Swaging is a metal forming process that involves applying compressive forces on the workpiece via a die. It enables workers to affix various components like fittings, bushes, sleeves, and other hardware on rods, tubings, wire cable, hoses, and other products with minimal effort. The process also produces high quality, polished finish. This helps reduce the need for secondary finishing processes. Swaging is a cold working process, although in some instances, the workpiece can be heated before being swaged.
There are two main categories of swaging machine tube swaging and rotary swaging. A rotary swager has two or four dies that are used to physically swage the metal workpiece into a desired shape. Rotary swaging is often employed for reducing the diameter of long lengths of tubing or creating a specific pointing profile on a tube. It is also commonly used to assemble MS type terminals onto standard galvanized or stainless steel cables from 1/16’’ up to 3/8’’ diameter.
Generally speaking, tubing swaging machines are designed to affix a variety of different kinds of fittings and other attachments to round tube or rod material. A rotary swager, on the other hand, is capable of manufacturing any type of cross-section, not just circular ones. It can even create a shaped section with a mandrel that is forced into the hollow workpiece.
Rotary swaging machines can be found in a variety of capacities from small handheld devices to larger, powered machines that may be fully automated for high-volume swaging production. They can be operated manually or electrically for added convenience. However, these tools should be regularly inspected and maintained in order to ensure they are functioning properly. This is especially true of the dies, hammers, and rollers that are used to contact and form the workpiece.
The swaging operation is very versatile and offers numerous benefits to the user, ranging from increased product yield and a high surface finish to reduced assembly time. It is also known to provide a higher level of strength to the workpiece, as well as lower insertion force than other methods.
The swaging process is quite noisy, but this can be mitigated by proper mounting of the machine or through the use of an enclosure. Additionally, swagers are known to be very robust and can continue to function for decades, provided they are properly maintained. Ideally, they should be lubricated with a suitable grease to help extend the life of the dies and hammers. They should be regularly checked and replaced as needed, in order to guarantee accurate swaging results. The proper swaging machine should be selected for your application, taking into account the workpiece dimensions and material type, as well as the desired outcome of the swaging. The ideal tool for the job will always be one that is easy to operate, durable, and affordable. This way, you can be sure you are getting the best value for your money.