SAE AS 22520 10-2015 CRIMPING TOOLS TYPE 2 TERMINAL HAND WIRE TERMINATION FOR COAXIAL TWINAXIAL TRIAXIAL SHIELDED CONTACTS AND FERRULES TERMINAL LUGS SPLICES AND END CAPS.pdf

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1、 AEROSPACE STANDARD CRIMPING TOOLS, TYPE 2, TERMINAL, HAND, WIRE TERMINATION, FOR COAXIAL, TWINAXIAL, TRIAXIAL, SHIELDED CONTACTS AND FERRULES, TERMINAL LUGS, SPLICES, AND END CAPS AS22520/10Copyright 2015 SAE International All rights reserved. No part of this publication may be reproduced, stored i

2、n 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 USA) Fax: 724-776-0790 Emai

3、l: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.org ISSUED2015-12THIRD ANGLE PROJECTION CUSTODIAN: AE-8/AE-8C2 FEDERAL SUPPLY CLASS 5120 AS22520/10 SHEET 1 OF 15 PROCUREMENT SPECIFICATION: AS22520 SAE Technical StandardsBoardRulesprovidethat:“ThisreportispublishedbySAE toadvancethestateofte

4、chnicalandengineering sciences. The use of thisreport isentirelyvoluntary, andits applicability andsuitability for any particularuse, includingany patent infringement arising therefrom,is the soleresponsibility of theuser.”SAE reviewseachtechnical reportatleasteveryfiveyearsatwhichtimeitmayberevised

5、,reaffirmed,stabilized,orcancelled.SAE invitesyourwrittencommentsandsuggestions.SAE values your input. To provide feedback on this Technical Report, please visit http:/www.sae.org/technical/standards/AS22520/10 RATIONALE AS22520/10 PERMITS THE CANCELLATION AND SUPERSESSION OF MIL-C-22520/10 WITH THI

6、S DOCUMENT. IT INCLUDES ENGINEERING POSITION LETTERS, MILITARY SPECIFICATION AMENDMENTS, AND TECHNICAL REQUIREMENTS TO REFLECT THE APPROVED QUALIFIED TOOLS. NEW DIES HAVE BEEN ADDED TO PROVIDE TOOLING FOR NEW CONTACT SPECIFICATIONS. GOVERNMENT DOCUMENTATION REFERENCES CHANGES ARE REMOVED. NOTICE THE

7、 COMPLETE REQUIREMENTS FOR PROCURING THE PRODUCT DESCRIBED HEREIN SHALL CONSIST OF THIS DOCUMENT AND THE LATEST ISSUE OF AS22520. TOOL SIDE VIEW TOOL BOTTOM VIEW FIGURE 1 - M22520/10-01 TOOL AEROSPACE STANDARD AS22520/10 SHEET 2 OF 15 CRIMPING TOOLS, TYPE 2, TERMINAL, HAND, WIRE TERMINATION, FOR COA

8、XIAL, TWINAXIAL, TRIAXIAL, SHIELDED CONTACTS AND FERRULES, TERMINAL LUGS, SPLICES, AND END CAPS TOOL RETAINER RING SECTION A-A BASIC TOOL MARKINGS PART NO. BODY COLOR HANDLE GRIP COLOR M22520/10-01 GOLD BLACK FIGURE 1 - M22520/10-01 TOOL (CONTINUED) FIGURE 2 - BASIC DIE DIMENSIONS (DIMENSION ARE APP

9、LICABLE TO BOTH HALVES) REQUIREMENTS: ALL REQUIREMENTS SHALL CONSIST OF THIS DOCUMENT AND THE LATEST ISSUE OF AS22520. 1. TOOL CONFIGURATION: BASIC TOOL CONFIGURATION SHALL BE IN ACCORDANCE WITH FIGURE 1. UNLESS OTHERWISE SPECIFIED, DIMENSIONS ARE IN INCHES. TOLERANCES: DECIMALS .010, ANGLES 1/2 . O

10、UTLINE CONFIGURATION AND TOOL CONSTRUCTION OPTIONAL WITHIN MAXIMUM DIMENSIONS SHOWN. REMOVE ALL BURRS AND BREAK ALL EDGES AND CORNERS. 2. DIE CONFIGURATION: BASIC DIE CONFIGURATION SHALL BE IN ACCORDANCE WITH FIGURE 2. DETAIL DIE CONFIGURATION SHALL BE AS SPECIFIED FOR EACH SPECIFIED COMPONENT DIE (

11、SEE TABLE 2 AND DETAIL DIE DRAWINGS). DIES ARE INTERCHANGEABLE WITHIN M22520/10-01 BASIC TOOL. ALL DIES SHALL HAVE A FULL LENGTH KEYWAY. UNLESS OTHERWISE SPECIFIED, DIMENSIONS ARE IN INCHES. TOLERANCES: DECIMALS .010 AND ANGLES 1/2. ALL RADII SHALL BE BLEND RADII. REMOVE ALL BURRS AND BREAK ALL EDGE

12、S AND CORNERS. FOR CRIMP DIE CLOSURE DETAILS SEE DIE DETAIL SPECIFICATION DRAWINGS. AEROSPACE STANDARD AS22520/10 SHEET 3 OF 15 CRIMPING TOOLS, TYPE 2, TERMINAL, HAND, WIRE TERMINATION, FOR COAXIAL, TWINAXIAL, TRIAXIAL, SHIELDED CONTACTS AND FERRULES, TERMINAL LUGS, SPLICES, AND END CAPS 3. LOCATOR

13、CONFIGURATION: COMPONENT LOCATOR (WHEN REQUIRED), UNLESS OTHERWISE SPECIFIED, SHALL BE ATTACHED TO THE LOWER DIE, SHALL PROVIDE A POSITIVE STOP FOR LOCATING THE COMPONENT TO BE CRIMPED, AND RETAIN THE COMPONENT IN PLACE WITHOUT BEING HELD BY THE OPERATOR. DURING THE CRIMPING OPERATION THE LOCATOR SH

14、ALL BE FREE TO MOVE AS NECESSARY TO PREVENT THE CRIMPED ITEM FROM BENDING IN ACCORDANCE WITH AS22520. 4. TOOL MARKING: TOOL IDENTIFICATION (SEE FIGURE 1) SHALL BE IN ACCORDANCE WITH MIL-STD-130, STAMP AND WHITE FILL OR LASER MARKED. UNLESS OTHERWISE SPECIFIED, THE STAMPED MARKING HEIGHT IS .093 MINI

15、MUM. PART NUMBER AND COLORS SHALL BE AS SPECIFIED. TOOL IDENTIFICATION SHALL INCLUDE THE M22520/10-01 PART NUMBER, MANUFACTURERS IDENTIFICATION OR SYMBOL, AND THE MANUFACTURERS PART NUMBER. IF SYMBOLS ARE USED ON TOOL FRAME, IT SHALL BE IN ACCORDANCE WITH AIR1351. LABEL PERMITTED ON TOOL FRAME, PROV

16、IDING THAT IT IS STILL LEGIBLE AFTER ALL ENVIRONMENTAL TESTING REQUIRE BY AS22520. 5. DIE MARKING: DIE IDENTIFICATION (SEE FIGURE 2) ON EACH HALF SHALL INCLUDE THE M22520/10-XXX PART NUMBER, AND MANUFACTURERS IDENTIFICATION OR SYMBOL. IF SYMBOLS ARE USED ON THE DIES, IT SHALL BE IN ACCORDANCE WITH A

17、IR1351. DIES CAVITIES SHALL BE MARKED IN ACCORDANCE WITH THE DETAIL DIE DRAWING. UNLESS OTHERWISE SPECIFIED, THE MARK SHALL BE STAMPED (LETTERING HEIGHT .062 MINIMUM) AND WHITE FILL OR LASER MARKED. 6. TOOL MATERIALS: UNLESS OTHERWISE SPECIFIED, MATERIAL IS IN ACCORDANCE WITH AS22520. SURFACE TEXTUR

18、E SHALL BE 63 RMS OR BETTER IN ACCORDANCE WITH ASME B46.1 (AMERICAN NATIONAL STANDARDS INSTITUTE). TOOL BODY SHALL BE 7075-T6 ALUMINUM OR EQUIVALENT. MOVABLE HANDLE AND INTERNAL PARTS SHALL BE STEEL. PUSHROD AND DIE HOLDER SHALL BE 400 SERIES STAINLESS STEEL. ALUMINUM COMPONENTS SHALL BE ANODIZED AN

19、D STEEL COMPONENTS SHALL BE BLACK OXIDE OR PLATED TO RESIST CORROSION. 7. DIE MATERIALS: DIES SHALL BE ALLOY TOOL STEEL HARDEN TO ROCKWELL C52-58 IN ACCORDANCE WITH ASTM A681. FINISH SHALL BE BLACK OXIDE PER MIL-C-13924 OR EQUIVALENT. SURFACE TEXTURE ON CRIMPING SURFACE SHALL BE 64 RMS, UNLESS OTHER

20、WISE SPECIFIED, IN ACCORDANCE WITH ASME B46.1. 8. INSPECTION GAGE: INSPECTION GAGES ARE SPECIFIED WITH EACH DIE DETAIL DRAWING. 9. WEIGHT: TOOL WEIGHT SHALL NOT EXCEED 2.0 POUNDS. DIE WEIGHT SHALL NOT EXCEED .50 POUNDS. 10. TOOL COMPRESSION FORCE: COMPRESSION FORCE SHALL BE IN ACCORDANCE WITH TABLE

21、1 USING THE SPECIFIED DIE AND COMPONENT. TABLE 1 - COMPRESSION FORCE REQUIREMENTS DIE PART NUMBER TEST CABLE TEST FERRULE (.002 ) COMPRESSION FORCE (POUND MAXMUM) M22520/10-03 RG62/U .261 I.D., .297 O.D. 100 11. TOOL CYCLE CONTROL RATCHET: RATCHET RELEASE FORCE ON THE HANDLE SHALL BE 30 POUNDS MINIM

22、UM TO 50 POUNDS MAXIMUM WHEN THE TOOL IS CLOSED ON A .650 INCH .0005 GAGE BLOCK OR DIE SET. THE TOOL SHALL BE MADE WITH A TAMPER-PROOF RATCHET WHICH LIMITS THE MOVEMENT OF THE TOOL HANDLE IN BOTH DIRECTIONS, AND ASSURES A COMPLETE CLOSURE OF THE TOOL HANDLE PRIOR TO RELEASE. 12. DIE INTERFACE: THE D

23、IE FACES SHALL TOUCH AT COMPLETION OF CRIMPING CYCLE. AEROSPACE STANDARD AS22520/10 SHEET 4 OF 15 CRIMPING TOOLS, TYPE 2, TERMINAL, HAND, WIRE TERMINATION, FOR COAXIAL, TWINAXIAL, TRIAXIAL, SHIELDED CONTACTS AND FERRULES, TERMINAL LUGS, SPLICES, AND END CAPS 13. ASSEMBLY INSTRUCTIONS: ASSEMBLY AND A

24、PPLICATION INSTRUCTION SHALL BE PROVIDED WITH EACH TOOL. 14. WARNING: AS22520/10 CONFIGURATION IS FOR HAND CRIMPING APPLICATIONS ONLY. USE OF HAND CRIMPING TOOLS COVERED BY THIS SPECIFICATION AS A COMPONENT IN ANY POWERED “PRESS” MAY VIOLATE OSHA REGULATIONS CFR 1910.211. SUPERSESSION INFORMATION: 1

25、. AS22520/10 SUPERSEDES MIL-DTL-22520/10D. PART NUMBERS REMAIN UNCHANGED. APPLICATION NOTES: 1. M22520/10-01 CRIMP TOOL FRAME IS INTENDED FOR USE WITH INTERCHANGEABLE CRIMP DIES TO TERMINATE COAXIAL CONNECTORS, TRI-AXIAL CONNECTORS, SHIELDED CONTACTS, TERMINALS, WIRE SPLICES, END CAPS AND SIMILAR WI

26、RE TERMINATING DEVICES (SEE TABLE 2). 2. WHEN THE DIE ASSEMBLY IS REQUIRED TO BE PERMANENTLY ATTACHED TO THE TOOL, AN MS171526 SPRING PIN IS RECOMMENDED (SEE NASM 171526 AND THE TOOL MANUFACTURER INSTRUCTIONS FOR DETAILS). 3. DIE CRIMP PERFORMANCE IS VERIFIED BY INSPECTION GAGING THE CRIMP CAVITY AS

27、 RECOMMENDED IN APPENDIX A. 4. CLOSE TOLERANCE HEX CAVITIES GAGING WITH AS22520 GAGES IN FIELD INSPECTION APPLICATIONS MAY REQUIRE SPECIAL HANDLING. APPENDIX A PROVIDES A RECOMMENDED PROCESS FOR THESE TYPES OF INSPECTION. 5. THE VARIOUS COMPONENT CRIMP BY AS22520/10 DIES ARE LISTED IN TABLE 2. TABLE

28、 2 - TOOL/DIE COMPONENT CRIMP APPLICATIONS CRIMP TOOL FRAME M22520/10-01 1/ COMPONENT DETAIL SPECIFICATION DIE PART NUMBER WIRE BARREL SIZE MIL-DTL-39012 CONNECTORS (SEE APPENDIX A) AS39029/102 AND -/103 OUTER CONTACT M22520/10-17 AND -21 SEE APPENDIX B AS7928/1, /2, /4, /5, /6, /8 -/13, AS17143, AS

29、25036, AS25274, AS27429 (CANCELED) M22520/10-100 12 THRU 10 M22520/10-101 26 THRU 14 AS7928/6 M22520/10-102 26 THRU 20 AS81824/3 M22520/10-104 26-20 (RED DIE) AS81824/1, /6, /7, /8, /9, /10, /11, /13, & /14 M22520/10-103 16 THRU 12 AS81824/1, /6, /7, /8, /9, /10, /11, /13, & /14 M22520/10-104 26 THR

30、U 20 20 THRU 16 AS21608 (SEE APPENDIX C) M22520/10-13 THRU -21, -25, -27 N/A APPENDIX A HEX CAVITY INSPECTION PROCESS - - APPENDIX B MIL-PRF-39012 CRIMP TOOL DATA - - APPENDIX C AS21608 FERRULES - - 1/ IN THE EVENT OF CONFLICT BETWEEN THIS LIST AND THE COMPONENT SPECIFICATION, THE COMPONENT SPECIFIC

31、ATION SHALL TAKE PRECEDENCE. IN SOME CASES THE COMPONENT SPECIFICATION MAY LIST A TOOL NOT INCLUDED IN THE TABLE. SPECIFICATION NOTE: 1. REVISION INDICATOR: A CHANGE BAR (l) LOCATED IN THE LEFT MARGIN IS FOR THE CONVENIENCE OF THE USER IN LOCATING AREAS WHERE TECHNICAL REVISIONS, NOT EDITORIAL CHANG

32、ES, HAVE BEEN MADE TO THE PREVIOUS ISSUE OF THIS DOCUMENT. AN (R) SYMBOL TO THE LEFT OF THE DOCUMENT TITLE INDICATES A COMPLETE REVISION OF THE DOCUMENT, INCLUDING TECHNICAL REVISIONS. CHANGE BARS AND (R) ARE NOT USED IN ORIGINAL PUBLICATIONS NOR IN DOCUMENTS THAT CONTAIN EDITORIAL CHANGES ONLY. AER

33、OSPACE STANDARD AS22520/10 SHEET 5 OF 15 CRIMPING TOOLS, TYPE 2, TERMINAL, HAND, WIRE TERMINATION, FOR COAXIAL, TWINAXIAL, TRIAXIAL, SHIELDED CONTACTS AND FERRULES, TERMINAL LUGS, SPLICES, AND END CAPS AS22520/10-02 THRU -27 HEX DIES FIGURE 3 - HEX DIE CONFIGURATION AEROSPACE STANDARD AS22520/10 SHE

34、ET 6 OF 15 CRIMPING TOOLS, TYPE 2, TERMINAL, HAND, WIRE TERMINATION, FOR COAXIAL, TWINAXIAL, TRIAXIAL, SHIELDED CONTACTS AND FERRULES, TERMINAL LUGS, SPLICES, AND END CAPS TABLE 3 - HEX DIE CONFIGURATION (REF FIGURES 2 & 3) PART NO. A .003 B .003 C .010 D .010 A/B E .003 F .003 IN-SERVICE INSPECTION

35、 GAGE M22520/6 DIM REF. SECTION DIM REF. SECTION DIE CLOSURE A DIE CLOSURE B M22520/10-02 .091 A3-A3 .068 B2-B2 .337 A: .090 B: .270 .125 .093 -030 -029 M22520/10-03 .255 A1-A1 N/A .325 - .050 - -011 N/A M22520/10-04 .138 A3-A3 .118 B2-B2 .337 A: .090 B: .270 .125 .156 -028 -002 M22520/10-05 .128 A1

36、-A1 .105 B1-B1 .325 - .102 .108 -003 -001 M22520/10-06 .160 A1-A1 N/A .400 - .050 - -005 N/AM22520/10-07 .213 A1-A1 .178 B1-B1 .325 - .107 .153 -008 -006 M22520/10-08 .128 A2-A2 N/A .337 A: .094 .050 - -003 N/AM22520/10-09 .118 A1-A1 N/A .375 - .030 - -002 N/A M22520/10-10 .128 A1-A1 N/A .375 - .050

37、 - -003 N/A M22520/10-11 .105 A1-A1 N/A .400 - .050 - -001 N/A M22520/10-13 .128 A1-A1 N/A .400 - .050 - -003 N/A M22520/10-15 .151 A1-A1 N/A .400 - .050 - -004 N/A M22520/10-17 .178 A1-A1 N/A .400 - .050 - -006 N/A M22520/10-19 .197 A1-A1 N/A .400 - .050 - -007 N/A M22520/10-21 .213 A1-A1 N/A .400

38、- .050 - -008 N/A M22520/10-23 .218 A1-A1 N/A .400 - .050 - -009 N/A M22520/10-25 .231 A1-A1 N/A .400 - .050 - -010 N/A M22520/10-27 .255 A1-A1 N/A .400 - .050 - -011 N/A REQUIREMENTS: 1. WHEN THE “C“ DIMENSION IS LESS THAN .350, THE .500 MAXIMUM CUT OUT SHALL NOT EXTEND ACROSS THE FACE OF THE DIE.

39、CONFIGURATION OF THE CUTOUT IS OPTIONAL. 2. WHEN BOTH A & B HEXS REQUIRE A COUNTER BORE, THE .250 DIAMETER MAXIMUM SHALL APPLY TO THE HEX WITH THE SMALLEST “D“ DIMENSION. THE COUNTER BORE FOR THE OTHER HEX CAN BE LARGER AND SHALL BE SHAPED SO NO SHARP EDGES ARE FORMED AT THE INTERSECTION OF THE COUN

40、TER BORES. 3. DIES WITH CRIMP CAVITIES .100 INCHES AND SMALLER (DIMENSION A OR B) SHALL HAVE ALIGNMENT GUIDE PINS INSTALLED. 4. M22520/5-25 DIES SHALL HAVE .188 DIAMETER COUNTER BORE INSTEAD OF THE REQUIRED .250 BORE (SEE SECTION A2-A2AND A3-A3). AEROSPACE STANDARD AS22520/10 SHEET 7 OF 15 CRIMPING

41、TOOLS, TYPE 2, TERMINAL, HAND, WIRE TERMINATION, FOR COAXIAL, TWINAXIAL, TRIAXIAL, SHIELDED CONTACTS AND FERRULES, TERMINAL LUGS, SPLICES, AND END CAPS M22520/10-100 DIE PART NUMBER DIE SIZE INSPECTION GAGE M22520/10-100 12-10 M22520/3-9FIGURE 4 - AS22520/10-100 DIE CONFIGURATION AEROSPACE STANDARD

42、AS22520/10 SHEET 8 OF 15 CRIMPING TOOLS, TYPE 2, TERMINAL, HAND, WIRE TERMINATION, FOR COAXIAL, TWINAXIAL, TRIAXIAL, SHIELDED CONTACTS AND FERRULES, TERMINAL LUGS, SPLICES, AND END CAPS M22520/10-101 DIE PART NO. DIE SIZE A B C D E (RAD) F .004 G H J K MIN L MIN M .005 INSPECTION GAGE M22520 /10-101

43、 26-14 .218 .062 .030 .078 .220 .100 .093 .125 .350 .050 .376 .276 M22520/3-10 FIGURE 5 - M22520/10-101 DIE CONFIGURATION AEROSPACE STANDARD AS22520/10 SHEET 9 OF 15 CRIMPING TOOLS, TYPE 2, TERMINAL, HAND, WIRE TERMINATION, FOR COAXIAL, TWINAXIAL, TRIAXIAL, SHIELDED CONTACTS AND FERRULES, TERMINAL L

44、UGS, SPLICES, AND END CAPS M22520/10-102 DIE PART NO. DIE SIZE A B C D E (RAD) F .004 G H J K MIN L MIN M .005 INSPECTION GAGE M22520 /10-102 26-20 .218 .042 .030 .078 .164 .070 .078 .090 .320 .050 .300 .200 M22520/3-11 FIGURE 6 - M22520/10-102 DIE CONFIGURATION AEROSPACE STANDARD AS22520/10 SHEET 1

45、0 OF 15 CRIMPING TOOLS, TYPE 2, TERMINAL, HAND, WIRE TERMINATION, FOR COAXIAL, TWINAXIAL, TRIAXIAL, SHIELDED CONTACTS AND FERRULES, TERMINAL LUGS, SPLICES, AND END CAPS M22520/10-103 DIE PART NO. CAVITY SIZE STAMPING COLOR IN SERVICE GAGE M22520/10-103 16-12 YELLOW M22520/3-12FIGURE 6 - M22520/10-10

46、3 CONFIGURATION AEROSPACE STANDARD AS22520/10 SHEET 11 OF 15 CRIMPING TOOLS, TYPE 2, TERMINAL, HAND, WIRE TERMINATION, FOR COAXIAL, TWINAXIAL, TRIAXIAL, SHIELDED CONTACTS AND FERRULES, TERMINAL LUGS, SPLICES, AND END CAPS M22520/10-104 DIE PART NO. CAVITY SIZE STAMPING COLOR IN SERVICE GAGE M22520/1

47、0-104 20-16 BLUE M22520/3-1326-20 RED M22520/3-14FIGURE 7 - M22520/10/104 DIE CONFIGURATION AEROSPACE STANDARD AS22520/10 SHEET 12 OF 15 CRIMPING TOOLS, TYPE 2, TERMINAL, HAND, WIRE TERMINATION, FOR COAXIAL, TWINAXIAL, TRIAXIAL, SHIELDED CONTACTS AND FERRULES, TERMINAL LUGS, SPLICES, AND END CAPS AP

48、PENDIX A - IN PROCESS INSPECTION GAGING RECOMMENDATIONS FOR HEX CAVITIES BACKGROUND: THE CLOSE TOLERANCES OF HEXAGONAL CRIMP CAVITIES AND THE SELF-ALIGNING (FLOATING) DESIGN OF THE M22520/5-01 CRIMP TOOL FRAME HAVE LED TO CONFUSION WHEN USING THE DESIGNATED CRIMP DIE GAGES. WHEN THE TOOL FRAME AND C

49、RIMP DIES ARE USED TO TERMINATE CIRCULAR PARTS, THE SELF-ALIGNING FEATURE OF THE TOOL WILL ALIGN THE HEX CAVITY HALVES APPROPRIATELY. CORRECTIVE ACTION REVIEW DURING INITIAL QUALIFICATION AND RETENTION OF QUALIFICATION HAS LED TO THE FOLLOWING PROCESS BEING RECOMMENDED FOR THE FIELD INSPECTION OF CRIMP DIE CAVITIES RELATING TO THIS SPECIFICATION: IN SERVICE INSPECTION PROCESS: 1. THE DIE SET IS FITTED INTO THE TOOL, AND THE TOOL HANDLE IS CLOSED WITH FIRM HAND PRESSURE