Swagged Cables & Manufacturing
Does your next project include a specialized cable or mechanical lanyard? Have you heard about swagged cables, their applications, and how they might be the perfect solution for your next project requiring industrial strength cables? To provide some insight into the process of swagging, swaggers and their applications this article will talk about:
Deca’s Experience with Swagged Cables
Applications of Swagging
Advantages of Swagging
Manufacturing Role of Swagging
Swaggers in Action
Conclusion
DECA Manufacturing's Experience with Swagged Cables
DECA added a hydraulic swagger to our shop floor to build mechanical cables and lanyards for the defense industry. Hydraulic swaggers rely on hydraulic pressure to create the force required for swaging. They are often used for larger, heavier materials or tasks requiring more precise control over the force applied. For a recent defense project, we used our swagger to build a mechanical lanyard, made with a heavy-duty cable and a component to retract and release the cable. Our swagger handles both aluminum and carbon steel with a wide range of:
Terminals
Sleeves
Wire rope clips
Hooks
Gliders
Cable clamps
Thimbles and more
Applications of Swaging
In addition to the defense industry, swaging is used across various industries for a variety of purposes including:
Aerospace. Swaging is commonly used to form aircraft cables, control rods, and fittings.
Automotive. Swaging is used to create components such as brake lines, wire cables, and connectors.
Electrical. Swagers are used for making terminals and connectors for wires, especially when high precision is needed.
Construction and Marine. Swaging is used to create rigging, bridge cables, and cabling for other structural and safety purposes.
Advantages of Swaging
All of these industries require components with very strong, very consistent materials. Swagging equipment, such as our Talurit swagger, provides more consistent results over other manufacturing processes such as manual labor. Additional benefits include:
Precision. The dies used in swaging allow for highly accurate and repeatable results.
Cost-Effective. Since swaging is a cold-working process, there is no need for heat treatment, making it more affordable compared to other methods such as forging or casting.
Speed. Swaging is a relatively fast process, especially when automated systems are used, this leads to high productivity rates.
Versatility. The swaging process can be applied to a wide range of materials and components, making it highly versatile across industries.
Manufacturing Role of Swagging
Swaging is a cold working, manufacturing process used to shape, form, or size metal components. It typically involves deforming metal by applying compressive forces. In simple terms, swaging reshapes a material by forcing it into a die (aka mold) under high pressure. The result is a part that is more finely tuned to its desired shape and size without adding heat, making the process suitable for sensitive materials that might be damaged by high temperatures.
The swaging process is highly efficient, producing high-quality parts with precise dimensional control. Swaging machines, known as swagers, are used to perform this task. These machines come in various forms, but the common factor is that they apply radial force to compress the material, reshaping it into the desired form. It’s a versatile process that can be used for creating wire terminals, reducing the diameter of rods, or even creating complex shapes from simple tubes.
Swaggers in Action; The Working Principle of a Swager
Swagers operate by using a set of dies or molds that guide the metal through the process. (You can see a video of a swagger in action. The material is placed into the machine, and the dies apply intense pressure, compressing the metal to the desired specifications. Here's how the process works:
Material Loading: The metal (typically wire, rod, or tube) is fed into the swaging machine, either automatically or manually, depending on the design.
Compression: The swager has rotating dies that move around the material, applying force. These dies can either compress the material radially (from the outside) or axially along the length of the material).
Forming: The material is gradually deformed and shaped according to the dimensions of the die. During the process, no heat is involved, which is why swaging is often referred to as a cold working method.
Finishing: Once the material has been sufficiently compressed and shaped, it exits the machine, typically with a more uniform cross-section and finished surface.
While there are many types of swaggers, DECA’s swagging machine, shown on the right/below, is a hydraulic one. Other types include rotary swagers and pneumatic swagers. Swagging can also be completed by hand, but it is a time intensive task and the results can be inconsistent. The choice of swager depends on the material being processed and the complexity of the task.
We believe that to build quality components it is vital to use quality equipment. When we wanted to add a swagger to our shop floor and expand our capabilities, DECA purchased a Talurit swagger. Talurit specializes in providing advanced swaging equipment and solutions for the cable and wire industries. The company’s swagers are known for their reliability, precision, and durability, They are also designed to meet the rigorous demands of modern manufacturing processes. Talurit’s swaging machines are equipped with advanced features, including the ability to adjust compression force, ensuring that the desired shape is achieved consistently. The swagged cables created using Talurit’s machines are found in a variety of industries, from aerospace to telecommunications.
Conclusion
Swaging is an essential manufacturing process for shaping and sizing metal components and creating cables for a variety of industries. The use of swagers allows for precision, speed, and cost-effectiveness, making it a popular choice for producing parts like wire terminals, rods, and cables. Whether it’s for aerospace, automotive, or electrical applications, swaging plays a crucial role in ensuring the production of high-quality, reliable parts.
Contact DECA for Your next project
What customized cables can we build for your company by joining wires and adding swage ferrules, terminals, and other fittings onto the wire cable material of your choice? If you need a more complete solution, we can provide additional manufacturing support by turning components into more completed products such as mechanized lanyards or other types of integrated systems aka box builds. No matter what industry you are in, DECA is always looking for new ways to support you with high quality, customized products.
Contact us today to discuss your next project.
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