CA2223298A1 - Tool kit and method for swaging and flaring metal tubes - Google Patents
Tool kit and method for swaging and flaring metal tubes Download PDFInfo
- Publication number
- CA2223298A1 CA2223298A1 CA 2223298 CA2223298A CA2223298A1 CA 2223298 A1 CA2223298 A1 CA 2223298A1 CA 2223298 CA2223298 CA 2223298 CA 2223298 A CA2223298 A CA 2223298A CA 2223298 A1 CA2223298 A1 CA 2223298A1
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- Prior art keywords
- tube
- swaging
- tool kit
- bar
- tube end
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D41/00—Application of procedures in order to alter the diameter of tube ends
- B21D41/02—Enlarging
- B21D41/025—Enlarging by means of impact-type swaging hand tools
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D17/00—Forming single grooves in sheet metal or tubular or hollow articles
- B21D17/02—Forming single grooves in sheet metal or tubular or hollow articles by pressing
- B21D17/025—Forming single grooves in sheet metal or tubular or hollow articles by pressing by pressing tubes axially
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D41/00—Application of procedures in order to alter the diameter of tube ends
- B21D41/02—Enlarging
- B21D41/021—Enlarging by means of tube-flaring hand tools
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Forging (AREA)
Abstract
A tool kit including a pilotless punch for swaging tube ends with beads, flares and portions of reduced diameter. The kit is particularly useful to auto-mechanics for reconditioning sending units on fuel tanks using common workbench tools and equipment. The tool kit includes a pair of clamping blocks cooperatively forming a chuck for enclosing a tube. Each clamping block has a flat portion along a segment thereof such that both blocks are forcibly retainable against one-another in a common shop vise for firmly clamping a tube. There is also provided a centering bushing and an annular collar for simultaneously enclosing portions of the clamping blocks and a portion of the centering bushing when the centering bushing is positioned adjacent the clamping blocks, for centering the centering bushing with the chuck. The round punch bar is mountable inside a central opening in the centering bushing. The punch bar has a first pilotless swaging die for swaging a tube end. Further, a gauge is incorporated into the centering bushing, and this gauge has a standard dimension corresponding to a required length of a tube end protruding from the chuck prior to swaging the tube end, for gauging a tube end prior to chucking it.
Description
TITLE: TOOL KIT AND METHOD FOR SWAGING AND
FLARING METAL TUBES
FIELD OF THE INVENTION
This invention pertains to tools for flaring metal tubes, and more particularly, this invention pertains to m~m~l tools and methods for swaging and fomming a bead on the end of a tube.
BACKGROUND OF THE INVENTION
Fuel injection systems in modem vehicles comprise a fuel sending unit mounted on the gas tank of the vehicle and functioning as a connection between the fuel pump and fuel gauge inside the tank, and the fuel piping system to the engine of the vehicle. The outlet tubes of a sending unit comprise swaged tube ends cooperating with mating mechanical fittings and defining with the mechanical fittings releasable connections in the fuel lines.
Similar releasable connections are often found at other locations along a fuel piping system and on power steering units. These tubes, as supplied by the original manufacturer are normally made of steel and are prone to corrosion for being located under the vehicle and for being exposed to all driving 1 5 conditions.
A sending unit with corroded outlet tubes is normally replaced by a new one at the expenses of the owner of the vehicle. The primary reason for not repairing sending units, which would save substantial amounts of money in repair costs, is believed to be because there are no tool available commercially to precisely m~mlf~cture the swaged tube ends using common garage equipment.
The swag,ing of a metal tube, and forming a bead on the end of the tube are difficult to control. It has been experienced that the tube tends to pucker,crumble or otherwise take unwanted deformation. The material of the tube may even crack or split.
Some types of bead-forming tools of the prior art have a pilot stem to enter the tube and to guide a die block onto the tube for mahllainillg the symmetry of the bead about the tube's axis. However, sending units of most North-American-made vehicles have tube ends formed with a bead and a reduction in tube diameter adjacent to the bead. In these cases, the use of a l o pilot member is useless for forming tube ends that are concentric with the axis of the tube.
It is believed that there are at least two requirements that must be taken into consideration for properly swaging a tube. The first one being that the swaging die must remain in perfect alignment with the axis of the tube, and the second being that the length of tube entering the swaging die must be precisely controlled. It is further believed that these two requirements must be found in a single tool in order to form tube ends that will not leak, that will easily engage into a mechanical ~ltting, and that will remain engaged in the mechanical fitting. It is believed that in general, the m~mlal flaring tools of the prior art are lacking at least one and most often both of these structural requirements.
In a first example of the tools of the prior art, U.S. Patent 2,483,982 issued on Oct. 4, 1949 to Joseph N. Paquin, discloses a manual flaring tool having a pair of elongated tube holder blocks. Each block is formed with a series of semicircular recesses which cooperate to form tube gripping bores when the blocks are brought together and clamped about a tube. A flaring head is movable along the tube holder blocks into a pair of guide channels respectively fastened to each of the tube holder blocks. A series of index marks are provided on the ch~nnel members, which marks are aligned with the axis of the corresponding tube recesses. A precise alignment of the flaring head over a tube to be flared is obtained by ~ligning an index mark on the 5 flaring head with a selected index mark on one of the channel members.
When this is done, the tube is readily flared by rotation of a flaring tool operator mounted through the flaring head.
In a second example, U.S. Patent 3,415,100 issued on Dec. 10, 1968 to Frank J. Britts, discloses a hand tool for swaging and forming a bead near 10 the end of a tube. The tool includes an inverted U-shaped frame portion having a pair of legs each provided with a notch for respective engagement with opposing side walls of a pair of tube clamping blocks. The blocks are provided with semicircular tube holding recesses to accommodate tubes of various diameters. The base of the U-shaped frame is provided with a 15 threaded aperture and a threaded shaft is mounted therein. The shaft has a head and a handle adapted to rotate the shaft to move the shaft up or down.
A die body is connected to the shaft and has a die opening to form the tube.
A pair of slots are provided along the die body. These slots are engaged onto the legs of the U-shaped frame, and are used for guiding the die body relative 20 to the tube during the tube forming process.
Another example of a manual swaging tool for forming a bead on a tube is disclosed in U.S. Patent 3,575,033 issued on April 13, 1971, to Howard F. Meyer, Jr. This tool comprises conventional flaring yoke and bar assembly similar to the previously described tools. The die member used in 25 this invention has a projecting guide pin that fits into the tube end and extends beyond the desired location of the bead to be formed. The projecting guide pin keeps the die member aligned with the tube during the bead forming process.
In yet another example of a m~ml~l tool for forming a bead onto a tube is disclosed in U.S. Patent 4,754,634, issued on July 5, 1988 to Sakae Murata.
In this device, the die member is guided between the legs of a U-shaped yoke and by a short pin projecting from the forming end of the die block and extending into the tube to be formed.
Other tube forming equipment are disclosed in several U.S. Patents and in particular in:
U.S. Patent 4,606,214, issued on Aug. 19, 1986 to Takeshi Miyazaki;
U.S. Patent 4,980,961, issued on Jan. 1, 1991 to Maurice L. Caudill;
0 U.S. Patent 5,487,294, issued on Jan. 30, 1996 to Horst U. Petersen.
These later examples of tools of the prior art are also characterized by the fact that each has a pilot stem entering into the tube for controlling the deformation of the tube. It will be appreciated that the flared tube ends formable using a tool having a pilot stem are limited to those where the inside diameter of the 15 tube beyond the bead is similar to the nominal inside diameter of the tube.
In view of the foregoing, it is believed that there is a significant market demand for tool kits capable of reliably swaging tube ends and providing for the replacement of outlet tubes on fuel sending units, fuel lines and power steering units, using common hand tools and equipment normally found in 20 mechanical workshops.
SUMMARY OF THE INVENTION
In the flaring tool kits of the present invention, however, there is provided a set of simple tools including a pilotless punch for swaging tube ends with beads, with inward flares and with portions of reduced diameter.
25 The kit is particularly useful to automechanics for reconditioning sending units on fuel tanks, using common workbench tools and equipment.
Broadly, in accordance with one feature of the present invention, there is provided, a tool kit for manually swaging a tube end, comprising a pair of semicircular clamping blocks cooperatively forming a chuck for enclosing a tube. Each clamping block has a flat portion along a segment thereof such 5 that both blocks are forcibly retainable against one-another in a common shop vise for firmly clamping a tube. There is also provided a centering bushing having a central opening and an outside surface comprising a first and second cylindrical sections contiguous with one another and having different diameters, the first diameter being similar to the outside diameter of the chuck.
There is further provided an ~nmll~r collar having an inside diameter substantially similar to the outside diameter of the chuck and to the first diameter of the centering buching and a width for simultaneously enclosing a portion of the chuck and the first cylindrical section of the centering bushing when the centering bushing is positioned adjacent the chuck, for centering the 15 centering bushing with the chuck.
A round punch bar is mountable inside the central opening through the centering bushing. The punch bar has a first and second extremities, and a first pilotless swaging die in the first extremity for swaging a tube end.
20 Fulther, a gauge is incorporated into the cent~ring bushing, and this gauge has a dimension corresponding to a required length of a tube end protruding from the chuck prior to swaging the tube end.
A first advantage of the tool kit of the present invention is that the gauge incorporated in one of the pieces of the kit is readily available for 25 positioning a tube end in the clamping blocks with an ideal length protrudingfrom the clamping blocks to form a perfect bead or flare on the tube end. The user of the kit of the present invention does not have to search for a ruler, to verify charts, read a vernier or small graduations on a measuring instrument.
The gauge being integrated into an essential component of the tool kit is kept with the kit at all times. Moreover, the gauge is a standard, or a comparative-type gauge whereby the positioning of the tube is effected using more of a 5 tactile skill than visual acuity. This aspect of the present invention prevents errors in properly positioning a tube end in the clamping blocks prior to forming the tube end, especially when the tool kit is being used in a busy workshop environment.
In another feature of the present invention, the circular clamping 10 blocks, the centering bushing and the armular collar have a common interference and this interference is selected amongst a precision running fit and a close running fit. The centering bushing and the punch bar also have a common i~ relellce that is also a precision running fit or a close running fit.
The engagement of the punch bar inside the centering bushing is at least 15 equivalent to the length of the tube end to be formed. These interferences and engagement contribute to m~ g the punch bar along a precise alignment with the axis of the tube end. The punch bar is therefore workable with a common h~mmer for swaging the tube end in a precise and consistent manner.
In accordance with another feature of the present invention, there is 20 provided a tool kit for use with a conventional manual tube flaring tool, wherein the m~nll~l flaring tool comprises a clamping bar set and a flaring yoke having a pair of spaced-apart hooked legs. In this aspect of the invention, the tool kit comprises a cylindrical pilotless forging die having a drive end, a swaging end, a circular cross section and a forming cavity in the 25 swaging end. A saddle collar is also provided. The saddle collar has an inside diameter which is a first sliding fit ~limen~ion over the forging die and an outside diameter which is larger than a width of the clamping bar. The outside diameter of the collar is a second sliding fit dimension inside the spaced-apart legs of the yoke. The saddle collar further has a pair of tabs spaced apart a third sliding fit dimension over the width of the clamping bar.
In accordance with yet another aspect of the tool kit for use with a 5 conventional m~nl~l tube flaring tool, the saddle collar has a gauge incorporated therein for measuring a length of tube extending from the clamping bar set. This gauge is also usable according to the aforesaid manner for preventing defects in a swaged tube end.
In yet a further aspect of the present invention there is provided a new l o method for m~ml~lly swaging a high-pressure releasable fitting on a tube endusing a round pilotless punch bar having a first die in a first end thereof. Themethod comprises the steps of:
A) enclosing a tube in a pair of clamping blocks;
B) positioning the tube in the clamping blocks and exposing a tube end portion of the tube beyond a surface of the clamping blocks while g~llging the length of the tube end portion according to an ideal dimension of a comparative-type standard;
C) forcibly retaining the clamping blocks in a vise;
D) fittingly enclosing the clamping blocks inside an annular collar;
20 E) fittingly enclosing a hollow bushing inside the annular collar, and against the surface of the clamping blocks;
F) fittingly inserting the punch bar inside the hollow bushing while guiding the punch bar along an engagement dimension in the hollow bushing which is at least as long as the length of the tube end portion; and G) striking the punch bar with a hammer for working the first die cavity onto the tube end for forming a fitting on the tube end.
The method described above is particularly advantageous for swaging a high-pressure releasable fitting on a tube end using common workbench tools available in most automotive garages. The fittings formed by this method are known to have an ideal shape and for being concentric with the 5 axis of the tube.
Other advantages of the tool kits of the present invention comprise the facts that the tool kits contain a small number of pieces, are relatively inexpensive to m~nllf~cture and are easy to use.
BRIEF DESCRIPTION OF THE DRAWINGS
Two embo-liment~ of this invention are illustrated in the accompanying drawings, in which like numerals denote like parts throughout the several views, and in which:
FIG. 1 is a perspective exploded view of a tool kit according to a first preferred embodiment of the present invention;
15 FIG. 2 is a side view of a swaged tube end of a first type;
FIG. 3 is a side view of a swaged tube end of a second type;
FIG. 4 is a partial cross-section view of a first end of a first punch bar usable with the tool kit according to the first preferred embodiment for swaging a tube end of the second type;
~0 FIG. 5 is a partial cross-section view of a second end of the first punch barillustrated in FIG. 4;
FIG. 6 is a partial cross-section view of a first end of a second punch bar usable with the tool kit according to the first preferred embodiment for swaging a tube end of the first type;
FIG. 7 is a side view of the clamping blocks and centering bushing, illustrating a method for positioning of a tube in the clamping blocks;
FIG. 8 is a partial cross-section of the tool kit of the first preferred embodiment, illustrating the swaging of the tube end for reducing the diameter of the tube end;
FIG. 9 is another partial cross-section of the tool kit of the first preferred embodiment, illustrating the formation of a bead on a tube end;
FIG. 10 is a cross-section view of the clamping blocks with a tube end therein, illustrating the flaring of the tube end;
FIG. 11 is perspective view of a partial manual tool kit according to a second preferred embodiment of the present invention;
FIG. 12 is a cross-section view through the flaring yoke of the tool kit of the second preferred embo-liment, illustrating the saddle collar of the tool kit as seen along line 12-12 in FIG. ll;
FIG. 13 is a cross section view through a first forming die usable with the tool kit of the second preferred embodiment;
FIG. 14 is a cross section view through a second forming die usable with the tool kit of the second preferred embodiment;
FIG. 15 is a cross section view through a third forming die usable with the tool kit of the second preferred embo-liment;
FIG. 16 is a cross section view through the saddle collar usable with the tool kit of the second preferred embodiment as seen along line 16-16 in FIG. 12;
FIG. 17 is a plan view of the clamping bar set and saddle collar usable with the tool kit of the second prefel,ed embodiment in a position for g~llging a proper length of a tube end to be formed.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
While this invention is susceptible of embodiment in many different forms, there are shown in the drawings, and will be described in details herein two specific embodiments, with the understanding that the present disclosure is to be considered as an example of the principles of the 15 invention and is not intended to limit the invention to the embodiments illustrated.
There is illustrated in FIGS. 1-10 a first flaring tool kit according to a first preferred embodiment of the present invention. There are also illustrated two types of typical swaged tube ends formable using the tool 20 kits of the preferred embodiments. FIGS. 7-10 in particular illustrate a preferred method of operation of the tool kit of the first preferred embodiment.
The flaring tool kit of the first preferred embodiment comprises a pair of semicircular clamping blocks 20,20' cooperatively forming a chuck 25 enclosing the tube to be formed. Each of the clamping blocks 20-20' has a flat portion along a segment thereof such that both blocks 20,20' are forcibly retainable against one-another in a common shop vise 22 for example, for filmly clamping a tube 24 to be swaged. An ~nn~ r collar 26 is provided and has an inside diameter for precisely sliding over and S enclosing the portion 'B' of the cl~mping blocks 20-20' extending above the vise 22. A cent~ring bushing 28 is further provided for mounting inside the ~nn~ r collar 26, for guiding a first swaging punch 30, also being part of the tool kit of the first preferred embodiment.
The dimension tolerances of, or the interference between, the clamping blocks 20-20', the annular collar 26, the centering bushing 28 and the first punch 30 are selected to constitute therebetween a precision running fit (RC 3) or a close running fit (RC 4) as defined in the American National Standards Institute, ANSI B4.1-1967, R1974, entitled Standard Limits and Fits, such that the punch 30 is kept precisely centred with the 15 axis of the tube to be formed, throughout the forming process.
The first flaring punch 30 usable with the tool kit of the first preferred embodiment consists of an elongated round bar having a tube-swaging cavity on each end thereof as will be explained later. The first punch 30 is preferably used with a protective anvil cap 32, on which a 20 manual hammer may be stricken for forming a flared end on a tube. The anvil cap 32 preferably has a recess in its lower surface for enclosing the drive end of the punch 30 completely, thereby protecting the punch from deformations associated with repeated hammer blows thereon.
The width 'A' of the ~nmll~r collar 26 is sufficient for enclosing the 25 portion 'B' of the clamping blocks extending above the vise 22 and a first shoulder 'C' on the centering bushing 28 extending toward the clamping blocks 20-20' and having an outside diameter similar to the inside diameter of the annular collar 26. For example and for reference purposes only, the dimension 'A' is 0.675 inch (17.1 mm); the dimension 'B' is 0.290 inch (7.3 mm), and 'C' is 0.425 inch (10.8 mm). The height 'D' of the centering bushing extt n~ing above the annular collar 26 hereinafter referred to as the 5 depth gauge 'D' is selected to correspond to the required length of tube extending above the clamping blocks 20,20' prior to swaging the tube end.
The depth gauge 'D' on the centering bushing 28 is therefore usable as a gauge or a standard for properly positioning the tube 24 in the clamping blocks 20-20' and for ensuring that the proper amount of material extends o above the clamping blocks 20-20' for forming a quality bead. This is one of the most important features, basically, to ensure that the tube end formed with the tool kit of the first preferred embodiment has a consistent quality.
Furthermore, the engagement of the punch bar 30 inside the centering bushing is at least a minimllm dimension corresponding to the 15 length of tube extpn~ling above the clamping blocks. It has been found that this minimum engagement dimension is required for ensuring that the punch bar remains in proper alignment with the axis of the tube. This minimum engagement of the punch bar inside the centering bushing is another most important feature to ensure that the tube end formed with the 20 tool kit is concentric with the axis of the tube.
Typical tube ends which are formable with the tool kits of the present invention are illustrated for reference purposes in FIGS. 2 and 3.
These tube ends are used in the automotive industry on gas lines, sending units of gasoline tanks and power steering hydraulic piping systems. The 25 first illustrated tube end 40 has a relatively long stem extending between a bead 42 and the end of the tube, and tapering down slightly at the open end of the tube. This type of tube end 40 is referred to in the industry as a high-pressure-clip fitting. The outside diameter of the stem 'E' is generally similar to the nominal outside diameter of the tube.
The second illustrated common tube end 44 is referred to in the 5 industry as a high-pressure-flare fitting. It has a relatively short stem witha diameter 'F' being smaller than the nominal tube size 'G'. The open end 46 of the tube is flared outwardly and has an O-ring 48 mounted thereon next to the bead 50. A first typical diameter 'F' of the stem is 5/16 inch (7.9 mm), for a nominal tube size 'G' of 3/8 inch (9.5 mm). A second lO typical diameter 'F' of the stem is 1/4 inch (6.35 mm), for a nominal tube size 'G' of 5/16 inch (7.9 mm).
The tube end of the first type 40 is formable in a single step with a second punch 60 having a straight cylindrical cavity 62 as partly illustrated in FIG. 6. The tube end of the second type 44 is formable in four steps as 15 illustrated in FIGS. 7-10. A first step is to properly position the tube end into the clamping blocks 20-20' as illustrated in FIG. 7, while using the dimension 'D' on the centering bushing 28 to properly gauge a length of tube 24 extending above the clamping blocks 20,20'. A second step is to reduce the diameter of the tube end using a first punch end 52 having a 20 tapering cavity 54 such as illustrated in FIG. 4. A third step comprises the forming of the bead 50 on the end of the tube using a second punch end 56 having a relatively shallow cylindrical cavity 58, with a depth equivalent to the length of the stem portion of the fitting 44. A fourth step comprises the flaring of the tube end using a pointed tool 64.
It will be appreciated that the forging cavities 54 and 58 are normally formed on respective ends of the first punch bar 30 such that a single punch bar is comprised in the tool kit of the first preferred embodiment for each size and type of tube fitting formable with a 5 particular kit. The swagg of the tube end with the first and second punch ends is effected by striking the punch bar with a common manual ball-peen hammer.
The outward flaring of the open end 46 of the fitting of the second type is done by working a pointed rod 64 in the open end 46 of the tube 24 lo with a hammer or by hand by swaying the rod sideways and around the axis of the tube. The pointed rod 64 is also used as a handle that is preferably insertable in a hole 66 extending diametrically through the first punch bar 30 as illustrated in FIG. 1, for working the first punch bar 30 loose from a formed tube end.
While the depth gauge 'D' on the centering bushing 28 has been described for use with the first punch bar 30, it will be appreciated that a second centering bushing (not shown) with a second depth gauge incorporated therein is preferred for use with the second punch 60 for forming a tube end of the first type 40. It will also be appreciated that a 20 separate centering bushing having a distinct dimension 'D' and distinct identification marks is preferably supplied for each size and type of tube end formable with a particular kit.
The aforesaid method has been found particularly efficient for manufacturing flared tube ends of consistent precision and quality on 25 copper, alu~ ~-u--l and steel tubing. It has also been found that the tool kit of the first pre~ d embodiment is usable for forming a flared tube end in less than a couple of minutes (in less than one minute for the experienced person) with few hammer blows using a common ball-peen h~mmer. The tool kit of the preferred embodiment is particularly useful to mechanics epailillg late model vehicles having the flared tube ends described herein.
Referring now to FIGS. 11-15, the tube flaring tool kit according to 5 a second preferred embodiment of the invention is illustrated therein. The flaring tool kit according to the second preferred embodiment is usable with a conventional tube-clamping-bar set 80 and a m~ml~l flaring yoke 82.
The flaring yoke 82 of the conventional type has a pair of hooked legs 84,84' spaced apart a distance which is slightly larger than the width of the o clamping bar set 80 as is customary with these tools. The tool kit of the second preferred embodiment comprises a first and second forming dies 86,88 having respectively a tapering cavity 90 and a bead-forming cavity 92 for forming a flared tube end of the second type 44 as illustrated in FIG.
3. Similarly, a single forming die 94 having a deep tapering cavity 96 is 15 required for forming the flared tube end of the first type 40 as illustrated in FIG. 2. Each of forming dies 86,88,94 has a cylindrical shape and a dimple 98 on its upper end for receiving the rounded tip 100 of a screw press 102 on the m~n~l~l flaring yoke 82.
The tool kit of the second preferred embodiment also comprises a 20 saddle collar 104 having an inside diameter of appropliate dimensions for precisely sliding over each of the cylindrical forming dies 86,88,94. The saddle collar 104 has an outside diameter which is slightly larger than the width of the clamping bar set 80, and which is preferably sized for providing a precise sliding flt between the hooked legs 84,84' of the yoke.
25 The sliding fits mentioned herein are similar to those specified earlier when describing the tool kit of the first preferred embodiment.
The saddle collar 104 also has a first diametrical slot 106 across the lower surface thereof. The slot 106 has a width substantially the same as the width of the clamping bar set 80 such that it is precisely mountable astride over the cl~mping bar set 80. The first diametrical slot 106 defines a pair of tabs 108,108' extending downward on both sides of the clamping bar set 80 when the saddle collar is positioned on the clamping bar set and is centred with a tube to be flared.
A thickness 'H' of the saddle collar 104 is preferably equivalent to the length of tube required for forming the flared end, such that the collar lo is usable as a standard for properly positioning the tube in the clamping bar set 80.
The purpose of the first diametrical slot 106 and of both tabs 108,108' is for keeping the saddle collar 104 centred about the tube to be formed, and for preventing both legs 84,84' of the yoke 82 from moving along the clamping bar set 80, or from tilting sideways during the forming of the flared tube end.
In use, a tube is secured in the clamping bar set 80; the saddle collar 104 is placed over the bar set and moved against the tube for g~lging a length of tube extending from the bar set. In case of a tube end of the first type 40, the height 'J' of the third die member 94 is used as a gauge for measuring the tube end protruding above the clamping bar set 80. For a tube end of the second type 44 as illustrated in FIG. 3, the saddle collar 104 is placed against the tube 114 for precisely measuring the portion of the tube ext~n~ing above the bar set 80, and for properly clamping the tube 114, as illustrated in FIG. 17. The tapering die 86 is then placed over the end of the tube, and into the saddle collar 104. The flaring yoke 82 is positioned on the clamping bar set 80 with one leg on each side of the saddle collar 104 and in ~imnlt~neous contact with the clamping bar set 80 and the saddle collar 104. Then, the screw press 102 of the m~m1~l flaring yoke 82 is actuated for pushing the tapering die 86 against the tube end for 5 swaging the tube end. The tapering die 86 is then replaced by the bead-forming die 88 and the screw press 102 is worked again for forming the bead 50 on the tube end 44.
The saddle collar 104 further has a second diametrical slot 110 lo inside and parallel to the first diametrical slot 106. When the saddle collar 104 is installed over the clamping bar set 80, the second slot 110 constitutes a window for monitoring a proper formation of the bead 50 on the tube end.
In the m~nll~l flaring tool illustrated herein, the flaring yoke 82 is IS centred transversally relative to the bar set 80 by twisting the tool and placing both legs 84,84' against a respective side of the bar set 80. The flaring tool 82 is centred longit~l-lin~lly relative to the bar set 80 by havingboth legs 84,84' in contact with the saddle collar 104.
The use of a saddle collar 104 in combination with a cylindrical forging die 86 ensures that the flaring yoke 82 is properly and rigidly aligned with the tube 114 to be formed, along a longih~-lin~l and transversal axis of the clamping bar set 80. In this arr~ngem~nt, both legs 84,84' of the yoke 82 are held into a pair of notches 116,116' defined by the saddle collar 104 and the sides of the clamping bar set 80. Because these notches 116,116' have the thickness of the bar set 80 plus the thickness 'H' of the saddle collar 104, the flaring yoke 82 is held in a stable and positive manner against movement along the cl~mping bar set 80, as well as against tilting relative to the axis of the tube to be formed 114. Further, when pressure is applied on the screw press 102, the friction of the hooked legs 84,84' against the underside of the clamping bar set 80 prevents the saddle collar 104 from moving along the bar set 80. Thus, the interlocking 5 arrangement ofthe saddle collar 104 with the flaring yoke 82 and with the clamping bar set 80 m~int~in the screw press 102 centred with the axis of the tube 114. This is one of the main reasons, basically, that the swaged tube ends forged with the tool kit of the second preferred embodiment have a consistent precision and quality.
A last step in forming the flared tube end of the second type as illustrated in FIG. 3, is to enlarge the end of the tube at 46. The handle 112 of the m~n~l screw press 102 advantageously has a pointed end 118 for working the tube end 46 as previously explained.
While two embo-limçnt.c of the present invention have been illustrated in the accompanying drawings and described hereinabove, it will be appreciated by those skilled in the art that various modifications, alternate constructions and equivalents may be employed without departing from the true spirit and scope of the invention. Therefore, the above 20 description and the illustrations should not be construed as limiting the scope of the invention which is defined by the appended claims.
FLARING METAL TUBES
FIELD OF THE INVENTION
This invention pertains to tools for flaring metal tubes, and more particularly, this invention pertains to m~m~l tools and methods for swaging and fomming a bead on the end of a tube.
BACKGROUND OF THE INVENTION
Fuel injection systems in modem vehicles comprise a fuel sending unit mounted on the gas tank of the vehicle and functioning as a connection between the fuel pump and fuel gauge inside the tank, and the fuel piping system to the engine of the vehicle. The outlet tubes of a sending unit comprise swaged tube ends cooperating with mating mechanical fittings and defining with the mechanical fittings releasable connections in the fuel lines.
Similar releasable connections are often found at other locations along a fuel piping system and on power steering units. These tubes, as supplied by the original manufacturer are normally made of steel and are prone to corrosion for being located under the vehicle and for being exposed to all driving 1 5 conditions.
A sending unit with corroded outlet tubes is normally replaced by a new one at the expenses of the owner of the vehicle. The primary reason for not repairing sending units, which would save substantial amounts of money in repair costs, is believed to be because there are no tool available commercially to precisely m~mlf~cture the swaged tube ends using common garage equipment.
The swag,ing of a metal tube, and forming a bead on the end of the tube are difficult to control. It has been experienced that the tube tends to pucker,crumble or otherwise take unwanted deformation. The material of the tube may even crack or split.
Some types of bead-forming tools of the prior art have a pilot stem to enter the tube and to guide a die block onto the tube for mahllainillg the symmetry of the bead about the tube's axis. However, sending units of most North-American-made vehicles have tube ends formed with a bead and a reduction in tube diameter adjacent to the bead. In these cases, the use of a l o pilot member is useless for forming tube ends that are concentric with the axis of the tube.
It is believed that there are at least two requirements that must be taken into consideration for properly swaging a tube. The first one being that the swaging die must remain in perfect alignment with the axis of the tube, and the second being that the length of tube entering the swaging die must be precisely controlled. It is further believed that these two requirements must be found in a single tool in order to form tube ends that will not leak, that will easily engage into a mechanical ~ltting, and that will remain engaged in the mechanical fitting. It is believed that in general, the m~mlal flaring tools of the prior art are lacking at least one and most often both of these structural requirements.
In a first example of the tools of the prior art, U.S. Patent 2,483,982 issued on Oct. 4, 1949 to Joseph N. Paquin, discloses a manual flaring tool having a pair of elongated tube holder blocks. Each block is formed with a series of semicircular recesses which cooperate to form tube gripping bores when the blocks are brought together and clamped about a tube. A flaring head is movable along the tube holder blocks into a pair of guide channels respectively fastened to each of the tube holder blocks. A series of index marks are provided on the ch~nnel members, which marks are aligned with the axis of the corresponding tube recesses. A precise alignment of the flaring head over a tube to be flared is obtained by ~ligning an index mark on the 5 flaring head with a selected index mark on one of the channel members.
When this is done, the tube is readily flared by rotation of a flaring tool operator mounted through the flaring head.
In a second example, U.S. Patent 3,415,100 issued on Dec. 10, 1968 to Frank J. Britts, discloses a hand tool for swaging and forming a bead near 10 the end of a tube. The tool includes an inverted U-shaped frame portion having a pair of legs each provided with a notch for respective engagement with opposing side walls of a pair of tube clamping blocks. The blocks are provided with semicircular tube holding recesses to accommodate tubes of various diameters. The base of the U-shaped frame is provided with a 15 threaded aperture and a threaded shaft is mounted therein. The shaft has a head and a handle adapted to rotate the shaft to move the shaft up or down.
A die body is connected to the shaft and has a die opening to form the tube.
A pair of slots are provided along the die body. These slots are engaged onto the legs of the U-shaped frame, and are used for guiding the die body relative 20 to the tube during the tube forming process.
Another example of a manual swaging tool for forming a bead on a tube is disclosed in U.S. Patent 3,575,033 issued on April 13, 1971, to Howard F. Meyer, Jr. This tool comprises conventional flaring yoke and bar assembly similar to the previously described tools. The die member used in 25 this invention has a projecting guide pin that fits into the tube end and extends beyond the desired location of the bead to be formed. The projecting guide pin keeps the die member aligned with the tube during the bead forming process.
In yet another example of a m~ml~l tool for forming a bead onto a tube is disclosed in U.S. Patent 4,754,634, issued on July 5, 1988 to Sakae Murata.
In this device, the die member is guided between the legs of a U-shaped yoke and by a short pin projecting from the forming end of the die block and extending into the tube to be formed.
Other tube forming equipment are disclosed in several U.S. Patents and in particular in:
U.S. Patent 4,606,214, issued on Aug. 19, 1986 to Takeshi Miyazaki;
U.S. Patent 4,980,961, issued on Jan. 1, 1991 to Maurice L. Caudill;
0 U.S. Patent 5,487,294, issued on Jan. 30, 1996 to Horst U. Petersen.
These later examples of tools of the prior art are also characterized by the fact that each has a pilot stem entering into the tube for controlling the deformation of the tube. It will be appreciated that the flared tube ends formable using a tool having a pilot stem are limited to those where the inside diameter of the 15 tube beyond the bead is similar to the nominal inside diameter of the tube.
In view of the foregoing, it is believed that there is a significant market demand for tool kits capable of reliably swaging tube ends and providing for the replacement of outlet tubes on fuel sending units, fuel lines and power steering units, using common hand tools and equipment normally found in 20 mechanical workshops.
SUMMARY OF THE INVENTION
In the flaring tool kits of the present invention, however, there is provided a set of simple tools including a pilotless punch for swaging tube ends with beads, with inward flares and with portions of reduced diameter.
25 The kit is particularly useful to automechanics for reconditioning sending units on fuel tanks, using common workbench tools and equipment.
Broadly, in accordance with one feature of the present invention, there is provided, a tool kit for manually swaging a tube end, comprising a pair of semicircular clamping blocks cooperatively forming a chuck for enclosing a tube. Each clamping block has a flat portion along a segment thereof such 5 that both blocks are forcibly retainable against one-another in a common shop vise for firmly clamping a tube. There is also provided a centering bushing having a central opening and an outside surface comprising a first and second cylindrical sections contiguous with one another and having different diameters, the first diameter being similar to the outside diameter of the chuck.
There is further provided an ~nmll~r collar having an inside diameter substantially similar to the outside diameter of the chuck and to the first diameter of the centering buching and a width for simultaneously enclosing a portion of the chuck and the first cylindrical section of the centering bushing when the centering bushing is positioned adjacent the chuck, for centering the 15 centering bushing with the chuck.
A round punch bar is mountable inside the central opening through the centering bushing. The punch bar has a first and second extremities, and a first pilotless swaging die in the first extremity for swaging a tube end.
20 Fulther, a gauge is incorporated into the cent~ring bushing, and this gauge has a dimension corresponding to a required length of a tube end protruding from the chuck prior to swaging the tube end.
A first advantage of the tool kit of the present invention is that the gauge incorporated in one of the pieces of the kit is readily available for 25 positioning a tube end in the clamping blocks with an ideal length protrudingfrom the clamping blocks to form a perfect bead or flare on the tube end. The user of the kit of the present invention does not have to search for a ruler, to verify charts, read a vernier or small graduations on a measuring instrument.
The gauge being integrated into an essential component of the tool kit is kept with the kit at all times. Moreover, the gauge is a standard, or a comparative-type gauge whereby the positioning of the tube is effected using more of a 5 tactile skill than visual acuity. This aspect of the present invention prevents errors in properly positioning a tube end in the clamping blocks prior to forming the tube end, especially when the tool kit is being used in a busy workshop environment.
In another feature of the present invention, the circular clamping 10 blocks, the centering bushing and the armular collar have a common interference and this interference is selected amongst a precision running fit and a close running fit. The centering bushing and the punch bar also have a common i~ relellce that is also a precision running fit or a close running fit.
The engagement of the punch bar inside the centering bushing is at least 15 equivalent to the length of the tube end to be formed. These interferences and engagement contribute to m~ g the punch bar along a precise alignment with the axis of the tube end. The punch bar is therefore workable with a common h~mmer for swaging the tube end in a precise and consistent manner.
In accordance with another feature of the present invention, there is 20 provided a tool kit for use with a conventional manual tube flaring tool, wherein the m~nll~l flaring tool comprises a clamping bar set and a flaring yoke having a pair of spaced-apart hooked legs. In this aspect of the invention, the tool kit comprises a cylindrical pilotless forging die having a drive end, a swaging end, a circular cross section and a forming cavity in the 25 swaging end. A saddle collar is also provided. The saddle collar has an inside diameter which is a first sliding fit ~limen~ion over the forging die and an outside diameter which is larger than a width of the clamping bar. The outside diameter of the collar is a second sliding fit dimension inside the spaced-apart legs of the yoke. The saddle collar further has a pair of tabs spaced apart a third sliding fit dimension over the width of the clamping bar.
In accordance with yet another aspect of the tool kit for use with a 5 conventional m~nl~l tube flaring tool, the saddle collar has a gauge incorporated therein for measuring a length of tube extending from the clamping bar set. This gauge is also usable according to the aforesaid manner for preventing defects in a swaged tube end.
In yet a further aspect of the present invention there is provided a new l o method for m~ml~lly swaging a high-pressure releasable fitting on a tube endusing a round pilotless punch bar having a first die in a first end thereof. Themethod comprises the steps of:
A) enclosing a tube in a pair of clamping blocks;
B) positioning the tube in the clamping blocks and exposing a tube end portion of the tube beyond a surface of the clamping blocks while g~llging the length of the tube end portion according to an ideal dimension of a comparative-type standard;
C) forcibly retaining the clamping blocks in a vise;
D) fittingly enclosing the clamping blocks inside an annular collar;
20 E) fittingly enclosing a hollow bushing inside the annular collar, and against the surface of the clamping blocks;
F) fittingly inserting the punch bar inside the hollow bushing while guiding the punch bar along an engagement dimension in the hollow bushing which is at least as long as the length of the tube end portion; and G) striking the punch bar with a hammer for working the first die cavity onto the tube end for forming a fitting on the tube end.
The method described above is particularly advantageous for swaging a high-pressure releasable fitting on a tube end using common workbench tools available in most automotive garages. The fittings formed by this method are known to have an ideal shape and for being concentric with the 5 axis of the tube.
Other advantages of the tool kits of the present invention comprise the facts that the tool kits contain a small number of pieces, are relatively inexpensive to m~nllf~cture and are easy to use.
BRIEF DESCRIPTION OF THE DRAWINGS
Two embo-liment~ of this invention are illustrated in the accompanying drawings, in which like numerals denote like parts throughout the several views, and in which:
FIG. 1 is a perspective exploded view of a tool kit according to a first preferred embodiment of the present invention;
15 FIG. 2 is a side view of a swaged tube end of a first type;
FIG. 3 is a side view of a swaged tube end of a second type;
FIG. 4 is a partial cross-section view of a first end of a first punch bar usable with the tool kit according to the first preferred embodiment for swaging a tube end of the second type;
~0 FIG. 5 is a partial cross-section view of a second end of the first punch barillustrated in FIG. 4;
FIG. 6 is a partial cross-section view of a first end of a second punch bar usable with the tool kit according to the first preferred embodiment for swaging a tube end of the first type;
FIG. 7 is a side view of the clamping blocks and centering bushing, illustrating a method for positioning of a tube in the clamping blocks;
FIG. 8 is a partial cross-section of the tool kit of the first preferred embodiment, illustrating the swaging of the tube end for reducing the diameter of the tube end;
FIG. 9 is another partial cross-section of the tool kit of the first preferred embodiment, illustrating the formation of a bead on a tube end;
FIG. 10 is a cross-section view of the clamping blocks with a tube end therein, illustrating the flaring of the tube end;
FIG. 11 is perspective view of a partial manual tool kit according to a second preferred embodiment of the present invention;
FIG. 12 is a cross-section view through the flaring yoke of the tool kit of the second preferred embo-liment, illustrating the saddle collar of the tool kit as seen along line 12-12 in FIG. ll;
FIG. 13 is a cross section view through a first forming die usable with the tool kit of the second preferred embodiment;
FIG. 14 is a cross section view through a second forming die usable with the tool kit of the second preferred embodiment;
FIG. 15 is a cross section view through a third forming die usable with the tool kit of the second preferred embo-liment;
FIG. 16 is a cross section view through the saddle collar usable with the tool kit of the second preferred embodiment as seen along line 16-16 in FIG. 12;
FIG. 17 is a plan view of the clamping bar set and saddle collar usable with the tool kit of the second prefel,ed embodiment in a position for g~llging a proper length of a tube end to be formed.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
While this invention is susceptible of embodiment in many different forms, there are shown in the drawings, and will be described in details herein two specific embodiments, with the understanding that the present disclosure is to be considered as an example of the principles of the 15 invention and is not intended to limit the invention to the embodiments illustrated.
There is illustrated in FIGS. 1-10 a first flaring tool kit according to a first preferred embodiment of the present invention. There are also illustrated two types of typical swaged tube ends formable using the tool 20 kits of the preferred embodiments. FIGS. 7-10 in particular illustrate a preferred method of operation of the tool kit of the first preferred embodiment.
The flaring tool kit of the first preferred embodiment comprises a pair of semicircular clamping blocks 20,20' cooperatively forming a chuck 25 enclosing the tube to be formed. Each of the clamping blocks 20-20' has a flat portion along a segment thereof such that both blocks 20,20' are forcibly retainable against one-another in a common shop vise 22 for example, for filmly clamping a tube 24 to be swaged. An ~nn~ r collar 26 is provided and has an inside diameter for precisely sliding over and S enclosing the portion 'B' of the cl~mping blocks 20-20' extending above the vise 22. A cent~ring bushing 28 is further provided for mounting inside the ~nn~ r collar 26, for guiding a first swaging punch 30, also being part of the tool kit of the first preferred embodiment.
The dimension tolerances of, or the interference between, the clamping blocks 20-20', the annular collar 26, the centering bushing 28 and the first punch 30 are selected to constitute therebetween a precision running fit (RC 3) or a close running fit (RC 4) as defined in the American National Standards Institute, ANSI B4.1-1967, R1974, entitled Standard Limits and Fits, such that the punch 30 is kept precisely centred with the 15 axis of the tube to be formed, throughout the forming process.
The first flaring punch 30 usable with the tool kit of the first preferred embodiment consists of an elongated round bar having a tube-swaging cavity on each end thereof as will be explained later. The first punch 30 is preferably used with a protective anvil cap 32, on which a 20 manual hammer may be stricken for forming a flared end on a tube. The anvil cap 32 preferably has a recess in its lower surface for enclosing the drive end of the punch 30 completely, thereby protecting the punch from deformations associated with repeated hammer blows thereon.
The width 'A' of the ~nmll~r collar 26 is sufficient for enclosing the 25 portion 'B' of the clamping blocks extending above the vise 22 and a first shoulder 'C' on the centering bushing 28 extending toward the clamping blocks 20-20' and having an outside diameter similar to the inside diameter of the annular collar 26. For example and for reference purposes only, the dimension 'A' is 0.675 inch (17.1 mm); the dimension 'B' is 0.290 inch (7.3 mm), and 'C' is 0.425 inch (10.8 mm). The height 'D' of the centering bushing extt n~ing above the annular collar 26 hereinafter referred to as the 5 depth gauge 'D' is selected to correspond to the required length of tube extending above the clamping blocks 20,20' prior to swaging the tube end.
The depth gauge 'D' on the centering bushing 28 is therefore usable as a gauge or a standard for properly positioning the tube 24 in the clamping blocks 20-20' and for ensuring that the proper amount of material extends o above the clamping blocks 20-20' for forming a quality bead. This is one of the most important features, basically, to ensure that the tube end formed with the tool kit of the first preferred embodiment has a consistent quality.
Furthermore, the engagement of the punch bar 30 inside the centering bushing is at least a minimllm dimension corresponding to the 15 length of tube extpn~ling above the clamping blocks. It has been found that this minimum engagement dimension is required for ensuring that the punch bar remains in proper alignment with the axis of the tube. This minimum engagement of the punch bar inside the centering bushing is another most important feature to ensure that the tube end formed with the 20 tool kit is concentric with the axis of the tube.
Typical tube ends which are formable with the tool kits of the present invention are illustrated for reference purposes in FIGS. 2 and 3.
These tube ends are used in the automotive industry on gas lines, sending units of gasoline tanks and power steering hydraulic piping systems. The 25 first illustrated tube end 40 has a relatively long stem extending between a bead 42 and the end of the tube, and tapering down slightly at the open end of the tube. This type of tube end 40 is referred to in the industry as a high-pressure-clip fitting. The outside diameter of the stem 'E' is generally similar to the nominal outside diameter of the tube.
The second illustrated common tube end 44 is referred to in the 5 industry as a high-pressure-flare fitting. It has a relatively short stem witha diameter 'F' being smaller than the nominal tube size 'G'. The open end 46 of the tube is flared outwardly and has an O-ring 48 mounted thereon next to the bead 50. A first typical diameter 'F' of the stem is 5/16 inch (7.9 mm), for a nominal tube size 'G' of 3/8 inch (9.5 mm). A second lO typical diameter 'F' of the stem is 1/4 inch (6.35 mm), for a nominal tube size 'G' of 5/16 inch (7.9 mm).
The tube end of the first type 40 is formable in a single step with a second punch 60 having a straight cylindrical cavity 62 as partly illustrated in FIG. 6. The tube end of the second type 44 is formable in four steps as 15 illustrated in FIGS. 7-10. A first step is to properly position the tube end into the clamping blocks 20-20' as illustrated in FIG. 7, while using the dimension 'D' on the centering bushing 28 to properly gauge a length of tube 24 extending above the clamping blocks 20,20'. A second step is to reduce the diameter of the tube end using a first punch end 52 having a 20 tapering cavity 54 such as illustrated in FIG. 4. A third step comprises the forming of the bead 50 on the end of the tube using a second punch end 56 having a relatively shallow cylindrical cavity 58, with a depth equivalent to the length of the stem portion of the fitting 44. A fourth step comprises the flaring of the tube end using a pointed tool 64.
It will be appreciated that the forging cavities 54 and 58 are normally formed on respective ends of the first punch bar 30 such that a single punch bar is comprised in the tool kit of the first preferred embodiment for each size and type of tube fitting formable with a 5 particular kit. The swagg of the tube end with the first and second punch ends is effected by striking the punch bar with a common manual ball-peen hammer.
The outward flaring of the open end 46 of the fitting of the second type is done by working a pointed rod 64 in the open end 46 of the tube 24 lo with a hammer or by hand by swaying the rod sideways and around the axis of the tube. The pointed rod 64 is also used as a handle that is preferably insertable in a hole 66 extending diametrically through the first punch bar 30 as illustrated in FIG. 1, for working the first punch bar 30 loose from a formed tube end.
While the depth gauge 'D' on the centering bushing 28 has been described for use with the first punch bar 30, it will be appreciated that a second centering bushing (not shown) with a second depth gauge incorporated therein is preferred for use with the second punch 60 for forming a tube end of the first type 40. It will also be appreciated that a 20 separate centering bushing having a distinct dimension 'D' and distinct identification marks is preferably supplied for each size and type of tube end formable with a particular kit.
The aforesaid method has been found particularly efficient for manufacturing flared tube ends of consistent precision and quality on 25 copper, alu~ ~-u--l and steel tubing. It has also been found that the tool kit of the first pre~ d embodiment is usable for forming a flared tube end in less than a couple of minutes (in less than one minute for the experienced person) with few hammer blows using a common ball-peen h~mmer. The tool kit of the preferred embodiment is particularly useful to mechanics epailillg late model vehicles having the flared tube ends described herein.
Referring now to FIGS. 11-15, the tube flaring tool kit according to 5 a second preferred embodiment of the invention is illustrated therein. The flaring tool kit according to the second preferred embodiment is usable with a conventional tube-clamping-bar set 80 and a m~ml~l flaring yoke 82.
The flaring yoke 82 of the conventional type has a pair of hooked legs 84,84' spaced apart a distance which is slightly larger than the width of the o clamping bar set 80 as is customary with these tools. The tool kit of the second preferred embodiment comprises a first and second forming dies 86,88 having respectively a tapering cavity 90 and a bead-forming cavity 92 for forming a flared tube end of the second type 44 as illustrated in FIG.
3. Similarly, a single forming die 94 having a deep tapering cavity 96 is 15 required for forming the flared tube end of the first type 40 as illustrated in FIG. 2. Each of forming dies 86,88,94 has a cylindrical shape and a dimple 98 on its upper end for receiving the rounded tip 100 of a screw press 102 on the m~n~l~l flaring yoke 82.
The tool kit of the second preferred embodiment also comprises a 20 saddle collar 104 having an inside diameter of appropliate dimensions for precisely sliding over each of the cylindrical forming dies 86,88,94. The saddle collar 104 has an outside diameter which is slightly larger than the width of the clamping bar set 80, and which is preferably sized for providing a precise sliding flt between the hooked legs 84,84' of the yoke.
25 The sliding fits mentioned herein are similar to those specified earlier when describing the tool kit of the first preferred embodiment.
The saddle collar 104 also has a first diametrical slot 106 across the lower surface thereof. The slot 106 has a width substantially the same as the width of the clamping bar set 80 such that it is precisely mountable astride over the cl~mping bar set 80. The first diametrical slot 106 defines a pair of tabs 108,108' extending downward on both sides of the clamping bar set 80 when the saddle collar is positioned on the clamping bar set and is centred with a tube to be flared.
A thickness 'H' of the saddle collar 104 is preferably equivalent to the length of tube required for forming the flared end, such that the collar lo is usable as a standard for properly positioning the tube in the clamping bar set 80.
The purpose of the first diametrical slot 106 and of both tabs 108,108' is for keeping the saddle collar 104 centred about the tube to be formed, and for preventing both legs 84,84' of the yoke 82 from moving along the clamping bar set 80, or from tilting sideways during the forming of the flared tube end.
In use, a tube is secured in the clamping bar set 80; the saddle collar 104 is placed over the bar set and moved against the tube for g~lging a length of tube extending from the bar set. In case of a tube end of the first type 40, the height 'J' of the third die member 94 is used as a gauge for measuring the tube end protruding above the clamping bar set 80. For a tube end of the second type 44 as illustrated in FIG. 3, the saddle collar 104 is placed against the tube 114 for precisely measuring the portion of the tube ext~n~ing above the bar set 80, and for properly clamping the tube 114, as illustrated in FIG. 17. The tapering die 86 is then placed over the end of the tube, and into the saddle collar 104. The flaring yoke 82 is positioned on the clamping bar set 80 with one leg on each side of the saddle collar 104 and in ~imnlt~neous contact with the clamping bar set 80 and the saddle collar 104. Then, the screw press 102 of the m~m1~l flaring yoke 82 is actuated for pushing the tapering die 86 against the tube end for 5 swaging the tube end. The tapering die 86 is then replaced by the bead-forming die 88 and the screw press 102 is worked again for forming the bead 50 on the tube end 44.
The saddle collar 104 further has a second diametrical slot 110 lo inside and parallel to the first diametrical slot 106. When the saddle collar 104 is installed over the clamping bar set 80, the second slot 110 constitutes a window for monitoring a proper formation of the bead 50 on the tube end.
In the m~nll~l flaring tool illustrated herein, the flaring yoke 82 is IS centred transversally relative to the bar set 80 by twisting the tool and placing both legs 84,84' against a respective side of the bar set 80. The flaring tool 82 is centred longit~l-lin~lly relative to the bar set 80 by havingboth legs 84,84' in contact with the saddle collar 104.
The use of a saddle collar 104 in combination with a cylindrical forging die 86 ensures that the flaring yoke 82 is properly and rigidly aligned with the tube 114 to be formed, along a longih~-lin~l and transversal axis of the clamping bar set 80. In this arr~ngem~nt, both legs 84,84' of the yoke 82 are held into a pair of notches 116,116' defined by the saddle collar 104 and the sides of the clamping bar set 80. Because these notches 116,116' have the thickness of the bar set 80 plus the thickness 'H' of the saddle collar 104, the flaring yoke 82 is held in a stable and positive manner against movement along the cl~mping bar set 80, as well as against tilting relative to the axis of the tube to be formed 114. Further, when pressure is applied on the screw press 102, the friction of the hooked legs 84,84' against the underside of the clamping bar set 80 prevents the saddle collar 104 from moving along the bar set 80. Thus, the interlocking 5 arrangement ofthe saddle collar 104 with the flaring yoke 82 and with the clamping bar set 80 m~int~in the screw press 102 centred with the axis of the tube 114. This is one of the main reasons, basically, that the swaged tube ends forged with the tool kit of the second preferred embodiment have a consistent precision and quality.
A last step in forming the flared tube end of the second type as illustrated in FIG. 3, is to enlarge the end of the tube at 46. The handle 112 of the m~n~l screw press 102 advantageously has a pointed end 118 for working the tube end 46 as previously explained.
While two embo-limçnt.c of the present invention have been illustrated in the accompanying drawings and described hereinabove, it will be appreciated by those skilled in the art that various modifications, alternate constructions and equivalents may be employed without departing from the true spirit and scope of the invention. Therefore, the above 20 description and the illustrations should not be construed as limiting the scope of the invention which is defined by the appended claims.
Claims (20)
1. A tool kit for manually swaging a tube end, comprising:
a pair of semicircular clamping blocks cooperatively forming a chuck for clamping a tube; said chuck having an outside diameter;
a centering bushing having a central opening therein and an outside surface comprising a first cylindrical section having a first diameter and a second cylindrical section having a second diameter and being contiguous with said first cylindrical section; said first diameter being similar to said outside diameter of said chuck;
an annular collar having an inside diameter substantially similar to said outside diameter and said first diameter for mounting over said outside diameter, and a width for simultaneously enclosing a portion of said clamping blocks and said first cylindrical section when said centering bushing is positioned adjacent said chuck, for centering said centering bushing with said chuck;
a round punch bar mountable inside said central opening in said centering bushing, said punch bar having first and second extremities, and a first pilotless swaging die in said first extremity for swaging a tube end; and a gauge incorporated into said centering bushing and having a dimension corresponding to a required length of a tube end protruding from said chuck prior to swaging said tube end;
such that said gauge is readily usable for positioning a tube end in said chuck, said centering bushing and said annular collar are cooperatively usable for aligning said punch bar along an axial axis of said tube end and said punch bar is workable with a manual hammer for swaging said tube end in a precise and consistent manner.
a pair of semicircular clamping blocks cooperatively forming a chuck for clamping a tube; said chuck having an outside diameter;
a centering bushing having a central opening therein and an outside surface comprising a first cylindrical section having a first diameter and a second cylindrical section having a second diameter and being contiguous with said first cylindrical section; said first diameter being similar to said outside diameter of said chuck;
an annular collar having an inside diameter substantially similar to said outside diameter and said first diameter for mounting over said outside diameter, and a width for simultaneously enclosing a portion of said clamping blocks and said first cylindrical section when said centering bushing is positioned adjacent said chuck, for centering said centering bushing with said chuck;
a round punch bar mountable inside said central opening in said centering bushing, said punch bar having first and second extremities, and a first pilotless swaging die in said first extremity for swaging a tube end; and a gauge incorporated into said centering bushing and having a dimension corresponding to a required length of a tube end protruding from said chuck prior to swaging said tube end;
such that said gauge is readily usable for positioning a tube end in said chuck, said centering bushing and said annular collar are cooperatively usable for aligning said punch bar along an axial axis of said tube end and said punch bar is workable with a manual hammer for swaging said tube end in a precise and consistent manner.
2. The tool kit as claimed in claim 1, wherein each of said clamping blocks has a flat portion along a segment thereof such that both said blocks are forcibly retainable against one-another in a common shop vise, for firmly clamping a tube.
3. The tool kit as claimed in claim 1, wherein said semicircular clamping blocks, said centering bushing and said annular collar have a first common interference selected amongst a precision running fit and a close running fit.
4. The tool kit as claimed in claim 3, wherein said centering bushing and said round punch bar have a second common interference selected amongst a precision running fit and a close running fit.
5. The tool kit as claimed in claim 1, wherein said gauge is a comparative-type standard incorporated in an outside surface of said centering bushing.
6. The tool kit as claimed in claim 5, wherein an engagement of said punch bar in said centering bushing is at least said dimension of said gauge.
7. The tool kit as claimed in claim 1, further comprising a cap member having a cavity for enclosing a portion of said round punch bar, for protecting said round punch bar.
8. The tool kit as claimed in claim 1, further comprising a pointed rod, and said round punch bar has a hole through a diameter thereof, and said pointed rod is insertable in said hole.
9. The tool kit as claimed in claim 1, wherein said round punch bar has a second swaging die in said second extremity thereof.
10. A tool kit for use with a conventional manual tube flaring tool for swaging a tube end, said manual flaring tool comprising a clamping bar set having a width and a flaring yoke having a pair of hooked legs spaced apart a distance larger than said width; said flaring tool kit comprising:
a swaging die having a drive end, a swaging end, a circular cross section, a forming cavity in said swaging end; and a saddle collar having an inside diameter being a first sliding fit dimension over said circular cross section of said swaging die and an outside diameter being larger than said width of said clamping bar, said outside diameter being a second sliding fit dimension inside said legs of said yoke; said saddle collar further having a pair of tab spaced apart a third sliding fit dimension over said width of said clamping bar;
such that when said saddle collar is adapted to be mounted on said clamping bar with said tabs extending astride said clamping bar, and when said flaring yoke is adapted to be mounted on said clamping bar astride said collar, said flaring yoke is restrainable in a pair of notches defined by said clamping bar set and said saddle collar, in a fixed position and alignment relative to said collar.
a swaging die having a drive end, a swaging end, a circular cross section, a forming cavity in said swaging end; and a saddle collar having an inside diameter being a first sliding fit dimension over said circular cross section of said swaging die and an outside diameter being larger than said width of said clamping bar, said outside diameter being a second sliding fit dimension inside said legs of said yoke; said saddle collar further having a pair of tab spaced apart a third sliding fit dimension over said width of said clamping bar;
such that when said saddle collar is adapted to be mounted on said clamping bar with said tabs extending astride said clamping bar, and when said flaring yoke is adapted to be mounted on said clamping bar astride said collar, said flaring yoke is restrainable in a pair of notches defined by said clamping bar set and said saddle collar, in a fixed position and alignment relative to said collar.
11. The tool kit as claimed in claim 10, wherein said flaring tool comprises a screw press having a rounded tip, and said swaging die has a dimple in said drive end for engagement with said rounded tip.
12. The tool kit as claimed in claim 11, further comprising a handle bar for actuating said screw press, and said handle bar has a pointed end which is usable for flaring a tube end.
13. The tool kit as claimed in claim 10, wherein said saddle collar has window means for visually monitoring a formation of a bead on a tube end.
14. The tool kit as claimed in claim 10, wherein said tabs define a first diametrical slot across a surface of said saddle collar, and said window means is a second diametrical slot inside said first diametrical slot.
15. The tool kit as claimed in claim 10, wherein said saddle collar has a gauge incorporated therein for measuring a length of tube extending from said clamping bar set.
16. The tool kit as claimed in claim 10, wherein said flaring yoke and said saddle collar have a first common interference, and said saddle collar and said clamping bar set have a second common interference, and said first and said second common interferences are selected amongst a precision running fit and a close running fit.
17. A method for swaging a high-pressure releasable fitting on a tube end using a round punch bar having a first pilotless die cavity in a first end thereof, said method comprising the steps of:
enclosing a tube in a pair of clamping blocks;
positioning said tube in said clamping blocks and exposing a tube end portion of said tube beyond a surface of said clamping blocks while gauging a length of said tube end portion according to an ideal dimension of a comparative-type standard;
fittingly enclosing said clamping blocks inside an annular collar;
fittingly enclosing a hollow bushing inside said annular collar, and against said surface of said clamping blocks;
fittingly inserting said punch bar inside said hollow bushing while guiding said punch bar along an engagement in said hollow bushing which is at least as long as said length of said tube end portion; and striking said punch bar with a hammer for working said first die cavity onto said tube end and for forming said fitting;
such that said fitting is formable with manual tools, has an ideal shape and is concentric with an axis of said tube.
enclosing a tube in a pair of clamping blocks;
positioning said tube in said clamping blocks and exposing a tube end portion of said tube beyond a surface of said clamping blocks while gauging a length of said tube end portion according to an ideal dimension of a comparative-type standard;
fittingly enclosing said clamping blocks inside an annular collar;
fittingly enclosing a hollow bushing inside said annular collar, and against said surface of said clamping blocks;
fittingly inserting said punch bar inside said hollow bushing while guiding said punch bar along an engagement in said hollow bushing which is at least as long as said length of said tube end portion; and striking said punch bar with a hammer for working said first die cavity onto said tube end and for forming said fitting;
such that said fitting is formable with manual tools, has an ideal shape and is concentric with an axis of said tube.
18. The method as claimed in claim 17, further comprising the step of covering an end of said round punch bar before striking said round punch bar.
19. The method as claimed in claim 17, wherein said round punch bar has a second die cavity in a second end thereof and said method comprises the step of turning said punch bar end to end and working said second die cavity onto said tube end.
20. The method as claimed in claim 17, further comprising the step of forcibly retaining said clamping blocks in a vise.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2223298 CA2223298A1 (en) | 1997-12-02 | 1997-12-02 | Tool kit and method for swaging and flaring metal tubes |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2223298 CA2223298A1 (en) | 1997-12-02 | 1997-12-02 | Tool kit and method for swaging and flaring metal tubes |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2223298A1 true CA2223298A1 (en) | 1999-06-02 |
Family
ID=29275325
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2223298 Abandoned CA2223298A1 (en) | 1997-12-02 | 1997-12-02 | Tool kit and method for swaging and flaring metal tubes |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2223298A1 (en) |
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN111822603A (en) * | 2020-06-09 | 2020-10-27 | 中国空气动力研究与发展中心设备设计及测试技术研究所 | Flaring device of building accessory |
| CN112658086A (en) * | 2020-11-10 | 2021-04-16 | 中国航发贵州黎阳航空动力有限公司 | Machining method and device for engine part with flanging bushing |
| CN115245998A (en) * | 2022-06-14 | 2022-10-28 | 攀钢集团攀枝花钢铁研究院有限公司 | Alloy forming method for hollow air valve |
-
1997
- 1997-12-02 CA CA 2223298 patent/CA2223298A1/en not_active Abandoned
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN111822603A (en) * | 2020-06-09 | 2020-10-27 | 中国空气动力研究与发展中心设备设计及测试技术研究所 | Flaring device of building accessory |
| CN112658086A (en) * | 2020-11-10 | 2021-04-16 | 中国航发贵州黎阳航空动力有限公司 | Machining method and device for engine part with flanging bushing |
| CN115245998A (en) * | 2022-06-14 | 2022-10-28 | 攀钢集团攀枝花钢铁研究院有限公司 | Alloy forming method for hollow air valve |
| CN115245998B (en) * | 2022-06-14 | 2024-05-17 | 攀钢集团攀枝花钢铁研究院有限公司 | Alloy forming method for hollow air valve |
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