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How to calculate Tonnage required for swaging of cold parts.

01/12/2022 11:14 PM

Hello All,

We have a part like below in the picture. we need to place a spherical ball inside the socket and close the lips by swaging using the hydraulic press so that the ball is locked inside the socket. As this a new part and machine we need to calculate the amount of tonnage required for this swaging operation. Please help on how to calculate the load required to swage this part. Material used is SAE 1541 and the lip area is local heat treated to hardness 210BHN for purpose of swaging.

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#1

Re: How to calculate Tonnage required for swaging of cold parts.

01/13/2022 2:48 AM
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#4
In reply to #1

Re: How to calculate Tonnage required for swaging of cold parts.

01/13/2022 6:51 PM

I think I would make the frame in 2 pieces and weld it together, or screw it together....

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#6
In reply to #4

Re: How to calculate Tonnage required for swaging of cold parts.

01/14/2022 10:47 AM

Or instead of being split "top to bottom" it could be split "side to side"

But without better understanding of the application it's difficult to know. It's hard to see how in its given form it could be part of a bearing or some kind of valve.

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#2

Re: How to calculate Tonnage required for swaging of cold parts.

01/13/2022 4:40 AM

How about a field trial?

  • It may be that this matter does not respond to rigorous calculation.
  • The <...tonnage...> needed to carry out the <...swaging operation...> is going to be much less than that needed to deform the <...spherical ball...>, so it may well be a case of "suck it and see". Have a go, and if it doesn't achieve the desired result, change it so that it does.
  • There is no mention of any temperatures in the post, which factor may well influence the <...tonnage...> required.
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#3

Re: How to calculate Tonnage required for swaging of cold parts.

01/13/2022 6:29 AM

It is possible to retain the <...spherical ball...> using two bends, any number above that, or a continuous circular bend. The <...tonnage...> required in each case will be different, increasing through that range.

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#5

Re: How to calculate Tonnage required for swaging of cold parts.

01/14/2022 5:34 AM

Swaging the way you propose, so that the swag cups the bottom of the ball, will push the ball up so that it locks against the top of your socket and the ball will be unable to rotate. If you invert the piece so that the ball drops into the socket you may solve that problem by pushing down to deform the rim so that it does not touch the ball. The shape of your swage will be different and probably inconsistent. Machining a tapered (45º) groove in the flat face of the rim so that the inside edge of the groove is 64mm creates an edge that will swage much more consistently. It will also reduce the force you need to apply and would use a much smaller press. By machining the groove to a more sophisticated shape and pressing with a shaped die to the correct depth you could create and internal edge on the socket what will mirror the curve of the ball where it mates. Also you don.t need to swag all round. Deforming the rim of the socket at three points will hold the ball and would reduce the size of the press further.

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#7

Re: How to calculate Tonnage required for swaging of cold parts.

01/16/2022 3:26 PM

Maybe a hammer swage with rotating blocks. I used to use one to put the balls on the end of cables for a manufacturer of sub assemblies for Ford Motor Co. They were brake cables assembled by Orscheln Industries of Moberly, Missouri. The parts are now made in Mexico, if their still using that design. Another consideration, if it's going onto a cable is to use a hot diecast injection machine. The ends of the cable were sent through a press to make a diamond cage basket for the liquid magnesium to be thoroughly attached to the multi stranded cable. We made thousnds of these parts daily to the production lines for Ford.

If I misunderstood it may help to give you the idea you need.

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#8

Re: How to calculate Tonnage required for swaging of cold parts.

01/17/2022 6:38 AM

There is not simple calculation that will solve your problem.There are a lot of unknown factors left out of your post

Consult the manufacturer of the of the part for specifications.

I would also research on the 'net for typical applications and solutions.

A diligent search may solve your problem

Here I have referenced just one instance.

Link below:

https://www.assemblymag.com/articles/95858-crimping-staking-swaging-and-clinching-with-presses

Good luck.

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#9

Re: How to calculate Tonnage required for swaging of cold parts.

01/17/2022 1:47 PM

It appears the joint is typical of a common automotive ball joint or outer tie rod end. Is this the case? In any event it also seems likely the design intent is a kinematic joint that constrains all 3 linear degrees of freedom without constraining any of the 3 rotational degrees of freedom. Is this so?

The tonnage required will certainly depend on what sort of tool or die is used and how much closure is desired. Although it may be your intent to "size" the press needed it might be better to think of the problem as "How far (Distance) should the cup be pressed (Using the specific tools you have or choose) to achieve the desired preload in the joint. It also might be a good idea to coat the inside of the joint with some extreme pressure (EP) grease before swaging to avoid seizing. Some ball joints also have a teflon liner and/or a spring under the ball to avoid seizing when they are swaged.

Yet another consideration is whether the assembly is a "one (or two) off" or if you are working on a process to mass produce them. Will the experimentation needed to determine the tooling and process parameters yield all the parts you need or will that just be the beginning?

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#10

Re: How to calculate Tonnage required for swaging of cold parts.

01/18/2022 5:15 AM

I agree with Mfmatusky that it would be better to approach from a "stroke" consideration rather than tonnage.

You could calculate tonnage for the drawn condition, but if you then have +/-0.1mm on ID and OD, the tonnage will be changed. Material variation within type will also introduce variation in tonnage.

Stroke dependent process will introduce some level of assurance to your process.

Also agree that you might investigate multiple localised deformation instead of full circumference swage. This approach might then lend itself to localised wall section reduction and further reduced process energy required.

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