The Anatomy of a FENN Swager

What is a Swaging Machine?

Over decades, rotary swaging has been developed and refined. The FENN swager has become a basic precision production machine capable of producing finished work to tolerances of +/- .001”. The range of swaging operations includes reducing, pointing, tapering, sizing, assembling, bonding, and forming I.D. contours – on tubing up to 6” diameter and solid bar stock up to 3 3/8” diameter.

Swaging improves grain structure since reduction is made by many forceful blows that do not critically disrupt the metal’s molecular arrangement. This allows a smooth flowing rearrangement of grain. It is possible to swage material of a fragile crystalline structure to a point where it can become ductile enough to withstand severe bending. Swaged pins and punches may have many times the wear life of a machined part due to the grain refinement and increased density.

How Does a Swager work:

During swaging, either a 2-die or 4-die configuration is backed up hammers usually held in a revolving spindle. The inertia of a flywheel drives the spindle which delivers a striking force as the hammer and die segments pass between rollers and the workpiece. This causes reshaping in conformance to the die form. A centrifugal force throws the die and hammer segments outward between blows.

A swager is a proportionally forceful machine. To duplicate a swager’s performance with a slower force would require a punch press or drop hammer with massive proportions. For example, a 1F swaging machine weighing 625 lbs. can deliver the equivalent of an 8-ton force, a 3F weighing 2100 lbs. can deliver approximately 75 tons of force, and a 6F weighing approximately 10,000 lbs. can deliver 700 tons of force – quite the ratio!

Components of a FENN Swager:

FENN swaging machines are designed and manufactured to the highest engineering specifications. Some important components for maintenance and successful production include:

  • Roll Cage Assembly: Manufactured from a steel forging to prevent cracking, which is inherent of other castings. FENN’s design prevents localized wear and permits easy in-field replacement.
  • Hammers: Machined from forge steel blocks of the highest-grade alloy tool steel.
  • Head Ring: Hardened forge bearing steel heavily press-fitted into a swager frame. Swaging machine head rings are a replaceable component critical to proper swaging, they can be replaced in-field.
  • Door: The double-hinged door allows for accessibility to the working parts of the swaging machine and to allow for rapid die change.
  • Frame: Solid one-piece meehanite® cast-iron frame with a heavy, thick-walled ring to back up heavy loads. The one-piece casting ensures machine alignment and helps to absorb vibrations during operation.
  • Dies: All dies are custom designed for customer’s specific applications. FENN is proud to have an in-house die design specialist and die manufacturer.
  • Spindle: The spindle is made of forged steel to control grain structure and to provide greater strength. The spindle is capable of accepting work through the bore. Heavy cross section at the head prevents deflection and breakage – hardened and ground spindle wear plates are replaceable in-field without removal of spindle.
  • Motor Drive: High-torque motor safely mounted within bed of machine to avoid damage. Drive transmitted to heavy meehanite cast flywheel which is securely keyed to spindle.
  • Flywheel: Cast iron and mounted outboard of the rear bearing. The flywheel dampens vibration and cancels work forces of the hammer and the dies.
  • Cage: Forged steel for better grain structure ad strength to reduce wear and damage from shock. The cage serves to support the hardened cage rollers.
  • Bearings: Preloaded anti-friction with ample capacity – selected for long-life under repeated axial loads, spacing allows for alignment accuracy and rigidity.

For over a century FENN has been providing quality and trusted metal forming solutions. Swagers are a robust and reliable metal forming machine, designed to withstand decades of repeated use. However, over time, applications and production requirements can change, and machines may no longer prove useful in their original configuration. Rebuilds can prove to be a favorable choice for customers unable to adequately use their existing swaging machine. For a fraction of the cost of a new machine, FENN equipment owners can increase their machine’s capabilities and stay current with safety standards, all while improving accuracy and increasing productivity.

Below is a list of wear parts in a FENN swager. Replacement of worn items can increase productivity of your swaging process. Contact us for any of your spare part or service requirements!
  • Roll cage
  • Side Plates
  • Bottom Plates
  • Hammers
  • Hammer Adjusting Ring
  • Rear Cage Thrust Ring
  • Front Cage Thrust Ring
  • Thrust Ring Gasket
  • Door Die Thrust Ring
  • Roll Bearing
  • Ball Bearing
  • Oil Seal

As the OEM, FENN offers a large inventory of high-quality spare parts. Valuable benefits of ordering spares and parts from FENN include selection from an expansive inventory and quick delivery on all in-stock items – shipped same say if order is received by 12 PM. Additionally, because we are the OEM we have the original machine prints which allows us to accurately supply you with the correct spare part. Don’t risk unexpected downtime waiting for the compatible spares, contact FENN to ensure you receive the right part, the first time!