Swaging process

2020

MAY 17

HOMEWORK #2
Authored by: MASA FUAD

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1- Introduction

The swaging process is usually a cold working process which can be used to reduce
the diameter, produce a taper and point with increase in length of the material
being swaged. Materials of spindle blade and aluminum plug of textile spindles can
be swaged thereby achieving a material saving and eliminating a reasonable
machining time. This will give rise to material productivity and machine
productivity. Presented here is a design of swaging process setup for the
manufacture of textile spindles and a computer program developed for analyzing
the process economy.
A swaged piece created by placing the tube inside a die that applies compressive
force by hammering radially.
The term swage can apply to the process of swaging (verb), or to a die or tool used
for swaging (noun).

2. General Description:

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This is done by placing the tube or rod inside a die that applies
compressive force by hammering radially. This can be further expanded
by placing a mandrel inside the tube and applying radial compressive
forces on the outer diameter. Thus, the inner diameter can be a different
shape, for example a hexagon, and the outer is still circular.

 Swaging is essentially a forging process. Pressure is applied (by a

constant hammering action) to adjust the shape of a work piece.
 Cold and hot swaging is possible. There are also 2 types of swaging:
rotary and extrusion.
 This process is for metals only, can create complex geometry with
minimal labor cost but tooling cost can be high.
 Good surface finishes can be achieved with no waste.

3.Types of Swaging Processes:

There are 2 types of swaging:
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 A. Rotary swaging process of tubes:
Rotary swaging process usually utilizes three, four or eight dies arranged uniformly in
the circumference of the work piece. The swaging dies revolve around the work piece
and perform high-frequency radial movement with short strokes, simultaneously.
Therefore, local uniform necking occurs on the tube or bar material owing to the
multidirectional forging and high-frequency loading method. As shown in Fig. 1,
rotary swaging can be divided into two categories, the infeed swaging process and
the recess swaging process. The main distinction between these two variations is
that the work piece is gradually fed into the swaging dies axially from the entrance of
the dies during the infeed swaging while it is positioned in the open swaging dies
during the recess swaging process. Therefore, the infeed swaging process is often
utilized at the occasion where the work piece is necked from one end. The recess
swaging process is often used to reduce diameter at a certain position of the work
piece or form a concave profile.

B. Extrusion swaging process :

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Extrusion is similar to wire drawing, where a work piece is forced through
a die to reduce the diameter. In rotary swaging, a constant hammering
force is applied by a die on the work piece to reduce the diameter of the
work piece.

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Rotary Swaging Machine product 1

Extrusion swaging process 1

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 There are also some other types:
Swaging can be classified as :
1. Internal swaging: can provide grip to hose material, and be used to
improve flow area through tubing or hoses. In fact, this form of
swaging increases the size of applicable items, and plays a key role in
lowering the risks of bacteria accumulating near the end of the hose
or tube. It also helps to reduce turbulence by providing a firm
mechanical adhesiveness and bond.

2. External swaging, as the term implies, is the opposite of internal

swaging. Combination swaging is similar to external swaging, except
for the fact it involves welding ends together. It also is known to be
more cost-effective than external swaging.

3. Combination swaging involves compressing the size of items to suit

the purpose. Dual swaging uses both internal and external swaging
and involves compressing both aspects by the same amount.

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 Advantages Disadvantages

Can produce complex parts. Suitable only for low production

processes.

A large range of shapes including square, High tooling costs.

round and rectangular are possible.

Produces excellent surface finish. Limited to metals only.

Produces excellent surface details.

Used :
Swaging is used in items all around you. Typical areas include car design, keyed
musical instruments and repairs, circuit boards, hose fittings, pipe fittings, lock bolts,
sawing blade teeth, ammunition and decorative metal items.
Swaging is a specialized field. Understanding the global definitions of this field can
enhance your overall respect for this craft.

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CONCLUSION :

Through the swaging process, a saving of not only in material, but also
in machining time is achieved. This also leads to an increase in tensile
strength of the textile spindles. This trial machine setup can be further
studied and improved.

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Swaging process video 1

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Swaging process video 2

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