Lifespan increase of electrical terminal crimping punches for the automotive industry

Abstract

In the Automotive Industry (AI), and in all other industries linked to it, the increase in competitiveness and the compliance with environmental requirements are mandatory. Thus, the efforts to increase the lifespan of fabrication equipment and tooling are greater than ever. This work was developed around this real need, seeking to increase the lifespan of electrical terminal crimping punches for the AI. The process to achieve the objective of the practical work began with the collection of samples from the main competitors in the market, to be able to analyze and characterize them. Subsequently, brainstorming sessions were carried out, enabling to choose which alternative samples would be produced, analyzed, and characterized. New crimping punches were then characterized at different stages of production, to study the importance and impact of the finishing stages of the production process. Finally, new samples were produced, put to the test at a real customer and advanced characterization tests were done, which allowed a better understanding of the evolution of tool wear during its lifetime. This work contributed to a better clarification of the lifespan of crimping punches, making it possible to identify potential wear mechanisms and, consequently, propose a solution that maximizes the lifespan of crimping punches. Moreover, significant lifespan improvements were attained with marginal production cost variation.