SAE AS 22520 5A-2017 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 AS22520/5 Copyright 2017 SAE International All rights reserved. No part of this publication may be reproduced, stored in

2、 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 Email

3、: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.org ISSUED2016-02REVISED 2017-02THIRD ANGLE PROJECTION CUSTODIAN: AE-8/AE-8C2 REV.A FEDERAL SUPPLY CLASS 5120 AS22520/5 SHEET 1 OF 24 REV. A PROCUREMENT SPECIFICATION: AS22520 6$(7HFKQLFDO6WDQGDUGV%RDUG5XOHVSURYLGHWKDW7his report is published b

4、y SAEtoadvance thestate of technicaland engineering sciences. The useof this report is entirelyvoluntary, and its applicability andsuitability for any particularuse, includingany patent infringement arisingtherefrom,is tKHVROHUHVSRQVLELOLWRIWKHXVHUSAE reviews eachtechnical reportatleast every fiveye

5、ars at whichtime it may be revised, reaffirmed, stabilized, or cancelled. SAE invites your written comments and suggestions.SAE values your input. To provide feedback on this Technical Report, please visit http:/standards.sae.org/AS22520/5A RATIONALE REVISION REQUIRED TO CORRECT M22520/5-06 GAGE LIS

6、TING. NOTICE THE COMPLETE REQUIREMENTS FOR PROCURING THE PRODUCT DESCRIBED HEREIN SHALL CONSIST OF THIS DOCUMENT AND THE LATEST ISSUE OF AS22520. FIGURE 1 - M22520/5-01 TOOL AEROSPACE STANDARD AS22520/5 SHEET 2 OF 24 REV. A CRIMPING TOOLS, TYPE 2, TERMINAL, HAND, WIRE TERMINATION, FOR COAXIAL, TWINA

7、XIAL, TRIAXIAL, SHIELDED CONTACTS AND FERRULES, TERMINAL LUGS, SPLICES AND END CAPS RETAINER RING (TWO REQUIRED) SECTION A-A PART NO. BODY COLOR HANDLE GRIP COLOR M22520/5-01 GOLD BLACK FIGURE 1 - M22520/5-01 TOOL (CONTINUED) FIGURE 2 - BASIC DIE DIMENSIONS (DIMENSIONS ARE APPLICABLE TO BOTH DIE HAL

8、VES) AEROSPACE STANDARD AS22520/5 SHEET 3 OF 24 REV. A CRIMPING TOOLS, TYPE 2, TERMINAL, HAND, WIRE TERMINATION, FOR COAXIAL, TWINAXIAL, TRIAXIAL, SHIELDED CONTACTS AND FERRULES, TERMINAL LUGS, SPLICES AND END CAPS REQUIREMENTS: ALL REQUIREMENTS SHALL CONSIST OF THIS DOCUMENT AND THE LATEST ISSUE OF

9、 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. OUTLINE CONFIGURATION AND TOOL CONSTRUCTION OPTIONAL WITHIN MAXIMUM DIMENSIONS SHOWN. REMOVE ALL BURRS AND BREA

10、K 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 (SEE TABLE 2 AND DETAIL DIE DRAWINGS). DIES ARE INTERCHANGEABLE WITHIN M22520/5-01 BASIC TOOL. ALL DIES SHALL H

11、AVE 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 EDGES AND CORNERS. FOR CRIMP DIE CLOSURE DETAILS SEE DIE DETAIL SPECIFICATION DRAWINGS. 3. LOCATOR CONFIGURATION: C

12、OMPONENT 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 SHALL BE FREE TO

13、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 MINIMUM. PART NUMBE

14、R AND COLORS SHALL BE AS SPECIFIED. TOOL IDENTIFICATION SHALL INCLUDE THE M22520/5-3$57180%(50$18)$;3$57180%(5$10$18)$&785(56IDENTIFICATION OR SYMBOL. IF SYMBOLS ARE USED ON THE DIES, IT SHALL BE IN ACCORDANCE WITH AIR1351. DIES CAVITIES SHALL BE MARKED IN ACCORDANCE WITH THE DETAIL DIE DRAWING. UNL

15、ESS 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 TEXTURE SHALL BE 63 RMS OVER ALL IN ACCORDANCE WITH ASME B46.1 (AMERICAN NATIONAL STANDARD

16、S 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 AND STEEL COMPONENTS SHALL BE BLACK OXIDE OR PLATED TO RESIST CORROSION. 7. DIE MATERIA

17、LS: DIES SHALL BE ALLOY TOOL STEEL HARDEN TO ROCKWELL C52-58. FINISH SHALL BE BLACK OXIDE PER MIL-C-13924 OR EQUIVALENT. SURFACE TEXTURE ON CRIMPING SURFACE SHALL BE 63 RMS, UNLESS OTHERWISE SPECIFIED, IN ACCORDANCE WITH ASME B46.1. 8. INSPECTION GAGE: INSPECTION GAGES ARE SPECIFIED WITH EACH DIE DE

18、TAIL 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 1 USING THE SPECIFIED DIE AND COMPONENT. AEROSPACE STANDARD AS22520/5 SHEET 4 OF 24 REV. A CRIMPING TOOLS, TYPE 2,

19、 TERMINAL, HAND, WIRE TERMINATION, FOR COAXIAL, TWINAXIAL, TRIAXIAL, SHIELDED CONTACTS AND FERRULES, TERMINAL LUGS, SPLICES AND END CAPS TABLE 1 - COMPRESSION FORCE REQUIREMENTS DIE PART NUMBER TEST CABLE TEST FERRULE (.002) COMPRESSION FORCE (POUND MAX) M22520/5-61 RG214/U .440 I.D./.495 O.D. 120 1

20、1. TOOL CYCLE CONTROL RATCHET: RATCHET RELEASE FORCE ON THE HANDLE SHALL BE 30 POUNDS MINIMUM TO 50 POUNDS MAXIMUM WHEN THE TOOL IS CLOSED ON A 1.000 INCH .0005 INCH 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 DIRECTI

21、ONS, AND ASSURES A COMPLETE CLOSURE OF THE TOOL HANDLE PRIOR TO RELEASE. 12. DIE INTERFACE: THE DIE FACES SHALL TOUCH AT COMPLETION OF CRIMPING CYCLE. 13. ASSEMBLY INSTRUCTIONS: ASSEMBLY AND APPLICATION INSTRUCTION SHALL BE PROVIDED WITH EACH TOOL. THE ASSEMBLY INSTRUCTION SHALL PROVIDE INSTALLATION

22、 DETAILS ON HOW TO PERMANENTLY ATTACH DIE ASSEMBLIES TO THE TOOL FRAME. 14. WARNING: AS22520/5 CONFIGURATION IS FOR HAND CRIMPING APPLICATIONS ONLY. USE OF HAND CRIMPING TOOLS COVERED BY THIS SPECIFICATION AS A COMPONENT IN ANY 32:(5(35(660$VIOLATE OSHA REGULATIONS CFR 1910.211. SUPERSESSION INFORMA

23、TION 1. AS22520/5 SUPERSEDES MIL-DTL-22520/5D AND MIL-C-0022520/5E (USAF). PART NUMBERS REMAIN UNCHANGED. APPLICATION NOTES 1. M22520/5-01 CRIMP TOOL FRAME IS INTENDED FOR USE WITH INTERCHANGEABLE CRIMP DIES TO TERMINATE COAXIAL CONNECTORS, TRI-AXIAL CONNECTORS, SHIELDED CONTACTS, TERMINALS, WIRE SP

24、LICES, END CAPS, AND SIMILAR WIRE TERMINATING DEVICES. 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 TH

25、E CRIMP CAVITY AS 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 INSPECTIONS. 5. THE M22520/5-104 DIES WERE DESIGNED TO BE USED TO CRIMP I

26、NNER CONDUCTOR AND OUTER SHIELDING OF MIL-C-39029/95 AND /96 CONTACTS WHICH WERE UNPUBLISHED. M22520/5-104 WAS CANCELED WITHOUT REPLACEMENT DUE TO CONTACT STATUS. 6. THE M22520/5-106, -107, AND -108 DIES ARE USED TO CRIMP TERMINALS AND SPLICES WITH INSULATED SUPPORT CUP CRIMP BARRELS. THE DIES SIMUL

27、TANEOUSLY CRIMPS THE WIRE INSULATION SUPPORT CUP AND THE INSULATED CRIMP BARREL. 7. THE VARIOUS COMPONENTS CRIMPED BY AS22520/5 DIES ARE LISTED IN TABLE 2. AEROSPACE STANDARD AS22520/5 SHEET 5 OF 24 REV. A CRIMPING TOOLS, TYPE 2, TERMINAL, HAND, WIRE TERMINATION, FOR COAXIAL, TWINAXIAL, TRIAXIAL, SH

28、IELDED CONTACTS AND FERRULES, TERMINAL LUGS, SPLICES AND END CAPS TABLE 2 - TOOL/DIE COMPONENT CRIMP APPLICATIONS CRIMP TOOL FRAME M22520/5-01 (SHEET 2) 1/ COMPONENT DETAIL SPECIFICATION DIE PART NUMBER WIRE BARREL SIZE MIL-PRF-39012 CONNECTORS (SEE APPENDIX A) AS39029/102 AND -/103 OUTER CONTACT M2

29、2520/5-02 THRU -63 SEE APPENDIX B AS7928/1, /2, /4, /5, /6, /8 -/13, AS17143, AS25036, AS25274 AS27429 (CANCELED) M22520/5-100 12 THRU 10 26 THRU 14 AS7928/5 M22520/5-101 26 THRU 20 AS81824/1, /6, /7, /8, /9, /10, /11, & /14 M22520/5-102 16 THRU 12 AS81824/1, /6, /7, /8, /9, /10, /11, & /14 M22520/5

30、-103 26 THRU 20 20 THRU 16 MIL-C-39029/95, /96 CONTACTS (UNPUBLISHED SEE APPLICATION NOTE 5) M22520/5-104 (CANCELED) CONTACT SHIELD SLEEVE AS39029/90-529, /91-530 & /113-625, /114-628 M22520/5-105 CONTACT SHIELD SLEEVE AS7928/1, /4, /5, /6, /8-/13, AS17143, AS25036, AS25274, AS27429 M22520/5-106 18

31、THRU 22 WITH INSULATION SUPPORT CUP CRIMP AS7928/1, /4, /5, /6, /8-/13, AS17143, AS25036, AS25274, AS27429 M22520/5-107 14 THRU 16 WITH INSULATION SUPPORT CUP CRIMP AS7928/1, /4, /5, /6, /8-/13, AS17143, AS25036, AS25274, AS27429 M22520/5-108 10 THRU 12 WITH INSULATION SUPPORT CUP CRIMP APPENDIX A -

32、 HEX CAVITY INSPECTION PROCESS - - APPENDIX B - MIL-PRF-39012 CRIMP TOOL DATA - - 1/ IN THE EVENT OF CONFLICT BETWEEN THIS LIST AND THE COMPONENT SPECIFICATION, THE COMPONENT SPECIFICATION SHALL TAKE PRECEDENCE. IN SOME CASES, THE COMPONENT SPECIFICATION MAY LIST A TOOL NOT INCLUDED IN THE TABLE. SP

33、ECIFICATION 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 CHANGES, HAVE BEEN MADE TO THE PREVIOUS ISSUE OF THIS DOCUMENT. AN (R) SYMBOL TO THE LEFT OF THE DOCUMENT TITLE INDICATES

34、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. AEROSPACE STANDARD AS22520/5 SHEET 6 OF 24 REV. A CRIMPING TOOLS, TYPE 2, TERMINAL, HAND, WIRE TERMINATION, FOR COAXIAL

35、, TWINAXIAL, TRIAXIAL, SHIELDED CONTACTS AND FERRULES, TERMINAL LUGS, SPLICES AND END CAPS M22520/5-02 THROUGH -63 HEX DIES FOR AS39029 CONTACT SHIELDS AND MIL-PRF-39012 CONNECTORS PART NO. DIE COLOR DIE IN-SERVICE INSPECTION GAGE M22520/5- XX (SEE TABLE 3) BLACK SEE TABLE 3 FIGURE 3 - M22520/5-02 T

36、HROUGH -63 HEX DIES (SEE FIGURE 2) AEROSPACE STANDARD AS22520/5 SHEET 7 OF 24 REV. A CRIMPING TOOLS, TYPE 2, TERMINAL, HAND, WIRE TERMINATION, FOR COAXIAL, TWINAXIAL, TRIAXIAL, SHIELDED CONTACTS AND FERRULES, TERMINAL LUGS, SPLICES AND END CAPS CONFIGURATION REQUIREMENTS 1. CONFIGURATION SHALL BE IN

37、 ACCORDANCE WITH FIGURES 2 AND 3, AND TABLE 3. 2. DIES WITH CRIMP CAVITIES .100 INCHES AND SMALLER (DIMENSION A OR B, FIGURE 3) SHALL HAVE ALIGNMENT GUIDE PINS INSTALLED (SEE FIGURE 3 DIE PARTED VIEW). ALIGNMENT GUIDE PINS AND HOLES ARE NOT REQUIRED FOR DIES WHERE ALL CRIMP CAVITIES ARE LARGER THAN

38、.100 INCHES. 3. WHEN THE “C“ DIMENSION IS LESS THAN .400, THE .750 MAXIMUM CUTOUT SHOWN IN FIGURE 3 - SIDE VIEW SHALL NOT EXTEND ACROSS THE FACE OF THE DIE. CONFIGURATION OF THE CUTOUT IS OPTIONAL. 4. WHEN BOTH A AND B HEXS REQUIRE A COUNTERBORE AS SHOWN IN FIGURE 3 IN SECTIONS A2-A2, B2-B2, AND B4-

39、B4, THE .250 DIAMETER MAXIMUM SHALL APPLY TO THE HEX WITH THE SMALLEST “D“ DIMENSION. THE COUNTERBORE FOR THE OTHER HEX CAN BE LARGER AND SHALL BE SHAPED SO NO SHARP EDGES ARE FORMED AT THE INTERSECTION OF THE COUNTERBORES. THE M22520/5-25 DIES SHALL HAVE .188 DIAMETER COUNTERBORE AS SHOWN IN SECTIO

40、N B-B, FIGURE 3. TABLE 3 - DIMENSIONS AND GAGES FOR HEX CAVITY DIES (SEE FIGURES 2 AND 3) PART NO. A .003 B .003 C .010 D .010 A/B E .003 F .003 IN-SERVICE INSPECTION 1/ GAGE M22520/6 DIM REF SECTION DIM REF SECTION DIE CLOSURE A DIE CLOSURE B M22520/5-02 .091 A-A .068 B-B .385 .090/.270 .175 .075 -

41、030 -029 M22520/5-03 .128 A-A .105 B-B .325 - .114 .246 -003 -001 M22520/5-04 .138 A-A .118 B-B .385 .090/.270 .174 .076 -028 -002 M22520/5-05 .213 A-A .178 B-B .325 - .114 .246 -008 -006 M22520/5-06 .128 A-A N/A .400 .094 .050 - -003 - M22520/5-07 .255 A-A N/A .325 - .050 - -011 - M22520/5-08 .128

42、A-A N/A .375 - .050 - -003 - M22520/5-09 .178 A-A .068 B-B .400 .093 .188 .125 -006 -029 M22520/5-10 .160 A-A N/A .400 - .050 - -005 - M22520/5-11 .213 A-A .068 B-B .400 .093 .188 .125 -008 -029 M22520/5-13 .255 A-A .068 B-B .400 .093 .188 .125 -011 -029 M22520/5-15 .263 A-A .068 B-B .400 .093 .188

43、.125 -012 -029 M22520/5-17 .118 A-A N/A .375 - .050 - -002 - M22520/5-19 .255 A-A .213 B-B .400 - .159 .231 -011 -008 M22520/5-21 .475 A-A N/A .400 - .050 - -025 - M22520/5-23 .384 A-A N/A .400 - .050 - -020 - M22520/5-25 .429 A-A .100 B-B .400 .120 .130 .258 -022 -031 M22520/5-27 .532 A-A N/A .400

44、- .050 - -027 - M22520/5-29 .324 A-A .100 B-B .400 .120 .187 .187 -017 -031 M22520/5-31 .501 A-A N/A .400 - .050 - -026 - M22520/5-33 .343 A-A .105 B-B .400 - .159 .191 -018 -001 M22520/5-35 .324 A-A .128 B-B .400 - .159 .191 -017 -003 M22520/5-37 .314 A-A .151 B-B .400 - .159 .191 -016 -004 M22520/

45、5-39 .309 A-A .160 B-B .400 - .159 .191 -015 -005 M22520/5-41 .290 A-A .178 B-B .400 - .159 .191 -014 -006 M22520/5-43 .268 A-A .197 B-B .400 - .159 .191 -013 -007 M22520/5-45 .231 A-A .218 B-B .400 - .199 .151 -010 -009 M22520/5-47 .359 A-A N/A .400 - .050 - -019 - M22520/5-49 .401 A-A N/A .400 - .

46、050 - -021 - M22520/5-51 .431 A-A N/A .400 - .050 - -023 - M22520/5-53 .454 A-A N/A .400 - .050 - -024 - M22520/5-55 .324 A-A N/A .400 - .050 - -017 - M22520/5-57 .213 A-A .100 B-B .400 .120 .185 .130 -008 -031 M22520/5-59 .255 A-A .100 B-B .400 .120 .185 .130 -011 -031 M22520/5-61 .429 A-A N/A .400

47、 - .050 - -022 - M22520/5-63 .263 A-A .091 B-B .400 .090 .159 .191 -012 -030 1/ SEE APPENDIX A FOR IN PROCESS GAGING PROCEDURE. AEROSPACE STANDARD AS22520/5 SHEET 8 OF 24 REV. A CRIMPING TOOLS, TYPE 2, TERMINAL, HAND, WIRE TERMINATION, FOR COAXIAL, TWINAXIAL, TRIAXIAL, SHIELDED CONTACTS AND FERRULES, TERMINAL LUGS, SPLICES AND END CAPS M22520/5-100 DIES FOR PRE-INSULATED TERMINALS AND SPLICES DIE PART NO. 1/ CAVITY SIZE STAMP COLOR FOR INSPECTION GAGING USE M22520/5-100 12-10 YELLOW M22520/3-09 26-14 WHITE M22520/3-10 1/ ATTACH LOCATOR TO UPPER DIE. FIGURE 4 - M