Factors to Considers While you Crimp Terminal Lugs

Crimp Terminal Lugs

Crimping lugs are bimetallic lugs used for joining cables to surfaces, electrical appliances, other cables or mechanisms. The clamp that connects wires with an automotive battery is a typical example of crimping lug.

Here are some essential points for crimping the lugs correctly:

Effortless Crimping

Once the conductor and connector are prepared, you can kick-off the crimping process. Cable lugs are able to be cleanly and rightly processed without under or over crimping when the suitable device is used. In other words, crimping tool and cable lug should relate to one system: the same supplier for the connector, cable lug and tool.

Competent crimping and matched tool parts save excessive transfer resistance along with the resultant extreme temperature. Elevated temperature can, in the worst case, cause a fire.

Crimping on the terminal lugs always start from the connection side and works towards the side of the cable. However, on a connector side, the first crimp is in the middle. If the crimp is not in the center, the cracks can develop, and material cannot elongate.

For example, with compression lugs, the required number of crimps as per DIN 46235 is identified by marks on the connector and the cable lug. With tubular cable lugs, the no. of crimps can be confirmed in the catalogue.

Make sure to complete the process of crimping. A furnished crimp is essential, since the crimped tool achieves the needed compression towards the end of the phase of crimping. A complete crimp is the only way for guaranteeing the correct crimp.

Hydraulic or Mechanical Crimping

The crimping is the crucial tool in a crimping process. Irrespective of whether this is completed through muscle power or hydraulic. As the cable lug gets crimped, the kind and degree of deformation are described by the device or the contract-specific wear parts related to press.

Here are some specifications regarding hydraulic tools for crimping lugs:

Crimping Tool Type

Crimping Range

Crimping Force


Up to 400 sq. mm LV HV

Cable Lugs

230 kN

Battery Operated

Up to 630 sq. mm LV HV

Cable Lugs

63 kN

Foot Pump + Crimp Head

Up to 630 sq. mm LV HV

Cable Lugs

230 kN

Mechanical press or electro-hydraulic press is the correct option for you? It depends upon the field of application. A compact mechanical crimping tool is best suited for the cross-sections ranging small to medium. For large cross-sections, generally, you should prefer a hydraulic device having interchangeable dies. The number of crimps must also be considered.

Without a doubt, hydraulic is appropriate for more substantial quantities as compared to mechanical ones. Although for small and straightforward crimps, you can easily apply enough pressure through mechanical pliers. Large conductors then crimped via electro-hydraulic presses being standard.


Before you start the crimping process, make sure that all components are clean. You must make sure that no trace of metal is on the conductor; this can cause corrosion.

Wrap Up

Crimping is a vital process in today’s connection technology. Therefore the above points make sure smooth crimping dies are not dirty or damaged.


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