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1. Tooling Design vs. Range of Inserted Component Wire
Created By: Suzy Carman on 2001-03-30 at 下午 10:51
Category: Applications Information
Sub-Category: Axial
this is Lightning stroke
process and we have
improved series 8 machines
to the point that two step
processs is not need I
recommend this be deleted
Tooling
Design
vs.
Range of
Inserted
Component
Wire
Submitted To: Kim
Cannon
Submitted By: Theresa

2. Taro
Date: July 21,
1995

3. 1.0 INTRODUCTION
Do you have
customers who are willing to
simplify the Axial automated
insertion process, speed up
machines, lower preventative
maintenance (pm) downtime
and ppm levels and generally
reduce manufacturing costs?
If so, then this paper may
interest you.
Universal Instruments
Corporation is currently
working to customize tooling
for customers who have
evolved their manufacturing
processes to two and three
step processes for Axial
insertions, thereby dedicating
machines to run a limited
range of components. In
step one for example, a
machine inserts only 5mm
insert spans and then in step
2, a second machine inserts
various wire diameters. This
is a radical change from the
current manufacturing
philosophy of fully populating
a board in one pass through
a machine. However, history
has shown that by limiting the
range of wire diameters
inserted and then designing
tooling to specifically handle
that range, the manufacturing
process becomes more
controlled, insertion
performance improves, pm
downtime and ppm levels
decrease and ultimately,
manufacturing costs
decrease.
Admittedly, this

4. approach is not viable for
every customer. Universal
offers a variety of tooling
configurations that if used
according to specification, will
provide excellent insertion
performance. A customer
may have no need to run a
wide range of wire diameters
or they may want to revisit
their manufacturing process
to make improvements. For
those customers, Universal
offers customized tooling for
dedicated applications.
Customized tooling will
handle a limited range of wire
diameters to optimize
insertion performance and
maximize tooling life.
This paper discusses
the relationship between
tooling design and wire
diameter range of inserted
components with the goal of
creating an awareness and
understanding of this
relationship and it’s
significance.

5. 2.0 FACTORS
AFFECTING THIS
RELATIONSHIP
2.1 Depth of V-Groove of
Outside Former
One important factor
affecting the relationship of
tooling design and range of
insertable wire diameters is the
depth of the V-groove of the
Outside Former. Our current
specifications for Axial tooling
are as follows:
Standard High Density Large Lead 5mm 26mm AAA
B
ot
to
m
Vi
e
w
of
O
ut
si
d
e
F
or
m
er
W
ir
e
Di
a
m
et
er
R
a
n
g
e /
M
at
er
ial
Steel:
.015”-.032”
(.39) - (.82)
Copper:
.015”-.032”
(.39) - (.82)
Steel:
.015”-.025”
(.39) - (.64)
Copper:
.015”-.032”
(.39) - .82)
Steel:
.025”-.032”
(.64) - (.82)
Copper:
.025”-.042”
(.64) - (1.01)
Steel:
.015”-.025”
(.39) - (.64)
Copper:
.015”-.028”
(.39) - (.72)
Steel:
.015”-.020”
(.39) - (.51)
Copper:
.015”-.024” (.39) -
(.61)
Dr
iv
er
.030”
(.77)
.030”
(.77)
.050”
(1.27)
.017” *
(.44)
.012” *
(.31)

6. Ti
p
W
id
th
Metric equivalents are bracketed
* Not entire width but dimension
from edge of Driver Tip to side of
Outside Former
When the wire diameter
is smaller than the depth of the
V-groove of the Outside Former,
the lead has excess space and
moves within the V-groove.
This uncontrolled condition
leads to a ‘weak’ form.
V-groove with Small Lead
Diameter
When the wire diameter
is larger than the depth of the
V-groove of the Outside Former,
the yieldable Inside Former
flexes to make room for the
bigger lead. Continual flexing
causes the O-rings to wear out
which leads to a ‘sloppy’ Inside
Former and ‘weak’ forms.
Outside Formers have been
known to split at the V-groove
from continual stress. Long
term, continual flexing will
damage the Tooling Housing by
loosening it and making it

7. ‘sloppy’.
V-groove with Large Lead
Diameter
The optimal condition is
wire diameter equal to the depth
of the V-groove of the Outside
Former. In this condition, the
lead is large enough so that is
does not ‘move’ within the
V-groove, and yet it does not
continually flex the Inside
Former.
V-groove with Optimal

8. Lead Diameter
When Standard tooling
is compared to 5mm tooling, it
becomes clear why 5mm tooling
is less reliable when inserting
components with large lead
diameters than Standard
tooling.
TOOL
ING
DEPTH
OF
V-GROO
VE
WIRE
DIAMETE
R RANGE
Stand
ard
.028” (0.7
1mm)
.015”
-.032” (0.39
mm -
0.82mm).
5mm .018” (0.4
6mm)
.015” -
.028” (0.39
mm -
0.72mm)
The depth of the V-grooves vary
by .010” (0.26mm) and yet the
range of wire diameter is very
similar.
2.2 Radius of V-Groove of
Outside Former
Another factor is the
radius of the V-groove of the
Outside Former. The V-groove
is actually a radius of
.016” (0.41mm) for all tooling
types except large lead tooling
which is .019” (0.49mm).
Because this is a radius, not a
diameter, the optimum lead size
for this size radius is
.032” (0.82mm) This radius
creates a situation that allows a
small wire diameter to ‘roll
around’ or be uncontrolled in the
groove. A true V-groove
improves this condition by
creating a 2 point contact.

9. One Point Contact Two Point Contact
2.3 Body Length to
Insertion Length
Body length to insertion
length is another critical issue in
this discussion. The bigger the
gap between the component
body and the bend of the lead,
the more room there is for the
insertion tooling. As the Driver
Tip descends, it can damage a
component body that is too long
for the specified insertion span.
Clearance is also needed for the
Inside Former coming beneath
the bend of the lead. A bend too
close to the component body
can also cause damage.
Maximum body length is
obtained with the following
formula:
Programmed Z-Span =
Insertion Span + 1 Lead
Diameter
Maximum Body Length
(clearance between Driver Tips)
= Insertion Span + 1 Lead
Diameter - 2 x Depth of Outside
Former V-groove - 2 x Driver Tip
Thickness
Do not use components with
body lengths at the maximum
length. Allow .020” (0.51mm) on
each side of a component body

10. for clearance and to account for
tolerances.
Component Body Leaving
Clearance
Component Body Leaving
No Clearance
2.4 Driver Tip Position
During a component
insertion, the Driver Tip rests
on the horizontal surface of
the lead. When a lead has a
‘weak’ form, the Driver Tip
rests on top of the bent
portion of the lead. As the
Driver Tip tries to push a
component through the holes
of the pc board, it has a
tendency to ‘slide off’ a lead,
leading to a standup or failed
insertion. This is true of 5mm
tooling because of its small
Driver Tip.
Driver Tip Position
during insertion
Driver Tip position during
insertion
of weak form lead

12. 3.0 SUMMARY OF
ABOVE CONDITIONS
· Wire diameters
significantly smaller than the
depth of the V-groove of the
Outside Former are
uncontrolled within the
V-groove. This is caused by
one point contact and excess
space, which leads to a
‘weak’ form and poorly
controlled insertion. Small
lead components without a
‘crisp’ form are also at risk of
misinserting because the
Driver Tip may ‘slip off’ the
lead, while pushing it through
the pc board. This condition
is seen most often with 5mm
tooling.
· Wire diameters
significantly larger than the
depth of the V-groove of the
Outside Former continually
flex the yieldable, Inside
Formers causing premature
tooling wear-out of the Inside
and Outside Formers as well
as other parts of the tooling.
· Acceptable component
body length varies with
Z-span, but clearance is
required for the Inside
Formers and Driver Tips
during insertion so the
component body is not
damaged.
4.0 OPTIMAL
CONDITIONS
To optimize insertion

13. performance and maximize
tooling life, it is best to limit
the range of wire diameters
inserted with any tooling
selection, keeping in mind the
optimal wire diameter is the
same size as the V-groove of
the Outside Former. For
example, if the wire diameter
range of a particular
application is .018” - .022”, a
.020” V-groove is optimal.
This eliminates the problems
mentioned above and allows
optimal tooling life, process
control and low insertion
ppm.
Making use of the
squeeze function when
writing pattern programs can
also help. If a component
lead diameter is small in
relation to the V-groove of the
Outside Former, the squeeze
function can improve a ‘weak’
form. The squeeze function
is also useful when inserting
steel leaded components as
they tend to have a memory
after the forming process. It
also helps insert components
with long bodies and a small
insertion span.
Allow clearance on
each side of a component
body so there is room for the
insertion tooling.

14. Consider dedicating a
manufacturing line to a
particular application for
optimal performance and
then customize the tooling for
a small range of wire
diameters. Universal offers
customized tooling for
dedicated applications.
Customized tooling can
include the following items,
as needed:
2 point contact in•
V-groove of Outside
Former based on an
optimum lead diameter
Increase size of•
Outside Former
footprint for a more
robust design
Improved bent lead•
input insertion
capability
Non-yieldable Inside•
Formers for improving
lead forms
Add width to the Driver•
Tip, for assuring good
contact with the lead.
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