Page 46 - 2021 Connectivity Components: Everything but the Connectors eBook

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Different techniques for machining a connector
Piece dimension: Ø=0.12” L=1”
A. Traditional leaded-brass material and cutting tools (carbide) with traditional geometry for leaded brass.
B. Lead-free brass material and traditional tools for leaded brass. The deterioration of the quality of the piece produced is unacceptable.
C. Lead-free brass material, tools with aggressive geometry, and adapted machining parameters. The overheating of the piece and the loss of productivity due to the very short tool life and reduced cutting speed are unacceptable. The quality of the component is slightly out of tolerance.
D. Lead-free brass material, successful tools, and cutting parameters.
The new process for lead-free brass machining (dedicated tools, parameters, and machinery) maintains the quality of the piece without losing cutting speed. There is a negligible reduction in tool life but not enough to substantially reduce the efficiency of the system.
This technology can be applied not only to electrical contacts, but to any brass piece, such as parts for faucets, locks, and decorative elements.
A very similar technology is also applied in the machining of steel, which no longer has to contain lead or sulfur. These two elements had the beneficial effect of reducing chip length; the short chip is particularly well-suited to machining with automatic machines.
» Examples of lead- and sulfur-free steel chips. Left, with dedicated technology; right, with conventional tools