Swaging 1

swaging

variation of foraging that has been developed to be more suitable for round or circular part

swaging uses

multiple dies that close on the part along radial paths rather than a single pair closing along a vertical path

usually performed on an

industrial scale, but can be perfomed using a hand tool

hand tool is usually used

when attaching fittings to a steel cable or wire rope

swaging tool

oversized pair of pliers that uses a compound lever action to generate large forces between the jaws (dies)

hydraulic swaging tools? can deform?

use a pumping action - can deform ferrous metals

swaging tools are used in conjuction with

ferrule to create a loop on a cable

ferrule

loop clamp to put on cables

how is the loop formed on a cable

initially looped through the oval hole in the ferrule which is then crushed between the jaws of the swaging tool

the jaw chape

semi circular cutouts on each side - different sizes to accommodate various standard ferrules - which create circular die cavities

the procedure of crushing the ferrule

intitally only in one direction, then its rotated through 90 degrees before crushing a second time

what means that its swaging

multiple deformation strokes along different radial lines

swaging in the manner is performed

through several stages and not all at once

industrial scale swaging

uses multiple dies that all move towards the center simultaneously

the mode industrial scale swaging generates

circumferential grain flow in circular parts

swaging is performed in cases

where superior strength is required

superior strength is required when

minimal metal is available to resist the loads

example of swaged product is

ratchet socket wrench set - designed to tighten or loosen hexagon shapes thread fasteners (bolts/nuts)

sockets

come in a variety of sizes to accommodate standard bolt/nut dimensions

sockets look like

circular on the exterior, in variably have a rather thin wall, necessary when dealing with a row of closely spaced bolts/nuts - transition from a hexagonal hole at one end to square at the other end

why is strength important

high torque is needed for the configuration

the holes of the sockets are NOT made

by cutting because it would sever the grain flow and compromise the strength - MUST be made through swaging

to create holes swaging

is performed around a mandrel

mandrel

generic term in engineering - refers to a metal tool around which other metal is formed - or shaped

mandrel and the socket

mandrel mirrors the internal cavity in the socket itself

the metal used for the mandrel is made

through open die forged to create a wrought structure and then formed into a tubular shape with internal and external dimensions larger than the final — tube heated to make pliable the placed at center of swaging dies

when the tube is heated up

mandrel fed into the center prior to the simultaneous forcible closing of the dies along radial paths - material is pushed down into the mandrel while the external circular dimensions are reduced

after the dies have pushed the material down

they are withdrawn and the workpiece is removed - the mandrel is pulled out revealing a thin walled circular component with the required configurations

flash on the swaged piece

there is no flash but the component got longer as the diameter was reduced - this is the flash of the component and needs to be trimmed off - grain flow follows the internal and external boundaries imparting superior strength to the socket