cable swager Interview Questions and Answers

1. What is cable swaging?

   • Answer: Cable swaging is a metalworking process that uses a swaging machine to deform a metal cable or wire, usually by compression, to create a secure termination or connection.

2. What are the different types of cable swaging dies?

   • Answer: Common types include barrel dies, conical dies, and compression dies, each suited for different cable types and termination styles.

3. Explain the process of swaging a cable.

   • Answer: The process typically involves inserting the cable end into a die, then using a swaging machine to apply high pressure, deforming the metal to create a secure, mechanically interlocked termination.

4. What are the advantages of cable swaging?

   • Answer: Advantages include high strength, reliability, corrosion resistance (with proper materials), and relatively fast application compared to some other termination methods.

5. What are the disadvantages of cable swaging?

   • Answer: Disadvantages can include the need for specialized equipment, potential for damage if not done correctly, and the cost of dies which can be specific to cable types and sizes.

6. What safety precautions should be taken when swaging cables?

   • Answer: Safety glasses, gloves, hearing protection are crucial. Proper training and understanding of the machine are paramount to avoid injury from high pressure and moving parts.

7. What types of cables are commonly swaged?

   • Answer: Steel cables, wire ropes, and various types of electrical cables are frequently swaged.

8. How do you choose the correct die for a specific cable?

   • Answer: The die selection is crucial and depends on the cable diameter, material, and the desired termination type. Manufacturer's specifications must be followed.

9. What is the role of lubrication in cable swaging?

   • Answer: Lubrication reduces friction, prevents galling (metal-on-metal seizing), and ensures a cleaner, more consistent swage.

10. How do you inspect a swaged termination for quality?

    • Answer: Visual inspection for proper shape and lack of defects, and often destructive testing (pull testing) to ensure the required strength is met.

11. What are the different types of swaging machines?

    • Answer: Hydraulic, pneumatic, and manual swaging machines exist, each with its own advantages and limitations regarding force, speed, and cost.

12. Describe the maintenance procedures for a swaging machine.

    • Answer: Regular lubrication, inspection of moving parts, and die replacement as needed are essential for maintaining machine function and safety.

13. What is the difference between a barrel die and a conical die?

    • Answer: A barrel die produces a uniform swage across the length, while a conical die tapers the swage. The choice depends on the application and desired stress distribution.

14. How does the material of the cable affect the swaging process?

    • Answer: Different materials have different ductility and strength, requiring adjustments in pressure, die selection, and potentially lubrication to achieve a proper swage.

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