Swaging Machines

Swagers

Why Choose FENN Swagers?

FENN has been a leader in quality metal forming machinery for over 120 years. Our experts take the time to design and build the right swaging machine to fit your exact specifications and fulfill your unique production requirements. With experience building standard and customized swagers, FENN's experts can design a swaging system to maximize your production goals.

Are you looking for Swager Spare Parts or Dies? Click here!

ModelNF2F3F4F5F6F7F8F
Capacity-Solid1/16"13/32"5/8"15/16"1-1/2"2-1/4"2-3/4"3-3/8"
Capacity-Tubing1/4"1"1-3/4"2-1/4"3-3/8"4-1/2"5-1/2"6"
PLEASE NOTE: Swager capacities listed above are for normal reduction on low-tensile material. Capacity must be reviewed for each specific application.

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.

FENN OFFERS THE COMPLETE PACKAGE
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.

Types of Swagers: View the FENN Swager brochure here.

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.

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.

Stationary Die 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.

  • Examples include: Aerospace tube components, and fluid control tubes.

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.

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

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.

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

 

Basic Swaging Applications: View the FENN Swager brochure here.

Assembling:
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:
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 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.

 

 

AUTOMATED SOLUTIONS
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.

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

Integrated solutions can include:

Swaging machine
Hydraulic feeder
Integrated robotics
Sound enclosures

Secondary operations can include:

Laser engravers
Cutters
Buffering systems
Welding systems

ACCESSORIES & OPTIONS
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.

Sound Enclosures: 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.

  • 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.
  • 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.
  • 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.

 

EXPERIENCE COUNTS
FENN provides high-quality products and replacement parts for a range of industries, including  agriculture, the military, and materials research. With more than 120 years of experience, we are the ideal metal forming company to provide top-notch swaging machines for materials such as aluminum, precious metals, titanium, lead, nuclear material, various steels and more!

 

INDUSTRIES SERVED BY SWAGING MACHINES

  • Materials Research – Development related to improving grain structure and finish
  • Aerospace – Wire role flight control cable assemblies, control rods, fluid transfer tubing
  • Medical – Catheter band assemblies, hypodermic needles, optical instruments
  • Automotive – Drive shafts, axels, emergency brake cables assemblies, optical instruments
  • Renewable Energy – Superconducting material, zirconium rod and cartridge heaters
  • Military – Anti-tank rocket tips, gun barrels, MS-spec fitting swaged onto cables

 

SERVICE, SUPPORT, & SPARES
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. They can be contacted at 860-259-6567 via email at info@fenn-torin.com. 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!

 

FENN’s people made the difference.

Our business was looking to continue the progression of new and improved equipment to meet the changing needs of our customers. We chose to work with FENN on this project because of their willingness to collaborate on design features to meet our specific requirements for a machine of this size. This was a 15-month process from initial discussion to final program sign-off and machine installation. Communication was excellent throughout the building process. We were able to collaborate on any items, whether it was with FENN’s executives or directly with the machine builders. As with any custom first-off machine, there were minor issues that needed to be addressed. FENN corrected each of these and provided dedicated staff and resources to do so, which is one of the reasons we chose them for this project. The machine is actually exceeding our expectations. After having gone through a similar project 10 years ago, the FENN team improved all aspects of this project – from communication to delivery to the final product. From the initial outreach and conversation with the executive team, all the way through the delivery and minor issue corrections, it was done with people. FENN’s people made the difference. Since the beginning, a very important part of our decision making-process was wanting to work with a company that closely resembles the culture of our business and FENN met and exceeded our expectations.

Tony Pesaresi
President / Winamac Coil Spring, Inc.

FENN was very easy to work with

We decided to have our worn-out W-125SA Torin mechanical coiler retrofitted to a 2-axis servo coiler because our production required more feed length than a standard mechanical offered. We have other FENN-Torin coilers in our shop and are pleased with the support and customer service. The 2-axis retrofit has met our expectations as far as ease of set-up, since there was really no learning curve to the set-up and programming of the retrofit. We are now able to take spring production jobs we couldn’t run before on the mechanical W-125SA. FENN was very easy to work with during the retrofit process, keeping us updated on progress of the rebuild with pictures and a video of the finished machine. We recommend the Torin retrofit program as an economical way of rebuilding used FENN-Torin coilers, it was the right choice for us. We are also purchasing a rebuilt/retrofitted FENN-Torin FZ-115 6-axis coiler, to be delivered in February 2020.

John Bentz
James Spring & Wire Co.

FENN-Torin is our choice

In 2018 Mann-Hummel decided to replace an outdated cam driven spring coiler on a high-speed valve assembly machine. We use these valves in our oil filters for O.E. and Aftermarket customers. The equipment had become inefficient and spare parts were becoming difficult to find. The age and design of the equipment also made it difficult to train new personnel. We recognized it was time to modernize. We are not experts in making springs, so we had to increase our knowledge before making this important purchase. We researched on the internet and contacted several spring suppliers. After making several contacts we decided to observe several brands of spring coilers in a production environment. This also gave us the opportunity to ask questions about the equipment they had purchased. After talking with several spring technicians in the field we decided on a FENN-Torin Spring Coiler. Our Torin coiler has been in use for about a year now. Efficiency has increased and overall equipment repair cost is down. Although there have been learning curves with the new equipment FENN-Torin has supported us every step of the way. We are currently looking at a second coiler coupled with an assembly machine. FENN-Torin is our choice.

Terry Alred
Mann & Hummel Purolator Filters, LLC

High Quality Machines & Excellent Service

We use FENN as the supplier of Wire Flattening & Shaping Line for our wedge wire (Screen Wire) production because of their experience in producing similar equipment and their top notch reputation in the industry. FENN’s engineers and metallurgy experts worked closely with our team in all aspects of the project – from examining and understanding our material specifications to machine design, trial run at their works prior to shipment, and finally Start Up, Commissioning & Training of our operators at our factory in India. We are very pleased that FENN ensured that all of our requirements were met, and that the machine functioned with precision, quality and reliability. I would highly recommend FENN for any company looking for a high quality machine supported by excellent customer service and metal forming process expertise.

Prakash Shah
Bilfinger Water Technologies (India) PVT. LTD.

Trusted Fenn for Decades

Ulbrich has trusted Fenn wire flattening and shaping lines for several decades to produce the highest quality shaped and flatwire available. Fenn's experienced staff has provided the process knowledge required to select, design and build machines to suit specific applications. Fenn machinery has always proven very reliable, consistently satisfying our critical tolerances and specifications. At Ulbrich, we pride ourselves on offerings superior products for over 90 years, and trust Fenn machinery to get the job done.

Chris Ulbrich
Ulbrich Stainless Steels & Specialty Metals

Top-Notch Machines

In 2009 we decided to purchase our first ‘Z’ CNC Coiler. The efficiencies gained by reduced setup time, increased throughput, and significantly reduced scrap rate while holding extremely tight tolerances was immediately realized through a complete statistical analysis. The machine paid for itself within months. Success with our first Torin ‘Z’ CNC led Springfield Spring to purchase another ‘Z’ CNC coiler, followed by three more of the latest model, the Torin FZ Series. Our five newest Torin spring coilers replaced all of our mechanicals, freeing up substantial space for new business endeavors. Fenn not only produces a top-notch machine but their sales, service, applications, and technical professionals are second to none. Fenn acts and responds like a business partner, not your traditional machine ‘dealer’.

Ryan Nadeau
Springfield Spring Corporation