Wire rope ferrules are used to terminate the end of a wire rope and are an important safety feature for wire ropes, there are many types and various applications for various purposes.
The first type is the oval wire rope ferrule which is oblong and has a smooth surface and is so contoured as to press the end of the wire rope into a loop. Oval swage sleeves are stronger than stop sleeve and are used in the same applications as hourglass sleeves. If fitted correctly, oval swage sleeves will maintain the rated breaking strength of the wire rope used with them, but the connection must be load tested before being put into service.
The second is the hourglass wire rope ferrule, a single-piece swage sleeve with two opposing creases in the middle that look like a double barrel. A load test must be carried out before use. If fitted correctly, it will maintain the rated breaking strength of the wire rope it is used with.
The third type is the stop sleeves which are light duty and can be used for simple swage and are used to terminate the end of the rope to prevent abrasion and prevent the end of the rope from passing through the panel. The connection must be load tested prior to use. If fitted correctly, it can withstand 1/3 of the rated breaking strength of the wire rope used in conjunction with it.
It is recommended to load test the termination to ensure its integrity.
When using wire rope ferrule, ensure that the cut end of the wire rope extends at least two wire rope diameters from the swage sleeves, so that the swage sleeve remains in contact with the wire rope as it expands during installation.
The number of crimps is determined by the size of the swage sleeve and the number of crimps is also determined by the size, larger swage sleeves require more crimps, 1/16'' and 3/32'' require 2, 1/8'' and 5/32'' require 3, 3/16'' and 1/4'' require 4, 5/16'' and 3/8'' require 5 and 1/2'' require 6. 6 are required.
Crimping on the outside of vinyl-coated wire rope is not recommended as this will significantly reduce the strength of the terminal.
Orient the swage sleeve and align it vertically, not horizontally, to accommodate the jaw of the crimper. leave a small space of no more than 2 wire rope diameters between the swage sleeves.
After splicing, use a crimp sleeve gauge to determine if the maximum crimp effect has been achieved. When fitted correctly, hourglass and oval swage sleeves will preserve more than 90% of the breaking strength of the wire rope and should always be load-tested prior to use.
Aluminum wire rope ferrule is usually used in conjunction with hot dip galvanised wir rope to fill the grooves of steel cables during installation and is an economical solution for both indoor and outdoor applications. It should be noted that Aluminium swage sleeves should not be used in conjunction with stainless steel wire rope as the prolonged contact between the two materials can cause galvanic corrosion.
Copper wire rope ferrule is an economical solution for loops or laps that can be used for indoor or outdoor applications and is generally available in a variety of finishes: plain self-colored, zinc plated, tin plated, nickel plated, etc. zinc plated provides an attractive and corrosion-resistant surface, tin plated provides corrosion-resistant, flat, low-gloss surfaces, and nickel plated for a corrosion-resistant and wear-resistant surface.
Stainless steel wire rope ferrules offer the best corrosion resistance and are suitable for use in salt water or nearby aggressive scenarios. The installation of stainless steel swage sleeves requires the use of hydraulic, pneumatic, full-length crimping machines in order to achieve the proper and maximum crimp size.
Steel wire rope ferrules are designed for flemish eye wire rope and low-temperature toughness. It is recommended to load test the termination to ensure its integrity.