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Photographs of Swaged Terminals showing various problems

ITEM DESCRIPTION           DIAGNOSIS OR CAUSE
1.  Good Roll Swage   Good.
2. Good Flare Swage Good.
3. Flare Swage Split due to excessive pressure and wrong tooling.
4. Roll Swage Damaged swaged end due to misalignment of anvil and Terminal with punch.
5. Roll Swage Insufficient swage due to improper anvil height adjustment.
6. Roll Swage Terminal flange not seated due to terminal not being fully inserted in board before swaging.
7. Roll Swage Swaged end split, due to excessive swaging pressure and incorrect punch.
8. Flare Swage One Terminal cracked and one swollen due to slightly excessive swaging pressure and excessive anvil height setting.
9. Bent Terminal Bent Terminal (next to straight terminal for comparison). Bent due to lifting board from anvil at an angle
10. Bowed Terminal board Board bowed during swaging due to undersized terminal mounting holes in board.
11. Damaged Board: Delaminated, Crazed or Cracked Board Damaged during swaging due to undersized terminal mounting holes and, or , improper swaging tools.
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