Wrong crimping tool or die use when putting in copper cable lugs has severe and potentially hazardous effects on electrical and mechanical performance:
Higher Contact Resistance: A wrong tool or die may not deliver the correct compression, resulting in inadequate deformation of the conductor and lug. This means higher joint resistance, leading to excessive heating up and, in extreme cases, cable fires.
Over- or Under-Crimping: Over-crimping may damage the conductor or lug by cracking or "wings" on the lug, while under-crimping produces a loose, unsatisfactory connection. Both conditions degrade the integrity and safety of the joint.
Mechanical Weakness: An improperly formed crimp may not secure the cable effectively, leaving the joint susceptible to vibration, pull-out, or mechanical stress. This can lead to intermittent connections or complete failure, particularly in harsh environments.
Non-Conformity with Standards: Employing incompatible tools and dies is a non-compliance with standards and manufacturer guidelines. This can result in equipment damage, product recall, and even legal action against the company in case of an accident or fire.
Visual Deception: Even if a crimp looks visually acceptable, it can be electrically or mechanically unsound if the improper tool or die was applied. Proper crimping is a well-engineered process, and appearances are not always reality.
Potential for Catastrophic Failure: In the end, improper crimps resulting from improper tooling can lead to equipment failure, downtime, higher maintenance expenses, and serious safety risks—including fire and electric shock.