Compression crimping is a method of joining or terminating cables or wires by compressing a lug or ferrule around a wire. It is done with a specially designed tool that imparts an oval or hexagonal restriction on the connector body. Compression crimping tools range in size from small hand tools to hydraulic machines. They are suitable for a wide range of cable splicing lugs and cable termination lugs, and are better suited for single-strand electrical wire than prong crimping.
A compression crimp is an efficient method of joining or terminating cables or wires. The term refers to the process of shrinking or compressing a lug or ferrule around a wire to form a secure mechanical or electrical joint. A compression crimp is typically done with a hand or power tool that has specially designed jaws that compress the ferrule or lug to make the crimp easier. This type of crimping tool generally imparts an oval or hexagonal restriction on the connector body which, if the connector size is correct, forms a high strength joint or termination. A compression crimp tool does not bump or force any part of the connector into itself as is the case with a stab crimp making it ideal for use on single core rigid wires.
A compression crimp is a quick and cheap way to get a good connection. Compression crimpers are typically tools that look like a pair of jawed pliers that have one or more crimp points. These crimp points are typically found with one half on each jaw of the tool. When closed, the two halves form an oval or hexagonal opening. These crimp points are usually numbered or have the intended ferrule or lug size marked on them to indicate the correct termination to use. These crimp points are smaller than the connectors they are intended for; when such a connector is placed in the opening and crimped, the tool compresses the connector body firmly onto the wire.
Crimping tools range in size from small pocket hand tools to hydraulic machines capable of crimping the joints of larger, high voltage wires. Hand operated examples may have articulating jaw systems which offer greater mechanical advantage when crimping larger connections. Hydraulic crimpers can be connected to an external hydraulic source or equipped with an integral hand pump system to complete the crimps. These machines usually have a clamshell type head that accepts different dies for various connector sizes.
A wide range of cable splicing lugs and cable termination lugs are available, suitable for compression crimping applications. These are generally made of copper for the electrical connections and aluminum or steel for the mechanical joints. Mechanical compression crimps are typically used on small, light load applications such as braided steel fishing tracks and non-load bearing steel wire rope. A compression crimp is better suited for single-strand electrical wire than a prong crimp; it does not press a portion of the ferrule into the wire which tends to weaken the copper core, often causing it to break.
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