Seeking perfection in metal forming
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Automotive compact production cell

This fully automatic production cell contains two #211 standard Torrington swagers, facing in opposite directions. The magazine brings the part to the first feeder to perform the reduction on the first end. An automatic transfer system then brings the part to a central station to be picked up and brought to the second feeder for the reduction on the second end of the tube. With the exception of the very first part, there is always 2 parts being swaged at a time. This system can run to produce up to 450 finished parts (reduced on both sides) every hour. The two feeders are slightly different, to accommodate the different requirements on each swaged end. All motions are pneumatically controlled for increased speed.

very long taper on large diameter tubing

This swager was designed especially for very long tapers on large diameter tubing. It is essentially an elongated version of our standard 1047 swager. The application required swaging a 15” long taper on both sides of a 36” aluminum tube. Making a spindle and head that could hold such a long die and function at a high level of precision proved to be a challenge that was successfully overcome by our specialized team of engineers, manufacturers and assemblers. The feeder features a rotating stopper assembly that can hold both the blank tube and the formed tapered tube once it is flipped for the second pass. This allows the swaging of both sides of the tube without having to stop for a change of stopper; thus keeping the production rate high, even for a semi-automatic system. Both the slide and clamping cylinders are hydraulically powered. The overall sound enclosure around the machine keeps the noise level to an acceptable level of 85 dB maximum, in compliance with the OSHA standards.

aluminum swaging over a mandrel

This fully automated system was made to swage different lengths and diameters of aluminum tubes over a mandrel. The swaged lengths go up to 19”, as shown in this video. The great production rate required for these automotive components requires a completely automatic system. The magazine is adjustable in both length and diameter to accommodate different dimensions of parts. All the motions are pneumatically controlled for increased speed to minimize the handling time of the component.

wire swaging

Torrington Forming Machinery developed a standard modular system to swage wires of all lengths. This system includes a feeder and an extractor, both semi-automatic, because the whole part needs to be swaged. If this is not the case, the extractor isn’t needed. For long parts, roll feeders are used. For shorter parts, a gripper feeder is used in front and a collet extractor at the back. In the video below, a roll feeder has been used in front and a collet extractor at the back. This combination allows to swage short parts and medium-long parts. In this case, this was necessary because a short blank was swaged multiple times which greatly increased its length after each step. By combining standard modules like in this example, Torrington Forming Machinery can accommodate all your needs in wire swaging. If the production volume is great, magazines can be added for fully-automatic production.

1047 dual rotary SWAger

guarding-generalyTorrington Forming Machinery designed and produced this machine for very heavy applications. Like a standard 1047 rotary swager, it can form bars up to 1 3/8 inches diameter and tubes up to 3 1/2 inches diameter. What makes it so special is that it can form materials with very low ductility like tungsten. The difference with the standard swager is that it applies very low torque on the part. To do so, the head and the spindle are both spinning in opposite directions, allowing the spindle to spin at a lower speed. This method reduces torque on the part but not the number of strokes required to form low ductility materials. This machine was also equipped with semi-automatic feeder and unloader that could accommodate parts
more than 2 feet long.

Suture needle forming and sharpening machine

A very interesting project was the manufacturing of a machine to produce suture needles. Three needles were loaded form a cassette magazine on a three spindles module. A conveyor circuit was moving the modules from station to station. The body of the needle was formed square with two consecutive SS swagers and the tip of the needle was formed in a triangular shape with a third SS swager. Then, the needles were sharpened by three diamond belt stations. The three faces of the tip of the needle were sharpened by a moving plateau raising the belt to the needles and following a specific pattern for each face. Finally, the needles were unloaded from the spindles module to a curving station.

 

Multi-forming and machining station machine

This next video shows a production line for tubes with double-D reductions on both ends. This machine was taking the blank tube from a slope magazine with a two grippers pick and place manipulator to bring it in a push-pull forming station. At the same time, a partially formed part was moved from the push-pull station to a waiting station. While passing the part to the waiting station, it was rotated to form the other end in the next forming station. The part was brought using the same type of pick and place manipulator through three push-pull forming stations, one milling station and two drilling station before exiting the machine.