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Aero Staking´s Aerospace Portable Tri-Roller Swaging Tool and the Story Behind It
For years, the industry retained bearings by aggressively pressing hardened die against the outer lip of the bearing, often resulting in sheering, cracking, and deformation. Moreover, the assemblies frequently fail during axial proof loading. Aero Staking, Inc. has observed that axial loads can easily double when the bearing swage lip is properly formed with no gap between the underside of the lip and the mount housing. This is achievable with flaring by rolling rather than a direct, frontal anvil hit.
The Drawbacks of Anvil Staking
Ark Maciaszek, an AeroStaking engineer, explained, “While using an anvil, you are effectively trying to shear the lip of the bearing. Swaging the lip fully with this type of tool is physically impossible. Additionally, so much load must be applied that the bearing ball gets locked to its race, freezing the bearing. The next step involves using the ball to effectively Brinell the race to provide axial clearance, destroying the ball-to-race spherical conformity, which the bearing manufacturer worked hard to achieve.”
Advantages of Rolling Swaging
Advocating for rolling swaging, Aero Staking highlights its controllability, safety, and reliability. The portable Tri-Roller Swaging Tool has emerged as a superior technology, making bearing retention safer, more efficient, and cost-effective in the long run. This method offers stronger retention, a superior surface finish, and ease of use, even for inexperienced operators. Portable Tri-Roller Swaging Tools are now preferred for aerospace bearing retention due to their numerous advantages over traditional methods.
The Superiority of Tri-Roller Swaging Tools
Ark advocates rolling swaging while emphasizing this process’s controllability, safety, and reliability; in other words, it is immensely superior to old-generation tools. Safer and better technology tools were developed for bearing retention purposes. Tools that are making bearing retention tasks much easier, safer, and less time-consuming. The method is called Tri-Roller Swaging, opposite to anvil (die) staking (flaring)
Long-Term Benefits of Tri-Roller Swaging Tools
Tri-roller or roll stake swaging tools have been developed to improve the traditional methods of Anvil staking or 2-wheel swaging. They are significantly more expensive than anvil stakes, but the cost will be equated and suppressed in the long run, making the whole process profitable.
By reputable aircraft manufacturers, roller-swaging has finally become more desired for aerospace bearing retention.
Preferred by OEMs for Superior Results
OEMs across the board prefer this method over anvil dies for the following reasons:
- Stronger retention
- Uniform, superior surface finish
- Lack of micro-cracks
- Less pressure, no friction, less chance to damage or ‘freeze’ bearing [better results of breakaway or swivel torque testing]
- Ease of re-swaging if necessary
- Ease of use, even by an inexperienced operator
- No heavy Press was used; only a light Drill Press or knee-type mill was required
How the Tri-Roller Swaging Tool Works
The portable Tri-Roller Swaging Tool or Roll Stake swaging tool offers the advantage of allowing the 3 rolling elements within the tool to better contact the V Groove surface of the bearing at the correct angle, allowing the outer portion of the V Groove to flare out into the housing.
Eliminating Damage with Rolling Swaging
Traditional 2 roller and Anvil tools cause damage to the bearing’s V Groove lip. The force required for anvil usage creates micro-cracks on the surface of the staked portion of the bearing. They become subject to rejection at NDT testing, such as X-ray refraction, Eddy Currents, or Mag Particle for fatigue and degradation or even dilapidation.
Cold-Working for Added Strength
On the other hand, the portable Tri-Roller Swaging Tool uses a combination of downward pressure and also roller rotation. The rollers push material from the bearing outer ring’s V groove against the housing’s chamfer to retain the bearing in the most solid way possible. Rollers self-locate themselves precisely and securely. They flare the bearing material in an even, controlled way. The rolling action is cold-working. This adds strength to the work material instead of weakening it.
Individually: Drill Press style and Portable roller swaging tools are supplied with both primary and secondary swaging locating fixtures.
Explore the Efficiency of Aerospace Portable Tri-Roller Swaging Tools.
Aerospace Portable Tri-Roller Swaging Tools for Bearings are indispensable for precision bearing installation and are designed specifically for precision installation and mobility. These tools are engineered for “on-wing” applications, meaning they can be used directly on aircraft for maintenance and repair without requiring the disassembly of whole components. They are ideal for secure and precision installation bearings, crucial in aerospace, automotive, and other industries.
Key Features:
- Designed for On-Wing Application: It can be used directly on aircraft without disassembly.
- Easy Maintenance: Simplified design for quick and effective upkeep.
- Light and Mobile: Engineered for easy transport and use in various locations.
- Fitting Constrained Spaces: Compact design allows operation in tight areas.
- No Weak Links: Built for durability and strength to ensure reliable swaging.
- No Power Tool Needed: Manual operation allows use in environments without electrical power.
Portable tri-roller swaging tool type A
Portable tri-roller swaging tool type B
Portable tri-roller swaging tool housing over the bearing
Portable U-roller swaging tool
Portable flat roller swaging tool
Portable tri-wheeler swaging tool
Conclusion
The portable Tri-Roller Swaging Tool represents a significant advancement in bearing retention technology. Its ability to provide stronger retention, superior surface finish, and reduced risk of damage makes it a preferred choice in the aerospace industry. By eliminating the shortcomings of traditional anvil and 2-wheel swaging methods, portable Tri-Roller Swaging Tools offer a safer, more reliable, and cost-effective solution. These tools are easy to use, even for inexperienced operators, and require only light equipment, making them highly efficient for assembly and maintenance tasks. As a result, reputable aircraft manufacturers and OEMs increasingly adopt this method for its proven benefits in ensuring secure and durable bearing installations.
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