Hi Steve - we typically use a washer type device to address the forming of TO type device leads when this concern/question is raised. That seems to make everyone happy. Dave Hillman Rockwell Collins [log in to unmask] On Thu, Jul 28, 2016 at 10:12 AM, Steve Gregory <[log in to unmask]> wrote: > Hi All, > > We're building a board for a customer that uses a 8-lead TO-5 style relay. > The footprint on the board requires that the leads are spread out to a > larger diameter circle than what diameter is when they come out of the body > at the bottom of the relay. Here's the information for one of the relays, > there are three others that are the same style: > > > http://www.digikey.com/product-search/en?lang=en&site=us&WT.z_cid=ref_findchips_standard&mpart=PRMAC-26X > > So we have a Simonds CLP274 lead processor with a die that matches the > footprint on the PCB: > > http://stevezeva.homestead.com/Simonds_CLP274.jpg > > We insert the part which spreads the leads out, then step on the pedal and > a guillotine style blade shears the leads off. I've used the prep unit > many, many time before at previous employers without issues. The customer > is saying that prepping the leads in this unit is damaging the relay. So > now we are to pot the leads before prepping them with a 2-part epoxy using > a tooling fixture as a mold for the epoxy, and the potted relay looks like > this: > > http://stevezeva.homestead.com/Potted_Relay.jpg > > Has anybody ever heard of this Simonds unit damaging relays like this? Has > anybody had to add potting to a relay like this? I can understand wanting > to keep the leads coming straight out of the bottom of the body before > making the bend to match the footprint on the board, but I think I can use > a Bivar permanent spacer and slip it over the lead and accomplish the same > thing. Something like this: > > > https://www.google.com/url?sa=t&rct=j&q=&esrc=s&source=web&cd=2&ved=0ahUKEwiqk8zCt5bOAhWJ1IMKHebaCR8QFggxMAE&url=http%3A%2F%2Fwww.bivar.com%2Fportals%2F0%2Fproducts%2F616-070.pdf&usg=AFQjCNESVvvX6qOo_-0T94sAYNLP8AJ21Q&cad=rja > > Or even a nylon washer that matches the diameter of the lead pattern > (.200") coming out of the bottom of the relay. Potting this relay is going > to be very time consuming and there's going to be a risk of getting the > epoxy on the leads that will ruin the solderability of the part. I'm just > trying to understand if it is truly the Simonds prep unit causing the > damage, and if this really is, and easier way other than potting them to > accomplish the same thing. > > Thanks all! > > Steve Gregory > > -- > > > This email and any attachments are only for use by the intended > recipient(s) and may contain legally privileged, confidential, proprietary > or otherwise private information. Any unauthorized use, reproduction, > dissemination, distribution or other disclosure of the contents of this > e-mail or its attachments is strictly prohibited. If you have received this > email in error, please notify the sender immediately and delete the > original. >