were added. Government documentation referen
6、ces have been removed. 1. SCOPE 1.1 Scope (see 6.5). This specification covers the general requirements for crimping tools, accessories and inspection gages used for connecting removable contacts (such as; signal, power, coaxial, shielded, thermocouple, and filter pin contacts) coaxial connectors, s
7、hielded connectors, ferrules, terminals, end caps and splices to wire conductors for use in electric connectors, terminal junction systems, and other electric or electronic components. 1.2 Classification. Crimping tools covered by this specification are of the following Types (see 6.2): Type I - Too
8、ls that produce an indent termination. Type II - Tools that produce a formed termination. Type III - Tools that produce a compression termination. 2. APPLICABLE DOCUMENTS The following publications form a part of this document to the extent specified herein. The latest issue of SAE publications shal
9、l apply. The applicable issue of the other publications shall 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. Nothing in this document, however, supersedes ap
10、plicable laws and regulations unless a specific exemption has been obtained. 2.1 General The documents listed in this section are specified in sections 3 and 4 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional i
11、nformation or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements documents cited in sections 3 and 4 of this specification, whether or not they are listed. 2.2 Non-Government Publications
12、The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of the documents which are DoD adopted are those listed in the issue of the DoDISS cited in the solicitation. SAE AS22520 Page 2 of 22 Unless otherwise specified, the issues of
13、 documents not listed in the DoDISS are the issues of the documents cited in the solicitation (see 6.2). 2.3 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. AIR
14、1351 Aerospace Electrical Crimp Style, Copper, General Specification for AS21608 Ferrule, Shield Terminating, Crimp Style AS22520/1* Crimping Tools, Type 1, Terminal, Hand, Wire Termination for Wire Barrel Sizes 12 through 20 AS22520/2* Crimping Tools, Type 1, Terminal, Hand, Wire Termination for Wi
15、re Barrel Sizes 20 through 28 AS22520/3* Crimping Tools, Terminal, Hand, Wire Termination, In-service Inspection Gages for Type I and II Tools AS22520/4* Crimping Tool, Type 2, Contact, Electric, Hand for Shielded Outer Contacts AS22520/5* Crimping Tools, Type 2, Terminal, Hand, Wire Termination, La
16、rge Frame for Coaxial, Shielded Contacts and Ferrules, Terminal Lugs, Splices and End Caps AS22520/6* Crimping Tools, Terminal, Hand, Wire Termination, In-service Inspection Gages for Type II Tools AS22520/7* Crimping Tools, Type 1, Terminal, Hand, Wire Termination for Wire Barrel Sizes 16, 20 and 2
17、2 AS22520/10* Crimping Tool, Type 2, Terminal, Hand, Wire Termination Small Frame for Coaxial, Shielded Contacts and Ferrules, Terminal Lugs, Splices and End Caps AS22520/17* Crimping Tools, Type 2, Terminal, Hand, Wire Termination for Crimp Type Removable Contacts, Electric Connectors AS22520/18* C
18、rimping Tools, Terminal, Hand, Wire Termination In-service Inspection Gage for AS22520/17 Tool AS22520/19* Crimping Tool, Type 2, Terminal, Hand, Wire Termination for Size 16 Shielded Contacts (Outer Contact) AS22520/20* Crimping Tools, Type 2, Terminal, Hand, Wire Termination for Size 16 Shielded C
19、ontacts (Shield Crimp Sleeve) AS22520/21* Crimp Tool, Type 2, Terminal, Hand, Wire Termination for Size 12 Shielded Contacts (Outer Contact) AS22520/22* Crimp Tool, Type 2, Terminal, Hand, Wire Termination for Size 12 Shielded Contacts (Shielded Crimp Sleeve) AS22520/23* Crimping Tools, Type 1, Term
20、inal, Hand or Power Actuated, Wire Termination, Pneumatic Tool For Wire Barrel Sizes 0000 through 8 AS22520/24* Crimping Tools, Type 2, Terminal, Hand or Power Actuated, Wire Termination, Tool, For Lug Terminal and External Power Plug Socket Contacts, Size 22-10 AS22520/28* Crimping Tools, Type 2, T
21、erminal, Hand or Power Actuated, Wire Termination, Pneumatic Tool for Wire Barrel Sizes 20 through 28 AS22520/29* Crimping Tools, Type 1, Terminal, Hand or Power Actuated, Wire Termination, Pneumatic Tool for Wire Barrel Sizes 12 through 20 SAE AS22520 Page 3 of 22 AS22520/30* Crimping Tools, Termin
22、al, Hand or Power Actuated, Wire Termination, Accessory Hardware for MIL-C-22520/28 and MIL-C-22520/29 Tools AS22520/31* Crimping Tool, Type 2, Terminal, Hand, for Shielded Size 12 Outer Contacts AS22520/34* Crimping Tools, Type 1, Terminal, Hand, Wire Termination, for Crimp Type Removable Contacts
23、for MIL-C-28840 Connectors AS22520/35* Crimping Tools, Terminal, Hand, Wire Termination; In-service Inspection Gages for AS22520/34 Tools AS22520/36* Compression Tool, Hand, Type 3 for Semirigid Coaxial Cable (Category F Connectors) AS22520/37* Crimping Tool, Type 2, Electrical, Wire Splicing, Hand
24、Actuated, Type II, For Environmental Splices, Wire Range 26-12 AWG AS22520/38* Crimping Tool, Type 2, Terminal, Hand Actuated, Wire Termination, Type II, For External Power Plug Socket Contacts Lug and Terminal Sizes 22-10 AS22520/39* Crimping Tool, Terminal, Hand Actuated, Wire Termination, In-serv
25、ice Inspection Gages for AS22520/37 and /38 Tools AS22520/40* Crimping Tools, Terminal, Type 2, Hand, Wire Termination, T-Head for Terminal Lugs and Splices, Wire 22-14 AS22520/41* Crimping Tools, Terminal, Type 2, Hand, Wire Termination, for Terminals and Splices, Wire 10-14 AS22520/42* Crimping To
26、ols, Terminal, Hand, Wire Termination, In-Service Inspection Gage for AS22520/41 Tools AS22520/43* Crimping Tools, Wire Termination, In-service Inspection Gages for AS22520/40 Tools AS22520/44* Crimping Tool, Type 2, Hand Actuated, for Single Piece Splice AS22759 Wire, Electric, Fluoropolymer-Insula
27、ted, Copper or Copper Alloy AS39029 Contacts, Electrical Connector, General Specification For AS81044 Wire, Electric, Crosslinked Polyalkene, Crosslinked Alkane-Imide Polymer, or Polyarlene Insulated, Copper or Copper Alloy AS81824 Splice, Electric, Permanent, Crimp Style, Copper, Insulated, Environ
28、ment Resistant * AS22520 Detail specifications 2.4 ANSI Publications Available from American National Standards Institute, 25 West 43rd Street, New York, NY 10036-8002, Tel: 212-642-4900, www.ansi.org. ANSI-Z540.1 Laboratories, Calibration and Measuring Test Equipment 2.5 ASME Publications Available
29、 from American Society of Mechanical Engineers, 22 Law Drive, P.O. Box 2900, Fairfield, NJ 07007-2900, Tel: 973-882-1170, www.asme.org. ASME-Y14.5 Dimensioning and Tolerancing SAE AS22520 Page 4 of 22 2.6 ASQ Publications Available from American Society for Quality, 600 North Plankinton Avenue, Milw
30、aukee, WI 53203, Tel: 800-248-1946 (United States or Canada) or +1-414-272-8575 (International), www.asq.org. ASQ-Z1.4 Procedures, Sampling and Tables for Inspection By Attributes 2.7 ASTM Publications Available from ASTM International, 100 Barr Harbor Drive, P.O. Box C700, West Conshohocken, PA 194
31、28-2959, Tel: 610-832-9585, www.astm.org. ASTM-B16/B16M Rod, Brass, Free-Cutting, Bar, and Shapes for Use in Screw Machines ASTM-B133 Copper, Rod, Bar, and Shapes (Metric) ASTM-B272 Copper Flat Products with finished (Rolled or Drawn) Edges (Flat Wire and Strip) 2.8 U. S. Government Publications Ava
32、ilable from the Document Automation and Production Service (DAPS), Building 4D, 700 Robbins Avenue, Philadelphia, PA 19111-5094, Tel: 215-697-9495, https:/assist.daps.dla.mil/quicksearch/. 2.8.1 Specifications and standards. The following specifications and standards form a part of this document to
33、the extent specified herein. SPECIFICATIONS DEPARTMENT OF DEFENSE MIL-A-8625 Anodic Coatings for Aluminum and Aluminum Alloys CID A-A-59551 Wire, Electrical, Copper (uninsulated) MIL-PRF-39012 Connectors, Coaxial, Radio Frequency, General Specification For MIL-DTL-16878 Wire, Electrical, Insulated,
34、General Specification For STANDARDS DEPARTMENT OF DEFENSE MIL-STD-130 Identification Marking of U.S. Military Property MIL-STD-202 Test Methods for Electronic and Electrical Component Parts MIL-STD-889 Dissimilar Metals SAE AS22520 Page 5 of 22 3. REQUIREMENTS 3.1 Specification Sheet The individual
35、item requirements shall be as specified herein and in accordance with the applicable specification sheet. In the event of any conflict between the requirements of this specification and the associated specification sheet, the latter shall govern. 3.1.1 Dimensions and Tolerances. Dimensioning and tol
36、erances used in this document and associated specification sheet shall be in accordance with ASME-Y14.5. 3.2 Use of Part Numbers Part numbers shall not be applied to a product, except for qualification test samples (see 6.3), until notification has been received from the activity responsible for qua
37、lification that the product has been approved. 3.3 Materials Materials shall be as specified herein. However, when a definite material is not specified, a material shall be used which will enable the tools to meet the performance and interface requirements of this specification, the applicable speci
38、fication sheet, and approved by the qualifying activity (See 6.4). 3.3.1 Finish. Aluminum parts shall be anodized in accordance with MIL-A-8625 or an anodizing process that meets the performance requirements specified in section 3.5 of this specification. All other metal parts shall be made of corro
39、sion-resistant material or protected with paint, plating, or surface treatment to meet the performance requirements of this specification. Color shall be as specified on the applicable specification sheet. Cadmium plating and lead shall not be used. 3.3.2 Dissimilar Metals. When dissimilar metals ar
40、e employed in intimate contact with each other, protection against electrolytic corrosion shall be provided as specified in MIL-STD-889. 3.4 Design and Construction Tools and accessories shall be in accordance with the applicable specification sheet. 3.4.1 Crimping Operation 3.4.1.1 Type I tools (se
41、e 6.1.9). When the tool is in the fully opened position, the contacts shall pass freely between the indenters, both before and after being crimped. All indenters shall be designed to travel with equal and simultaneous movement. The motion and dimensional configuration shall be specified in the appli
42、cable specification sheet. The tool design shall provide for positive closed positioning for the indenters. The indenter closure selector shall have a positive detent at each setting. The tool shall be designed such that the tool can meet specified closure with or without positioners or turrets inst
43、alled. All positioners and turrets shall provide positive location of wire barrels for crimping the specified contacts. 3.4.1.2 Type II tools (see 6.1.10). The crimping operation shall be accomplished by the closure of a set of dies or jaws with the specified configuration (see 3.1). The movement of
44、 the opposing crimp dies or jaws shall be perpendicular or radial to the mating die or jaw face, and the fully closed position (gage dimension) shall be as specified on the applicable specification sheet. 3.4.1.3 Type III tools (see 6.1.12). Operation of the tool shall be in accordance with the indi
45、vidual specification sheet. SAE AS22520 Page 6 of 22 3.4.2 Tool Malfunction. The tool shall be provided with a return mechanism and a full cycling mechanism that shall not jam or malfunction if operated with or without a contact or connector, and with or without a positioner, turret, or die. The too
46、l operation shall neither create a jammed mechanism nor impair the function of the tool. Metal particles from the operation of the tool or the crimping operation shall not accumulate within the tool nor cause any malfunction of the tool mechanism. 3.4.2.1 Full cycle mechanism. The full cycle mechani
47、sm shall be tamperproof to prevent disengagement prior to or during the crimp cycle. 3.4.3 Removal of Crimped Parts. The crimped assembly shall be removed from the tool without impediment upon completion of the crimping operation. 3.4.4 Calibration Adjustments (see 6.1.13). Tool calibration adjustme
48、nts shall be accessible only when the tool is disassembled. These adjustments shall be made only by the supplier or by an approved calibration laboratory as specified in ANSI-Z540.1. 3.4.5 Gages (see 6.1.13). Inspection gages shall conform to the gaging limits specified on the applicable tool specif
49、ication sheet. 3.5 Performance a. Type I Tools. Type I tools shall crimp AS39029 wire barrels and other electrical connector contacts to wires as specified in the applicable component specification. b. Type II Tools. Type II tools shall crimp terminal splices, end caps conforming to AS7928 and AS81824, shielded or coaxial contacts conforming to AS39029, coaxial connectors conforming to MIL-PRF-39012, ferrules conforming to AS2
