The challenge with creating electrical connections is on one hand to form material tight to achieve gap-free contact between the joined components.
The tight connection should achieve very high continuity and prevent corrosion. On the other hand, applying excessive force should also be prevented, which may deform components.
The radial process is extremely effective in forming material in three different directions, or 3-dimensionally, while keeping the applied force to a minimum. With optimized process parameters and tooling, the deformation of components can be prevented and still meet customers' requirements.
Facts & Figures
|Material||Copper, brass, aluminum|
|Geometry||Various – relay contacts to heavy gauge, high current cables|
|Shank type||Solid and tubular rivets. Round or rectangular|
|Rivet head geometry||Flat, crown, eyelet flare, flat flare, high crown|
|Forming Tool||Per application|
|Performance Data||Typical forming time: 0.3 – 1.0 sec. Typical machine cycle time : 1.0 – 2.0 sec.|
|Equipment||CLASSIC or ELECTRIC radial forming|
|Application Area||Electrical terminals and connections, bus bar riveting, electrical power rail, battery terminals|
|Devices||Most applications: 2-6 kN. Occasionally up to about 20 kN|
|Process Control||HPP-25 or HPPi|
|User Benefits: Process||Excellent gap filling with minimal necessary force|
|User Benefits: Economic||Flexibility regarding setup. Process stability & assurance of quality product being produced|