Pressing tools and crimping tools

Table of contents Pressing and crimping tools

1. What are pressing tools and crimping tools?

a. Pressing tools

b. Crimping tools

2. What types of crimping tools are there?

a. Crimping tool by function

b. Crimping tool by application

c. Crimping tool by design

3. What are crimping tools used for?

a. Example of areas of application for crimping tools

4. Which materials can be processed with crimping tools?

a. Metals

b. Plastics

5. How do you choose the right crimping tool?

6. What is the correct way to care for and maintain pressing tools?

7. Where can I find suitable press inserts?

8. Bench presses: Everything you need to know about these versatile tools

9. How bench presses work and how they are constructed

What are pressing tools and crimping tools?

Pressing tools and crimping tools are both types of hand tools or machines that are used in various industrial and manual applications to shape, join or consolidate materials. Although they are both used to connect wires and cables, they work in different ways and are therefore suitable for different applications.

Both types of tools are designed for precise applications where a permanent, strong connection or moulding is required. Their effective use often requires specific expertise and care to achieve the best results.

Pressing tools

Pressing tools are devices that use pressure to mould, bend or join materials. They can be operated manually, mechanically or hydraulically. Pressing tools are often used in metalworking, plastics processing and assembly. A typical example of a pressing tool is a hydraulic press used in metalworking to bend or mould metal plates, or a tablet press in the pharmaceutical industry.

• Connection method: Pressing tools use a connector that is pressed around a cable. This creates a gas-tight and durable connection with high tensile strength.

• Application: Crimping tools are often used in electrical installation and generally in the production of electrical connections.

Advantages: Press connections offer a number of advantages over other connection methods, such as

• Durable and gas-tight: The connection is insensitive to moisture and corrosion

• High tensile strength: Press connections can withstand high tensile loads

• Clean working: No sparks or heat are produced, which increases work safety

Crimping tools

Crimping tools specialise in connecting parts by pressing them together, typically when working with cables and electrical connections. These tools are used to crimp metal sleeves around stripped wire ends to create a permanent connection. Crimping tools are essential in electrical installation and in the manufacture of electronic devices as they ensure a secure, reliable connection that conducts electrical current efficiently. They are also used in network installations to create RJ45 or coaxial cable connections.

• Connection method: Crimping tools work by deforming metal parts. Two metal parts, such as a cable lug and a cable end, are joined together by applying pressure

• Application: Crimp connections are often used to secure cable ends or to connect components with crimp contacts

Advantages: Crimp connections also offer several advantages over crimp connections:

• Quick and easy processing: crimp connections are generally quicker and easier to produce than press connections

• Cost-effective technology: Crimping tools and connectors are generally cheaper than press tools and connectors

What types of crimping tool and crimping tool are there?

Crimping tools come in many shapes and sizes and can be designed for different materials and applications. Crimping tools can also be categorised according to function, application and design.

Crimping tool by function

• Manual pressing tools: These tools are operated manually by the user using muscle power to actuate a lever or handle to close the pressing pliers. They are compact, lightweight and mobile, but are only suitable for smaller cable cross-sections and work where little force is required

• Hydraulic crimping tools: These tools use hydraulic pressure to close the crimping tool. They offer high crimping force and precision, but require a hydraulic pump as a power source. Hydraulic crimping tools are used for cables with large cross-sections and applications with high connection quality requirements

• Pneumatic crimping tools: These tools use compressed air to actuate the crimping pliers. They are lighter and more compact than hydraulic crimping tools and still offer a high crimping force. Pneumatic pressing tools are often used in industrial series production

• Electromechanical pressing tools: These tools are operated by an electric motor and offer precise and automated control of the pressing force. They are particularly suitable for applications that require high reproducibility and documentation of the joint quality.

• Hydraulic pressing tongs: Hydraulic pressing tongs utilise hydraulic pressure to generate a high pressing force. They are particularly suitable for large cable cross-sections and provide a reliable connection.

• Hydraulic crimping pliers: Are particularly suitable for electrical connections where a secure and durable crimp is required. Hydraulic crimping pliers enable fast and precise crimping of cable lugs and connectors.

• Hydraulic hand crimpers: Ideal for mobile applications or confined working areas. Hydraulic hand crimpers combine the advantages of hydraulic crimping force with the flexibility of a portable tool.

Pressing tool by application

• Universal crimping tools: These tools can be used for a wide range of cable types and sizes. They can be used flexibly, but may not offer optimum performance for specific applications

• Special crimping tools: These tools are designed for specific cable types or applications, e.g. for coaxial cables, high-voltage cables or luster terminals. They offer greater precision and performance for the respective application

Crimping tool by design

• Crimping tools: These tools consist of two gripper arms that enclose the cable and the connector and make the connection by pressing. Crimping pliers are compact and lightweight, but are only suitable for smaller cable cross-sections

• Die crimping tools: These tools use crimping jaws or dies that enclose the connector and cable from all sides, ensuring even pressure distribution. Die crimping tools offer high crimping force and precision and are used for cables with large cross-sections and applications with high connection quality requirements

The most common include mechanical crimping tools, which are operated manually, and hydraulic crimping tools, which are operated by hand or battery and can apply higher forces. Battery-operated hydraulic pressing tools offer the advantage of mobility, while hand-operated hydraulic pressing tools are often known for their reliability and power. In Germany, you will find a large number of manufacturers that offer high-quality crimping tools.

What are crimping tools used for?

Crimping tools are used to permanently connect electrical cables and connectors. The crimping process deforms the metal of the connector so that it is pressed around the wire, creating a mechanically strong and electrically conductive connection.

These tools are used in electrical installation, in the automotive industry and in communications technology. Mechanical crimping pliers are intended for simple tasks, while battery-powered mechanical crimping tools or hand-held hydraulic crimping tools can exert greater force and are suitable for more demanding connections.

Examples of application areas for crimping tools

• Securing cable ends: Crimp connectors are used to protect the ends of cables and ensure a secure connection to plugs or other components

• Connecting components with crimp contacts: Crimp contacts are used to connect circuit boards, connectors and other electronic components together

• Repairing damaged cables: Crimp connections can be used to repair damaged cable sections and thus restore the function of the cable

• Manufacture of cable harnesses: Crimping tools are often used in industrial manufacturing to produce wire harnesses for appliances and machines.

What materials can be processed with crimping tools?

Crimping tools are extremely versatile and can be used to process a wide range of materials . Here are some of the most common materials that are typically processed with pressing tools:

Metals:

Metals are the most common material processed in press tools. Various types of metal, including steel, aluminium, copper, brass and stainless steel, can be formed, stamped, bent or pressed . Metal presses are used in the automotive industry, mechanical engineering and many other industrial sectors.

• Steel: Various types of steel, such as carbon steel, stainless steels and alloy steels, can be processed with pressing tools. Steel is often used for crimp connectors, press fittings and other components that require high strength and resilience

• Aluminium: Aluminium is a lighter and more corrosion-resistant material than steel and is often used for crimp connectors in the electronics industry and for press fittings in plumbing and heating installations

• Copper: Copper is a good conductor of electricity and heat and is often used for crimp connectors in electrical applications and for press fittings in water pipes

• Brass: Brass is an alloy of copper and zinc and is often used for crimp connectors in plumbing and heating applications as it is corrosion resistant and easy to work with.

Plastics:

Press tools are also used to mould plastic parts. This can be done through processes such as hot pressing, where plastic sheets are heated and then pressed into moulds. Plastic presses are widely used in the manufacture of consumer goods, automotive components and electronic housings.

• Thermoplastics: Various thermoplastics, such as polyethylene (PE), polypropylene (PP) and polyvinyl chloride (PVC), can be processed using compression moulding tools. Thermoplastics are often used for press fittings in pipes and hoses

• Thermosets: Thermosets, such as epoxy resins and polyurethanes, can also be processed using pressing tools. Thermosets are often used for electrical insulation and housings.

• Elastomers/rubber: Various types of rubber, such as natural rubber and synthetic rubber, can be processed with compression moulding tools. Rubber is often used for seals and sleeves in press fittings.

In addition to these materials, there are other special materials that can be processed with pressing tools, e.g. glass fibre, ceramic and wood.

How do you choose the right pressing tool?

To select the right pressing tool, you should consider the area of application and the material to be pressed. Mechanical pressing tools are suitable for smaller projects, while hand hydraulic pressing tools offer more power for denser joints. Battery-powered hydraulic crimping tools offer mobility without sacrificing performance.

For electrical connections, mechanical crimping pliers and battery-powered mechanical crimping tools are recommended. It is also important to pay attention to the quality and reputation of crimping tool manufacturers and to choose products that comply with German standards. Also consider whether the crimping tool is suitable for sanitary installations if this is your area of application.

How do you properly care for and maintain pressing tools?

Regular care and maintenance is necessary to ensure the longevity and functionality of your pressing tools. Clean mechanical crimping tools, mechanical crimping pliers and battery-powered mechanical crimping tools after each use to remove dirt and dust. Check hand hydraulic crimping tools and battery-powered hydraulic crimping tools for leaks and hydraulic function. Lightly lubricate moving parts to minimise friction. Store pressing tools in a dry place to prevent corrosion. Follow the maintenance instructions of the pressing tool manufacturer and have pressing machines inspected regularly by specialised personnel to ensure safety and efficiency. Observe specific requirements for pressing tools for pipe connections and pressing tools for plumbing to ensure proper use.

Where can I find suitable pressing inserts?

Crimping dies are an important component of crimping tools and ensure a secure and reliable connection of cables and pipes. Choosing the right crimping dies is crucial for the quality of the connection.

You can find suitable crimping dies in our online shop. Make sure that they are compatible with your crimping machine. We have listed the most common compatibilities for the respective products so that you can order the right press insert from us. Buy press inserts for renowned pressing tools from KW Hydraulik.

Which interchangeable inserts does KW Hydraulik list?

KW Hydraulik offers a large selection of interchangeable inserts for various pressing tools and applications. The inserts are available in various series and designs to meet different requirements.

Are your pressing inserts compatible with different pressing tools?

Yes, our pressing inserts are designed for a wide range of pressing tools. This means that we also list compatible interchangeable inserts from pressing tool manufacturers such as Dubuis, Klauke, Rema and Cimco.

With the right interchangeable inserts, you can optimise the use of your pressing tools and achieve professional results.

To find out which interchangeable inserts are suitable for your pressing tools and applications, you can use the filter function on the category page of our pressing inserts or contact one of our employees.

Bench presses: Everything you need to know about these versatile tools

Bench presses are versatile tools that are used in various workshops, hobby rooms and even in some households. They offer a compact and powerful solution for a variety of tasks, from metalworking to punching leather.

Our bench presses are mainly compact versions of larger industrial presses and are often used in smaller workshops, laboratories or in education due to their size and versatility.

At KW Hydraulik, you can buy bench presses conveniently via our online shop. Do you have any questions about our products? Please contact us.

Functionality and design of bench presses

A benchtop press essentially consists of a robust frame on which a movable pressure head is mounted. The pressure head is moved downwards via a screw spindle or a hydraulic cylinder to exert the desired force on the workpiece. Depending on the model, the bench press can be equipped with a fixed work table or an adjustable worktop.

Buy hydraulic crimping pliers online at KW Hydraulik

Hydraulic crimping pliers, crimping pliers and manual presses are indispensable aids for secure and durable cable connections. Whether for industrial applications, electrical installation or network technology - KW Hydraulik offers you high-quality solutions for a wide range of requirements. Take advantage of our large selection and find the right crimping tool for your applications.

You are also welcome to visit our crimping tool category and find the right accessories for your hydraulic crimping tool.