How much force to test “fat wires”

[TASEsq]

Made my first “fat wire” today using 2AWG (circa 35mm) marine cable. The lugs were crimped using the 35mm dies until the crimper pressure release went off. I setup a quick test rig to pull the cable using some luggage scales.

I was able to pull around 50kgs before the luggage scale error’d out.

This seems like heaps enough to me, but is there a number the professional shops use for a crimped lug on 2AWG?

 

[rv8ch]

I was able to pull around 50kgs before the luggage scale error’d out.

That'll do, pig. That'll do.



For "small" wires, Bob Nuckolls suggests "about the weight of a gallon of milk" - which is about 4kg or about 8.5 lbs in freedom units.

I imagine that 50kg is plenty for the fat wire, assuming it's not structural.

 

[WhiskeyCharlie23]

Just, why? Do you plan on using it like a rope?

 

[jacoby]

FWIW it looks like you've choked up on the terminal too close to the palm. And you're not supposed to overlap crimps for whatever reason. TE has a nice guide on crimping including the PIDG and CCT terminals. https://www.te.com/content/dam/te-com/documents/appliances/global/guide-to-crimping.pdf

 

[wirejock]

I had a Bob Nuckolls document in which he recommended soldering the big ones after crimping. It was the only place he recommended it. I had to cut one for some reason so I cut it in half to look. It looked like one hunk of metal and I could not chisel the remainder out. Maybe his document is on VAF somewhere.

 

[DanH]

This seems like heaps enough to me, but is there a number the professional shops use for a crimped lug on 2AWG?

Yep, 3 lbs, as in "3 lb hammer"

 

[Mikeyb]

It’s a big number. The wire is supposed to break first type of thing. You are after a gas free connection between the wire bundle and the terminal at least as large as the wire cross section. They want 100 percent deformation in the crimp area. The lug and individual strands are a solid mass. The wire strands and lug are compressed until they are slightly smaller in diameter and longer

 

[TASEsq]

FWIW it looks like you've choked up on the terminal too close to the palm. And you're not supposed to overlap crimps for whatever reason. TE has a nice guide on crimping including the PIDG and CCT terminals. https://www.te.com/content/dam/te-com/documents/appliances/global/guide-to-crimping.pdf

Thank you! I just figured more was better!

 

[TASEsq]

Just, why? Do you plan on using it like a rope?

Yep - towing gliders.

 

[esco]

It’s a big number...

Mike: what's the source of this table? I didn't see it in the TE guides.

thx!

 

[Mikeyb]

View attachment 108389
Mike: what's the source of this table? I didn't see it in the TE guides.

thx!

I should have noted that this is a destructive test where the wire is pulled at a constant rate to max force or failure. Not to be confused with a dead weight test. just that it was way more than 50 kg. In general all wire connections are designed to be stronger than the wire. Hence to $$$ tools for the Dsub connectors.

How to check crimp terminals on wires?

A good crimping of a terminal on a cable increases the life time of the connection and avoid micro cuts when using the cable in a car or an airplane.

www.andilog.com

 

[esco]

How to check crimp terminals on wires?

A good crimping of a terminal on a cable increases the life time of the connection and avoid micro cuts when using the cable in a car or an airplane.

www.andilog.com

thanks for the source!