Overcrimping

Overcrimping refers to the process of applying excessive force or pressure when crimping a terminal or connector onto a wire. This can occur with various types of crimping tools, including manual hand crimpers, hydraulic crimpers, and pneumatic crimpers. The primary consequence of overcrimping is damage to the wire conductor, the terminal itself, or both.

When a wire is overcrimped, the strands of the conductor can be severely deformed, compressed, or even severed. This reduction in the effective cross-sectional area of the wire can lead to increased electrical resistance. High resistance in a connection can cause overheating, which in turn can result in a loss of conductivity, potential fire hazards, and premature failure of the electrical circuit.

Overcrimping can also damage the terminal. The barrel of the terminal, which is designed to hold the wire, can be distorted, split, or weakened. This compromised mechanical integrity can lead to a poor electrical connection and a physically insecure bond between the wire and the terminal. In some cases, the metal fatigue caused by overcrimping can result in the terminal failing under vibration or stress.

Identifying overcrimping often involves visual inspection. Look for signs of excessive deformation, such as flattened or stretched terminal barrels, severed wire strands, or a visibly pinched wire within the crimp. Proper crimping technique involves using the correct tool for the specific wire gauge and terminal type, and applying only the necessary force to create a secure and electrically sound connection. Many professional crimping tools have ratcheting mechanisms that ensure a complete and consistent crimp cycle, preventing overcrimping.