Project Description

Swagers

An efficient, cost efficient way to point, reduce & form rod, wire or tube.

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FENN Swagers Trusted Since 1900​

Swaging machines, also known as swagers, are a low-cost way to efficiently point, reduce and form rod, tube or wire. Based on a simple principle, it is the process of shaping metal (forging) by means of a series of very rapid, blows delivered by rotating hammers and forming dies around a piece of work. It is a highly economical method to point tubing, rod, and wire for redraw, and to size, reduce, shape, taper, bond or form metal parts, hot or cold. Metal is formed – not machined – so there are no wasteful chips.

Swaging can be performed both hot or cold, although cold is popular because of its hardening effect on most materials. The process also improves grain structure, giving the part greater strength and an unusually fine finish.

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Swager Machine
Types & Offerings

We Maximize Productivity Of Your Process​

A United States-based company, FENN offers swaging machine solutions for industries across the globe. From the manufacturing of state-of-the-art machines to installation, maintenance, and upgrades, we provide customers with unparalleled customer service from start to finish. Our team of engineers is highly trained to deliver metal forming solutions to address a variety of business initiatives that center around the formation of custom metal parts. We can help you take your business to the next level by working closely with your research and development department to manufacture all new equipment or to retrofit and update your existing FENN metal forming equipment to better meet the ever-changing needs of your business.

Maximize Productivity with FENN Swagers

Stationary Swagers

Stationary Swagers

Used for the pointing, sizing and forming of wire, rod and tube. With a rotary swaging machine, the swaged section is always circular. Rotary swaging machines include 2-die and 4-die configurations.

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Rotary Swagers

Rotary Swagers

Used for the pointing, sizing and forming of wire, rod and tube. With a rotary swaging machine, the swaged section is always circular.

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Long-Die Swagers

Long-Die Swagers

This type of swaging machine is only needed with taper length exceeds the standard die length of a rotary swager.

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Hydroformers

Hydroformers

Used for the assembling of parts such as fittings to cable and for making reductions between shoulders such as on convoluted tubing.

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Stationary Swagers

Complete parts can be made from entry rounds, squares, or rectangles – hot or cold. Types include simultaneous blow used to create fluted shapes & cross circular sections and alternate blow used to create rectangular shapes, squares, & hexagons. This method is capable of any cross-section other a perfect circle. During stationary die swaging, the spindle assembly remains stationary, and the roller cage rotates.​​

Swaging Simultaneous vs Alternate Blow

Examples include: Aerospace tube components and fluid control tubes.

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Rotary Swagers

Used for the pointing, sizing and forming of wire, rod and tube. With a rotary swaging machine, the swaged section is always circular.
Rotary swaging machines include 2-die and
4-die configurations.

Examples include: Cartridge heaters, hypodermic tubing, piping, armaments, and logging industry applications.

Rotary Swaging Diagram

During rotary swaging, forming dies back by hammer blocks revolve around the workpiece. As the spindle revolves, centrifugal force throws the hammers and dies outwards against a series of rollers surrounding the spindle. Each time the hammer blocks strike diametrically opposed rolled, they are driven inward – causing the dies halves to close and compress the metal being swaged.

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Long-Die Swagers

This type of swaging machine is only needed with taper length exceeds the standard die length of a rotary swager. Long die swaging utilizes the same principle as the rotary method to produce long, shallow tapers for items such as furniture legs, sporting goods and aerospace products.

Long Die Swagers FENN Equipment

Serves a wide variety of materials: both welded & seamless tubing of either ferrous or nonferrous metals, from stainless steel to aluminum.

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Hydroformers

Used for the assembling of parts such as fittings to cable and for making reductions between shoulders such as on convoluted tubing. Hydroforming is a modification of the rotary swaging principle where wedges are used to open the dies while the spindle is rotating so the workpiece can be inserted before and removed after swaging.

Hydroformers FENN Equipment

Examples include: Sailing rigging equipment, architectural cable railings and recreational ropes course cables.​

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Basic Swaging Applications

We have experience with a variety of applications:

ASSEMBLING

Hydroformers FENN Equipment

A fitting is set over a cable, then inserted into the Swager and the cold forming force of the hammer actions produces a complete assembled piece. Examples include: Sailing rigging equipment, architectural cable railings and recreational ropes course cables.

END FORMING

Rotary Swagers

A single piece of tube or rod is inserted into the Swager to a specified depth and reduced to a smaller diameter. The piece may be complete or ready for secondary operations such as drawing, drilling or tapping. Examples include: Aerospace tube components and fluid control tubes.

THROUGH SWAGING/REDUCING

Long Die Swagers FENN Equipment

Long lengths of cable, rod or tube are passed through the Swager. The entire length of the material is reduced to a smaller overall diameter, and the cold forging process produces a desired tensile strength or material property. Examples include: Cartridge heaters and logging industry applications.

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Supporting your industry, streamlining your process, maximizing your productivity

A United States-based company, FENN offers swaging machine solutions for industries across the globe. From the manufacturing of state-of-the-art machines to installation, maintenance, and upgrades, we provide customers with unparalleled customer service from start to finish. Our team of engineers is highly trained to deliver metal forming solutions to address a variety of business initiatives that center around the formation of custom metal parts. We can help you take your business to the next level by working closely with your research and development department to manufacture all new equipment or to retrofit and update your existing FENN metal forming equipment to better meet the ever-changing needs of your business.

Military

Military

Anti-tank rocket tips, gun barrels, MS-spec fitting swaged onto cables

Aerospace

Aerospace

Wire role flight control cable assemblies, control rods, fluid transfer tubing

Renewable Energy

Renewable Energy

Superconducting material, zirconium rod and cartridge heaters

 

Medical

Medical

Catheter band assemblies, hypodermic needles, optical instruments

Automotive

Automotive

Drive shafts, axels, emergency brake cables assemblies, optical instruments

Research

Research

Development related to improving grain structure and finish

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Accessories & Options to best suit your production

Recognizing that there are many applications for swaging machines, FENN can provide optional equipment for your swager geared towards ease of use, process automation and operator safety.

Coolant/Slushing Systems:

Available as an option on all sized swagers.

The used of a self-contained FENN slushing/coolant system will help lubricate critical swager wear parts and keep the cage assembly free of foreign materials.

Swagers Accessories

Sound Enclosures:

Sound Enclosure Wrap Swagers

Reduce the sound of your swaging operation to below OSHA’s permissible exposure limit for hearing protection.

  • FENN recommends sound enclosures for most swagers, and they provide health and safety benefits.
  • Access ports can be included for features such as exhaust fans, wiring in & out, through swaging and feeder tables.
  • FENN can design customized sound enclosures to meet each customer’s specific swaging requirements. Standard enclosures are constructed of welded 14-gauge steel, paired with 2 3/8” of soundproofing foam.

Feeder Options:

 Optimize your swaging operation and increase operator safety with feeders.

Swagers Hydraulic Feeder

Custom Application Feeder – FENN can design a customized feeder to meet your unique and demanding production requirements. Systems are available for unique shapes, varying sizes or high capacity products. Available for all FENN swaging machines sizes NF – 8F.

Custom Application Feeder

Door Mounted Feeder (DM500 – DM1250) – Mounted to the door of the swager and feeds material using hydraulically powered pinch rolls. This feed is engineered to work well with wire & rod customers to point material for drawbench use. Also ideal for continuous through swaging of spool material such as high tensile wire rope. Available for FENN swager sizes 3F – 8F, others upon request.

Door Mounted Feeder

Hydraulic Table Feeder (25H, 45H & 60H) – this table feeder uses a rigid base with hydraulically powered, accurate, sliding top for precision applications. Ideal for high-accuracy products and high reduction applications, such as aerospace. The system is controlled using an HMI touch screen. Available for FENN swagers sizes 3F – 8F, others upon request.

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Automated solutions to get the job done

FENN designs and fully integrates solutions to maximize efficiencies and ultimately reduce swager operating costs. In addition to designing new and customized systems, FENN can also retrofit and integrated system around an existing piece of FENN equipment.

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Automatic Swaging Solution with Robotic Arm

Turn-key system benefits:

Single source supplier eliminates the need for multiple vendors to produce one system
Automation improves equipment safety
Collaborative robotics save time during production

Automatic Swaging Solution with Robotic Arm

Integrated solutions can include:

Swaging machine
Hydraulic feeder
Integrated robotics
Sound enclosures

Automatic Swaging Solution with Robotic Arm

Secondary operations can include:

Laser engravers
Cutters
Buffering systems
Welding systems

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Service, Support, Spare & In-House Made Dies!

FENN leads the metal forming industry when it comes to providing unbeatable swaging machines that are backed by our superior customer service, repair/rebuild program (see product literature for details) and operator training. We also offer replacement parts, tooling, dies, and rebuild services for your machines. Contact us today to learn more!​​

Every swaging machine, die, hammer and wear part are crafted in-house at FENN’s East Berlin, CT location. Our application specialists and spare parts department are available to assist you with a full range of stocked parts, ready for shipment. FENN offers additional swager components and options to optimize your swaging process. Our experienced spare parts staff will help you order and receive your swaging machine spare parts as quickly as possible, to maximize uptime and profitability.

From sound enclosures, coolant/slushing systems, feeders, and completely automated turn-key systems – FENN can design and build a swaging machine for your application. FENN welcomes the opportunity to serve you!

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