Swaging is much more than ‘squishing the fitting’
Swaging refers to the installation technique to permanently connect a Stainless Steel fitting or terminal to a length of stainless steel wire rope.
Swaging is actually a cold forging process in which the dimensions of a fitting are altered using dies. The dies can be designed for either a
- a Hydraulic Swage Press (typically a single or double acting vertical hydraulic ram that presses the fitting into a size dictated by the die dimensions). Talurit is an excellent brand in this category or
- a Roller Swage Press through which the item is forced (typically single or double acting hydraulic rams actuating cammed dies that work by forcing the fitting through a decreasing radius) Wireteknik (Full Swedish Company name is WIRETEKNIK LEIF ANDERSSON AKTIEBOLAG)is an excellent brand in this category.
It is important that swage terminals are swaged down to the correct diameter. Because of standards (sizing of fittings globally), a reliable and repeatable MBS can be achieved in a connection if Stainless Steel terminals are swaged to the wire rope with an adequate swaging machine (mechanical or hydraulic) that will achieve the required reduction in outside diameter.
The table below is for reference only. It is the sole responsibility of the person or company doing the swaging to ensure the correct dies are used and that the swage has been correctly applied. In any critical application, destruction testing of a construction where all components and dimensions are known and documented must be completed to ensure a properly tested rig.
Low Cost Wire has a full rigging shop and prototype fabrication facility, and can arrange destruction testing and proof certificates. In our shop we sell and use a wide range of machines (presses) including Talurit Presses and Wireteknik Roller Presses. Our decades of rigging and swaging experience can often simplify a problem in minutes or prevent a costly disaster with a small conversation. If in doubt, contact us to discuss your swaging requirements.
| Valid Swaging Dimensions | |||||
| Stainless Steel Fitting | |||||
| Wire Diameter | Before Swaging | After Swaging | |||
| Outside Diameter | Inside Diameter | Outside Diameter | Pocket Depth | Outside Diameter | |
| Metric | Imperial | in mm (+/- 0.2mm) | in mm (+/- 0.1) | in mm (+/- 1.5) | in mm |
| 2.0 | 1/16″ | 2.2 | 5.5 | 32.0 | 4.70 – 4.82 |
| 2.5 | 3/32″ | 2.8 | 5.5 | 32.0 | 4.70 – 4.82 |
| 3.0 | — | 3.8 | 6.5 | 38.0 | 5.44 – 5.56 |
| 3.2 | 1/8″ | 3.8 | 6.5 | 38.0 | 5.44 – 5.56 |
| 4.0 | 5/32″ | 4.4 | 7.7 | 45.0 | 6.23 – 6.35 |
| 4.8 | 3/16″ | 5.3 | 9.0 | 51.0 | 7.83 – 7.95 |
| 5.0 | — | 5.5 | 10.0 | 51.0 | 8.23 – 8.95 |
| 5.5 | 7/32″ | 5.8 | 10.8 | 59.0 | 9.35 – 9.50 |
| 6.0 | — | 6.5 | 12.4 | 64.0 | 10.95 – 11.12 |
| 6.4 | 1/4″ | 6.8 | 12.6 | 64.0 | 11.05 – 11.42 |
| 7.0 | 9/32″ | 7.5 | 14.2 | 70.0 | 12.50 – 12.70 |
| 8.0 | 5/16″ | 8.4 | 16.0 | 83.0 | 14.07 – 14.30 |