What Is a Swaging Machine?

Swaging machine uses compressive force to change the shape of a metal workpiece via a die. It’s a type of forging process that essentially forces a workpiece to take the shape of a die, thereby increasing the diameter and forming a point on the end of the piece. Swaging machines are used for assembling and repairing a wide range of products in numerous industries, including marine-industrial, logging, aerospace and military.

There are two primary types of swaging machine processes: tube swaging and rotary swaging. In tube swaging, a worker places a rod in a die to expand it. This allows the inner shape of the tube to differ from its outer diameter, creating a tapered shape. This can be done for a variety of materials, ranging from steel to aluminum and even titanium and zirconium.

The hilmor compact swager is an all-in-one portable tool that allows you to perform multiple swaging tasks without having to move your machine around. Its pistol-shaped design allows it to fit into confined spaces, making it an ideal solution for applications where space is limited. The hilmor compact swager also reduces on-the-job fatigue with its unique ergonomic design and one-handed operation.

FENN offers several different swaging tools that can be utilized to assemble terminals or lugs onto various types of cables and wires. Its versatile swaging tools are available in both manual and power driven options. The swaging kits are ideal for swaging MS-type terminals to standard galvanized or stainless steel cables up to 3/8” cable diameter. They include a hardened steel tool, hammer, yoke assembly, air hose assembly with single-action foot control valve, baseplate, gages, swaging dies and instruction manual.

Rotary swaging machines utilize a chuck that holds the stock centered within a group of two or four shaped swaging dies. Each time a hammer block strikes a roller, the die halves are forced together in a process called centrifugal force. The swaging dies, which may be cammed or lobed, close on the stock as they rotate, often thousands of times per minute.

This process is used to form a lug or terminal on the end of a rod, wire or cable, and it’s ideal for assembling components such as recreational ropes course cables or sailing rigging equipment. It can also be utilized to secure termination and joint fittings onto electrical and wire rope cable by deforming a lug or ferrule on the core.

The swaging process is extremely versatile, and it’s employed in many industry applications, such as forming components for logging industry rigging or naval armaments. This technique is also used in manufacturing medical devices like hypodermic needles, producing piping, and forming cartridge heaters for the automotive industry. It’s even used in the production of renewable energy products such as zirconium rod and superconducting material. For aerospace applications, swaging is utilized for manufacturing controls and wire rope cable assemblies.

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