| Stage I | Stage II | Stage III |
Stage IV + End stage
Diameter 1/2“, 2 sec. cycle time, series runs from 20,000 parts, finished part falling out, power requirement approx. 30 kW.
Swaging of pipe material 3/8″
| Stage I | Stage II | Stage III |
Stage IV
Diameter 3/8“, 2.4 sec. cycle time, series runs from 20,000 parts, finished part falling out, power requirement approx. 25 kW
Swaging
Swaging is a forming process commonly applied on metal wires, pipes and strips to change the dimensions of the profile by forcing them into dies as a cold or hot working process. To achieve it, different methods are used, including extrusion through a die and the use of two or more rotary dies from the outside, to reduce the diameter of a section.
An important characteristic of this process is that, although there is a reduction in the diameter, no material is lost as it happens with other manufacturing processes such as machining.
There are different applications for this process, for example:
- As part of forging a piece with the intention of making it more beautiful or to make it fit for the desired purpose.
- To create permanent joints between pipes and fittings.
- In electronics as a substitute of welding.
Moreover, a common application of this process is creating collars on tubes, bars or wires with a round section, also known as collar swaging. Collars are used to provide locking power to a non-threaded part such as a bolt or to increase the locking power of threaded ones.
Combination with other processes
Many applications require more than swaging to generate the part and get it ready for market. Some common applications involve parts that require bends, threaded sections, flat sections with holes for fasteners, together with collar swaging and, perhaps, other processes.
Traditionally, each process is performed independently requiring specific tooling (presses and dies) and operators for each of them. Of course, these requirements result in higher costs and reduced efficiency, which in turn means less productivity, a longer time to market and lower profitability.
To avoid those negative aspects when needing to perform swaging combined with other processes on the same piece, Schmale machines provide fully automated solutions that integrate more than one process as required, including bending, threading, flattening and swaging, allowing you to achieve a high level of efficiency and productivity.
The process begins where a wire with a diameter of up to 1″ is fed into the tool set by automatic servo-electric feeders. Then the wire goes through the different processes where an arrange of automated benders and presses generate the expected results.
The entire cycle for the shown sample part only takes 2 seconds, with series runs beginning at 20,000 parts, which clearly represents an enormous increase in efficiency and productivity and a significant reduction in the time to market, meaning that the profitability of your business will be higher.
To have a better view of the process please refer to the pictures and videos.
Swaging of Pipe Material
Briefly, swaging of pipe material is a forming process commonly applied on pipes to change the dimensions of the profile by forcing them into dies as a cold or hot working process. To achieve it, different methods are used, including extrusion through a die and the use of two or more rotary dies from the outside, both to reduce the diameter of a section or the entire part.
Pipes can be given new forms and be processed into a wide variety of different workpieces through swaging. An important characteristic of this process is that, although there is a reduction in the diameter, no material is lost as it happens with other manufacturing processes such as machining.
Swaging is commonly applied on pipes to produce a uniform collar, multiple collars or a head on the workpiece as part of a very complex fabrication cycle that may include other processes, such as bending, flattening or punching, where a wide variety of components are produced for different industrial segments.
Swaging of Pipe Material with Schmale Machinery
As it was said before, swaging is usually a part of a complex fabrication cycle that may include other processes such as bending, flattening and punching.
Traditionally, each process is performed independently requiring specific tooling (presses and dies) and operators for each of them. Of course, these requirements result in higher costs and reduced efficiency, which in turn means less productivity, a longer time to market and lower profitability.
To avoid all those negative aspects and improve the efficiency of the fabrication cycle, Schmale Machinery offers fully automated solutions which are extremely energy efficient, capable of integrating swaging of pipe material with the rest of the processes required.
These solutions include swage presses that can work in the pressure range from 24 tons to 300 tons, and all units can be modified to custom specifications, including higher forces and customized dies. The majority of the pneumatic components used in our machines come from our partner Festo, while many electric components and automation, are provided by our partner Siemens. The great relationship with these outstanding partners allows us to also offer original spare parts even at short notice with a stock of more than 1 Million USD around the world.
All the machines designed by Schmale Machinery are capable of efficiently integrate the swaging of pipe material into a complex production process. Special machines that are custom designed for a specific production situation can also be suitable for the swaging of pipe material as part of a tailored production process.
If the swaging of pipe material is desired by a customer, Schmale firstly analyses the specific production situation and then develops the optimal production machine. As it is the case with all other production technologies, Schmale places the highest standards on the productivity and future viability of the machines for the swaging of pipe material. This enables the swaging of pipe material to be integrated into the intelligent automation of various technologies.
The machines produce complex components from pipes in an economical and flexible manner. The customer receives a modern, future-oriented and energy-efficient machine that has been precisely tailored to his requirements.
The fabrication cycles obtained with Schmale integrated solutions only take a few seconds along the different stages to obtain the part ready for market, which clearly represents an enormous increase in efficiency and productivity and a significant reduction in the time to market, meaning that the profitability of your business will be higher. Moreover, series can run 20,000 parts or more depending on the specific part being produced.
Schmale Machinery has delivered hundreds of integrated and automated machines to serve a wide range of industries including the automotive industry, the household industry, the building industry, the public transportation industry and others, resulting in a large list of happy customers.
If you are looking for an automated solution for swaging of pipe materials, integrated with other processes required in your production cycle, or you have any further questions, please do not hesitate to contact us and we will gladly help you.