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How to grind armored optical cables

How to grind armored optical cables

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How to grind armored optical cables - BENNIE OPTICAL [PDF]

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Armored optical cables require specialized cutting, slitting, and polishing techniques to maintain fiber integrity and ensure safe installation.

Cutting and Slitting Armored Cables

Armored optical cables, such as SWA (Steel Wire Armored) or AC (Aluminium Conduit) types, must be handled carefully to avoid damaging the inner fibers. Common methods include:

  • Rotary Tool with Cutting Disc: Provides precise control for scoring and cutting the armor gradually, minimizing risk to the inner fibers .
  • Angle Grinder: Fast and powerful, suitable for thicker armor, but requires a steady hand to prevent accidental damage .
  • Manual Armored Cable Cutters: Ideal for tight spaces; no power needed but requires significant grip strength .
  • Hacksaw with Bi-Metal Blade: A last-resort option; slower and may produce uneven cuts .
  • Armored Cable Slitter: Tools like the Miller ACS slitter allow both longitudinal and ring cuts. The blade depth is adjustable to avoid cutting the optical fibers, and the cable can be pried open safely after scoring . Step-by-step approach:
  1. Measure and mark the cable precisely around its circumference.
  2. Secure the cable in a bench vise to prevent movement.
  3. Score gradually using the chosen tool, deepening the cut in multiple passes.
  4. Clean and deburr the cut area with a wire brush to remove metal swarf.
  5. Install the gland or protective fitting immediately to maintain mechanical protection and earth continuity .

Polishing Optical Fiber Ends

For fiber optic connectors within armored cables, grinding or polishing is essential to ensure low signal loss:

  • Lapping Films and Polishing Pads: Use ultra-fine abrasives for ceramic, MPO/MTP, or POF connectors. Start with rough polishing (SC9), then fine grinding (SC3), followed by further polish (PUMD), and finish with final polish (PUMZ), .
  • Controlled Pressure and RPM: Proper polishing requires correct pressure, rotation speed, and cleaning between steps to avoid scratches or contamination .

Safety and Protection Considerations

  • Avoid crushing fibers: Use proper supports, conduits, and cable trays to prevent mechanical damage .
  • Use hook-and-loop fasteners instead of tight cable ties to prevent sharp pressure points .
  • Implement crush protection: Armored cables provide mechanical protection, but additional measures like vibration dampers and impact-resistant sleeves help maintain fiber integrity . By combining careful cutting, precise slitting, and controlled polishing, armored optical cables can be processed safely while preserving the performance of the internal fibers. Proper tools, stepwise procedures, and protective measures are essential for reliable installation and long-term durability.
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