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Swaging and Radial Forging(new) (Manufacturing Process)

Swaging (also known as rotary swaging or radial forging) uses external hammering to reduce the diameter or produce tapers or points on round bars or tubes. Figure16-20 shows a typical swaging machine, and Figure 16-22 shows a schematic of its internal components. The dies, located in the center of the apparatus, consist of two blocks of hardened tool steel. They combine to form a central hole that generally has a conical input transitioning to a cylinder. An external motor drives a large, massive flywheel, which is connected to the central spindle of the machine. High-speed rotation of the central unit generates centrifugal force, which causes the matching die segments and backing blocks to separate. As the spindle rotates, the backing blocks are driven into opposing rollers that have been mounted in a massive machine housing.To pass beneath the rollers, the backer blocks must squeeze the dies tightly together. Once the assembly clears the rollers, the dies once again separate and the cycle repeats,generating between 1000 and 3000 blows per minute.



With the machine in motion,the operator simply inserts a rod or tube between the dies and advances it during the periods of die separation. Because the dies rotate, the repeated blows are delivered from various angles,reducing the diameter and increasing the length. Since the rotating spindle is usually hollow, the workpiece can be passed completely through the machine or withdrawn after a preset length has been reduced.
Swaging operations can also be used to form tubular products with internal cavities of constant cross section.A shaped mandrel is inserted in to a thick-walled tube (or hollow-end workpiece), and the metal is collapsed around it to simultaneously shape and size both the interior and exterior of the product. Swaging over a mandrel can be used to form parts with internal gears, splines, recesses, or sockets. Figure 16-23 shows variety of swaged products, many of which contain shaped holes.





The term swaging has also been applied to a process where material is forced into a confining die to reduce its diameter. This process is usually performed on heated  material. Figure 16-24 shows a  hot-swaging sequence being used to form the end of pressurized gas cylinder.
(Materials and Processes in Manufacturing, E. Paul DeGarmo,p.398-400)
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