What Is a Swaging Machine

Swaging machine are typically utilized for pointing, sizing and forming metal wires, rods and tubes. They utilize a series of forming dies backed by hammer blocks that rotate around the workpiece.

It is the most popular modern method for swaging soft copper, especially when replacing cable in recreational ropes course cables and sailing rigging. It also works well for securing termination and joint fittings onto steel cable and wire.

1. Precision

Swaging is a metal forming process that shapes or changes the diameter of a rod or tube. It uses a rapid succession of hammer strikes to reduce the rod or tube, change its shape or add a point. It can also be used to taper or bond materials. Swaging can be performed manually by hand or automatically using a machine. There are two primary types of swaging machines: tube and rotary.

Rotary swagers typically use two or four dies that split and close up to 2,000 times per minute. These dies are mounted on a spindle inside a cage that looks like a roller bearing. As the spindle rotates, the hammer blocks push out to ride the rollers, which then push the die halves together by centrifugal force.

2. Durability

Swaging machines range from simple, portable hand-operated devices, often for service level / piece work requirements, to larger, powered – some even fully automated – machines that are used in high-volume hose assembly production.

Unlike other methods, like bending or riveting, swaging leaves the swaged connection with a very high level of durability. In addition, swaging does not require any subsequent machining or forming to achieve a high-quality finish.

Several industries benefit from swaging:

3. Speed

Swaging machines offer a fast and efficient way to point rod, tube or wire. Also referred to as cold forming, swaging is a chip-less metal forming process that uses a rapid succession of hammer strikes to form the metal workpiece.

The rotary swager is used for reducing the diameter of round rod or tubes and changing their shape and/or length. It is used for a variety of applications including standing rigging and lifelines for sailboats, theatre rigging, slings for climbing and ropes in industrial settings and oceanography.

Our SW-1 swaging machine is equipped with multispeed rolling rolls so that you can change rotating speed of each one depending on the operation you are going to make. This feature makes it a very versatile tool for production processes of ventilation, chimney and air conditioner systems.

4. Efficiency

The swaging process allows for internal shapes to be imparted to hollow workpieces through use of a mandrel (provided that the shape has a constant cross-section). This capability eliminates the need for an external mandrel.

This reduces overall labor costs since highly skilled operators are not required to be on hand. It also reduces the need for inventory because multiple machines can be utilized to swage multiple fittings at one time.

A rotary swaging machine utilizes split dies that separate and close up to 2,000 times per minute. When this occurs, the forming dies apply pressure to the workpiece to compress it to a desired size and shape. This type of swaging is typically used for reducing the diameter or adding a point to round materials such as wire, rod, and tubes.

5. Cost

Swaging is an efficient and cost-effective method to point, reduce, and shape rod or tube. This chip less metal forming technique uses a rapid succession of hammer strikes to form the metal without producing scrap materials. This makes it ideal for reducing metal products with small diameters, such as pipe nipples.

A swaging machine can be used for both hot and cold reductions, although cold is more common due to the hardening effect it has on most metals. This process is particularly useful for work-hardening materials, such as copper or zirconium. It is also a better option than welding for many metal products. It is utilized in the military, automotive, aerospace, medical, and renewable energy industries to create components like hypodermic tubing and cartridge heaters, among others.