Abstract: A method of manufacturing a panel assembly includes supporting the panel assembly in a free state using a holding fixture. The panel assembly has a skin panel, and sacrificial material coupled to a skin panel inner surface. The method includes acquiring a free state outer surface contour of the panel assembly by scanning a skin panel outer surface while the panel assembly is supported by the holding fixture. The method also includes developing a numerically controlled (NC) machining program having cutter paths configured for machining the interface locations to an inner surface contour that reflects nominal thicknesses of the panel assembly based off of the free state outer surface contour. In addition, the method includes machining the sacrificial material at the interface locations by moving a cutter along the cutter paths while the panel assembly is supported by the holding fixture.

Abstract: Tools for crimping or cutting of an object such as a wire, cable, or connector. The tool includes a first member and a second member configured to come together through a gap to crimp or cut a wire, cable or connector and a laser positioned to visually indicate a region where at least one member traverses as the first and second member come together through the gap. This visual indication aids in alignment of the object for the crimping or cutting operation.

Abstract: A welding electrode and a method of using the welding electrode for resistance spot welding are disclosed. The welding electrode includes a body and a weld face. The weld face includes a central dome portion and a shoulder portion that surrounds the central dome portion and extends from an outer circumference of the weld face upwardly and radially inwardly to the central dome portion. The central dome portion has a series of radially-spaced ringed ridges that project outwardly from a base dome face surface. The series of radially-spaced ringed ridges on the central dome portion includes an innermost ringed ridge and an outermost ringed ridge. The outermost ringed ridge on the central dome portion has a radial inner side surface and a radial outer side surface. The radial outer side surface extends below the base dome face surface down to the shoulder portion of the weld face.

Abstract: A tool for repairing an interior surface of a conductor tube comprises an elongate body having a proximal end and a distal end. The tool includes a profiled end surface that mates into the interior surface of the conductor tube. The tool includes a central protrusion that extends from the profiled end surface for aligning the tool within the internal passageway of the conductor tube. An imparted force is exerted on the proximal end and the force reshapes the interior surface of the conductor tube around the profiled end surface.

Abstract: Methods of thermo-mechanically processing a preform composed of tool steel and tools to modify a workpiece. The preform has a region containing austenite. The method comprises establishing the region at a process temperature between a martensitic start temperature and a stable austenitic temperature. While at the process temperature, the region is deformed to change an outer dimension and to modify the microstructure to a depth of 1 millimeter or more. The tool comprises a member composed of tool steel. The member includes a first region that extends from the outer surface to a depth of greater than 1 millimeter and a second region. The first region includes a plurality of grains having an average misorientation angle greater than about 34°, an average grain size that is at least 10% smaller than the second region, and has a different grain orientation than the second region.

Abstract: Provided are a bending die having surface microstructures and a bending punch thereof applicable to stamping processing to bend a blank to form a shape. The bending die includes a lower die, an upper die, and a workpiece placing piece. The lower die includes a die, and the die includes a forming surface. The upper die includes a bending punch, the bending punch stamps a blank placed on the die in a back and forth stroke, and the bending punch includes a working portion coming into contact with the blank during stamping. The workpiece placing piece is disposed between the upper die and the lower die and used to position or/and press the blank placed on the die. A plurality of microstructures are disposed on the forming surface and/or on the surface of the working portion.

Abstract: A forming die apparatus includes a first die on which a die surface is formed and a second die for pressing a workpiece placed on the first die. At least one of the first die and the second die is configured by assembling a plurality of die members. Each die member has a concave side surface facing another die member.

Abstract: A movable die component for a press device includes a plate body having a workpiece engagement surface configured to engage a workpiece formed by the press device. The plate body has a plurality of internal pockets completely enclosed by the plate body. Optionally, the plate body may be formed by an additive manufacturing process, such as by forming a plurality of direct metal laser sintering layers. The direct metal laser sintering layers may include a lower layer, a plurality of middle layers, and an upper layer with the internal pockets being provided in the middle layers, and with the lower layer covering a bottom of each internal pocket and the upper layer coving a top of each internal pocket.

Abstract: A knockout has a support surface and the support surface has: (i) a first knockout outer diameter capable of supporting the first inner diameter of a container side wall when the knockout is inserted into an opening of the metal container and when the metal container is being necked with a necking die; and (ii) a second knockout outer diameter capable of supporting the second inner diameter of the container side wall when the knockout is inserted into the opening of the metal container and when the metal container is being necked with the necking die, and wherein the first knockout outer diameter is larger than the second knockout outer diameter.

Abstract: The invention relates to a press hardening tool having a shaping surface (2) that is used to shape a blank. The shaping surface (2) of the tool (1) is micro-structured at least in some areas by micro-recesses (3) introduced into the shaping surface (2). In said areas, the contact surface between the shaping surface (2) of the tool (1) and the surface of a blank is limited to the surface portions (4) located between the recesses (3) of the forming surface (2) and raised with respect to the recesses (3).

Abstract: Provided is a tooling system for use in an associated press comprising a lower tool shoe, an upper tool shoe, a first set of tooling plates, and a second set of tooling plates. The lower tool shoe comprises an upwardly facing surface, part of a shoe locator set defining an axis of elongation, a first locator element defining an axis of elongation, and an offset second locator element defining an axis of elongation. The upper tool shoe comprises a downwardly facing surface, part of a shoe locator set defining an axis of elongation, a first locator element defining an axis of elongation, and an offset second locator element defining an axis of elongation. The first set of tooling plates comprises a first lower tooling plate and a first upper tooling plate. The second set of tooling plates comprises a second lower tooling plate and a second upper tooling plate.

Abstract: A bending die having a first bending surface and a second bending surface that is rotatable with respect to the first bending surface. The second bending surface rotates with respect to the first bending surface during a bending operation. The first bending surface is engagable with a workpiece during the bending operation to bend a first portion of the workpiece. The second bending surface is engagable with the workpiece during the bending operation to bend a second portion of the workpiece. The first portion of the workpiece and the second portion of the workpiece are disposed on a first side of a bend line formed by the bending operation.

Abstract: In one aspect, an apparatus for manufacturing a framing member can include a translation path for transporting a metal sheet. The translation path can include a translation axis, a first set of rollers, which can include a plurality of first bottom rollers and a plurality of first top rollers, the first set of rollers can have a first centerline, and a second set of rollers, which can include a plurality of second bottom rollers and a plurality of second top rollers, the second set of rollers can have a second centerline, line, where the first centerline and the second centerline can extend away from the translation axis at an angle in the direction of translation.

Abstract: Bucking bar devices, and methods of assembling bucking bars devices, for use in riveting parts together are described. In one example embodiment, the bucking bar device includes a bucking bar and a sleeve positioned so that the bucking bar extends within the sleeve. One end of the sleeve is configured to be positioned adjacent to at least one of the parts.

Abstract: A method is provided for making a composite part layup tool. A surface of a base is shaped and used as a tool to incrementally form a metal sheet. The formed metal sheet is friction plug welded to the shaped surface on the base to form a metal tool surface of the layup tool.

Abstract: In a crossbow-style tube bender, a curved bending mandrel having a channel into which the tube in bent to form the bent tubing length has at least one relief surface forming a localized recess or depression in the surface of the channel. A forming bar or cross bar adapted to cooperate with a bending mandrel has on a first side of the forming bar a least one first pair of forming mandrels configured for a first tubing size, and on a second side of the forming bar has at least one second pair of forming mandrels configured for a second tubing size. The bender has a quick connect-disconnect mechanism permitting quick disconnection from and connection to the forming bar to utilize either the at least one first or at least one second pairs of forming mandrels.

Abstract: Described are embodiments of a portable crimping device for creating frame assemblies. The device includes in embodiments a rod that is movable from a first position to a second position. A head is connected to the rod, and a stud is connected to the head. When the rod is moved from the first position to the second position the stud engages a rail of a frame and deforms a portion of the rail, which secures a bracket in a channel of the rail. A second rail can then be secured to a second side of the bracket in a similar way to create a corner of a frame. The process can be repeated to generate an enclosed frame assembly for holding items such as photovoltaic panels.

Abstract: A manufacturing method for appropriately manufacturing an arc-shaped rail that is C-shaped in cross section includes: a first process of forming one side wall 313 and one of circumferential wall portions 312 by bending a ring R of a thin metal plate by spinning, the circumferential wall portions 312 being portions on both sides of a width direction of the inner circumferential wall or the outer circumferential wall divided by a slit 314; a second process of forming the other side wall 313 and the other circumferential wall portion 312 by spinning using a plurality of cores 41 to 43 so as to envelop the cores 41 to 43, the cores 41 to 43 being obtained by dividing a core in a width direction to not more than a width of the slit 314; and a third process of separately extracting the cores 41 to 43 from the slit 314.

Abstract: A swaging press (30) includes a piston member (16) and a plurality of die shoes (18), the piston member (16) in use driving the die shoes (18) inwardly during a swaging process in response to axial movement of the piston member (16), the piston member (16) having a recess (42) defining a plurality of substantially flat die shoe engaging surfaces (31) configured to provide a polygonal shape in transverse cross-section, each die shoe (16) being located at each corner (32) of the polygonal shape whereby a portion of each die shoe (16) engages a corresponding die shoe engaging surface (31) on either side of the corner (32).

Abstract: A punch for forming opposite ends of a copper tube into a T includes a tapered or shovel-nose such that the spacing between the ends of the opposed punches is reduced, thereby reducing the excess copper remaining in the T once formed. A method of forming the fitting employs the shovel-nose punches in a hydro-forming process to accommodate such results.

Abstract: A die includes upper contacts, lower contacts and conductive elements. The upper contacts are formed on an upper face of the die. The upper contacts include a non-connected upper contact and connected upper contacts. The lower contacts are formed on a lower face of the die. The lower contacts include a non-connected lower contact and connected lower contacts. Each of the conductive elements connects a related one of the connected upper contacts to a related one of the connected lower contacts.

Abstract: A die element configuration for use in a swaging or crimping press includes at least two cooperating die elements that, in use, are radially moved inwardly during a swaging or crimping process. Each die element has a body portion with a work element engaging surface located at a radially inner location on the body portion, the work element engaging surface having an axial direction and a circumferential direction transverse to the axial direction with the work engaging surface being concavely curved in the circumferential direction. The work engaging surface has a first central section extending axially with at least a pair of axially spaced first lateral sections and at least one second lateral section extending from the first central section oppositely to the first lateral sections, whereby a first lateral section of a first die element in the configuration is located axially adjacent a second lateral section of a second similarly formed die element.

Abstract: A fastener installation tool including an anvil member having a swage cavity, a collet having a pull section with a fastener engagement end and a plurality of teeth, and an anvil member. The plurality of teeth includes a first tooth with a first inner diameter, and each of the remainder of teeth includes a second inner diameter, the first inner diameter being greater than the second inner diameter. The collet has a protrusion extending the length of the pull section to increase the contact area with the anvil member. The anvil member includes a swage cavity with an entrance section, a swage land located adjacent to the entrance section, and an inner bore located adjacent to the swage land.

Abstract: A punch for use in molding a workpiece with lubricating oil interposed between the punch and the workpiece includes a straight portion at its end and a diameter-increasing portion. The straight portion includes an end face at its end and a side face. The straight portion extends in an axial direction. The end surface extends in a radial direction perpendicular to the axial direction. The side surface is connected to the end surface. The diameter-increasing portion is connected to the straight portion. The diameter-increasing portion includes a width in the radial direction, which is identical to that of the straight portion, at a junction between the straight portion and the diameter-increasing portion. The width of the diameter-increasing portion in the radial direction increases with distance from the straight portion. At least one of the end surface and the side surface of the straight portion is formed with a pit.

Abstract: A stake punch for securing a pin in a gearset is provided. The stake punch includes a body defining an axis and a punch extending from the body along the axis. The punch includes a pair of opposing top and bottom surfaces, an end face, and a pair of stake faces each connected to the end face. The stake faces each have a curved surface extending between the top surface and bottom surface. The curved surface has a constant radius of curvature along a length of the stake face. The pair of stake faces are at an angle with respect to the axis.

Abstract: A method of forming a pin adapted to be used in a PGA joint, and a flattening head used to perform the method. The method includes: providing a pin blank; and forming a pin head by coining an end of the pin blank using a flattening head thereby forming the pin, the pin having a pin stem and the pin head attached to the pin stem, the flattening head being shaped to impart a topography to an underside surface to the pin head that is non-smooth during coining, the topography being adapted to allow gases to escape from a pin-attach solder disposed adjacent to the underside surface.

Abstract: The fastener of this application is designed to facilitate the insertion of rotating power driven tools into the fastener recess. The recess of this fastener generally uses spirally configured driving surfaces and is formed in a counterbore in the upper surface of the fastener. The driving lobes have upper surfaces that are depressed a distance into the counterbore. A ramp surface is formed on each of the upper surfaces that causes a spinning bit to fall into the recess in an engaged manner. The ramp surfaces are constructed with both removal and installation ramp portions.

Abstract: A self-attaching fastener and panel assembly wherein the free end of the tubular barrel portion is coined and deformed axially and radially outwardly against a planar die face into an annular shape having a planar annular bearing surface supporting the panel and a flat end face. The die includes a central post and an annular planar die surface extending substantially perpendicular to the longitudinal axis of the die member. The method of installation includes coining and deforming the barrel portion axially and radially eliminating cracking of the barrel, frictional resistance and hoop-stress.

Abstract: A stapler anvil and method for clinching a staple is disclosed. The anvil includes a body having a well. The well has an axis extending between the legs of a staple and is defined by a first surface having a first portion along which the first leg of the staple is directed as the staple is being clinched, and a second portion extending substantially at an angle relative to the first portion to direct the second leg of the staple at least partially away from the axis as the staple is clinched. The well is further defined by a second surface spaced from the first surface. The second surface is configured to redirect the second leg of the staple at least partially back toward the axis after the second leg has been directed at least partially away from the axis by the second portion of the first surface.

Abstract: The present invention is directed to a one piece sinker reversibly attachable to a fishing line. The sinker is a streamlined, truncated cone shape having a line accepting passage along the center line thereof. The sinker includes line centering surfaces to prevent line twist as the sinker is drawn though water, and a elongated thumb slot for inserting a tool having a length longer than the sinker to allow a user to manually opening the sinker. Also disclosed is a method of making the sinker employing a unique core blade punch for forming the line accepting passage with the sinker jaws having discontinuous but mateable line engaging surfaces.

Abstract: A resinous die for press-shaping a blank material into a desired configuration, which comprises a die member and a mating punch, both having respective shaping portions. Each shaping portion is formed of an epoxy resin layer provided at portions thereof where a relatively low surface pressure is applied, and a plurality of reinforcing pieces provided in an embedded fashion at portions thereof where a relatively high surface pressure is applied, for reinforcing the shaping portion. This arrangement imparts increased durability to the shaping portion and hence the die while keeping the cost of manufacture of the die to a minimum.

Abstract: In the present tool (2) for machining metallic, sheet-type molded parts (4), the tool (2) including at least one component (10-14) for exerting a force, at least one of the components (10-14) of the tool (2) is provided virtually parallel to the force-exertion direction of the component (10-14) with channel-like recesses (20) in a predetermined pattern, the recesses extending at least over a large portion of the length of the component (10-14) and having a predetermined cross section (38). These measures assure a uniform vertical pressure resistance that is attained with a low financial outlay. Consequently, the cost of machining the tool is reduced. The construction outlay can be reduced with simple, derivable construction rules.

Abstract: A precision bucking bar comprising a unitary rigid structure having a bucking surface thereon and a sidewall extending from the bucking surface such that, during a spreading operation, the bucking surface cannot contact the workpiece, thus producing a square butt of uniform thickness and a method for using the same. In another embodiment, the bucking surface is incorporated into a squeeze point for squeezers.

Abstract: Method of producing a contact terminal (1; 17; 18; 35; 36; 60) provided with a least a first contact surface (4; 25; 26; 64) for contacting e.g. a mating contact area (6; 18; 17) including at least the following steps: a) stamping the contact terminal from a) piece of blank having a substantially flat surface with a predetermined first width, said first contact surface (4; 25; 26; 64) being substantially perpendicular to said flat surface; b) pressing said first contact surface (4; 25; 26; 64) against a first, highly polished surface (27; 66) of a support tool (16), said first polished surface (27; 66) having a first predetermined shape; c) exerting a first predetermined force on said contact terminal in order to deform said first contact surface (4; 25; 26; 64) against said first, highly polished surface (27; 66) of said support tool (16), thus polishing said first contact surface.

Abstract: An automobile body repair kit including a first tool adapted for shaping quarter panel, trunk lid lines, and fender lines of the body of the automobile. A second tool is adapted for straightening top edges of a frame of the body of the automobile. A third tool is adapted for removing kinks from inside frame rails of the body of the automobile. A fourth tool is adapted for straightening frame rails of the body of the automobile.

Abstract: A spiral drive system for threaded fasteners includes driver-engageable surfaces on the head end of the fastener in which at least some of the driver-engageable surfaces are defined by a spiral segment configured to maximize torque transmission while spreading the driving load over a broad driver-fastener interface to reduce the risk of development of high stress regions. Drivers and related tooling also are disclosed.

Abstract: The present invention relates to a bucking bar that upsets a shank of a rivet. The bucking bar includes an L-shaped bucking die having a wide section and a thin angular section capable of sliding between an obstacle and the shank. The L-shaped bucking bar consists of Tungsten Carbide. The bucking bar also includes a bucking bar arm coupled to the wide section of the L-shaped bucking die for positioning the thin angular section of the bucking die between the obstacle and the shank of the rivet.

Abstract: An improved bucking tool construction 10 including a generally L-shaped main tool body unit 11 having opposite ends 22, 23, and a pair of replaceable impact surface units 12 removably disposed on the opposite ends 22, 23 of the tool body unit 11. The tool body unit 11 is fabricated with a material 21 which is softer than the material 32 from which the impact surface units 12 are fabricated.

Abstract: A solid-steel anvil of symmetrical configuration, having a top head, depending intermediate web and a base, and with the anvil being of light weight that a person can manipulatively grasp the anvil's top head with one hand to easily carry the anvil with his grasping hand, is produced by the method of providing a rectilinear elongated section, appropriately disposing the elongated section preparatory to successive cross-cuttings of the section, and cross-cutting successive lengths from the section to thereby provide a plurality of separate anvils.

Abstract: A fin forming device folds fin material into a plurality of corrugations by creating a fold radius at each fold. The device comprises a substantially rectangular plane of metal having a front side, and an opposing back side. The perimeter of the plane is defined by a top edge which is applied to the fin material to form the fold radius, a bottom edge, and a pair of opposing side edges. Initially, each of the edges has a substantially similar thickness. An angled surface is created on at least one side of the plane, commencing in an interior area of the plane below the top edge of the plane and terminating at the top edge of the plane. This creates an angled blade surface along at least a portion of the top edge of the plane. The angled blade surface has a narrower thickness than the initial edge thickness.

Abstract: A solid-steel anvil of symmetrical configuration, having a top head, depending intermediate web and a base, and with the anvil being of light weight that a person can manipulatively grasp the anvil's top head with one hand to easily carry the anvil with his grasping hand, is produced by the method of providing a rectilinear elongated section, appropriately disposing the elongated section preparatory to successive cross-cuttings of the section, and cross-cutting successive lengths from the section to thereby provide a plurality of separate anvils.

Abstract: The invention concerns a method for riveting a packet (50) of sheets (51,52) by means of unannealed aluminum rivets made from an alloy harder than that of the relatively soft AD rivets in common use; this method is characterized by the fact that the expansion of the head to be formed at the shank end (58,59) of the rivet during the riveting process is controlled by a snap-tool (62) which encloses the shank end (58,59) at first loosely. When the expansion of the head diameter approaches D=1,5 d (with d the rivet diameter), i.e., the limit above which cracks form in the head, the tool (62) prevents further deformation and forces the material of the head to deflect towards the central portion of the rivet shank (57) which subsequently expands and widens the hole (53) sufficiently to make the riveted joint last considerably longer. The good loosely and, later in the process, tightly fitted enclosing of the shank end (58,59) by the snap-tool (62) allows the riveting to be done manually.

Abstract: An electrical connector crimping tool has a head with a stationary anvil and a movable ram. The anvil has two angled contact surfaces for contacting a connector. The ram has a front with a pyramid and angled side portions. The pyramid is suitably sized and shaped such that the angled side portions of the ram can contact the anvil angled contact surfaces to stop forward advancement of the ram without the pyramid contacting the anvil.

Abstract: An edge-finishing device comprises a drive unit (L), a holder (M) and a notched tip (N). The tip combines a number of geometric features known as land radius (Y), flank faces (K), flank radii (I) and root radius (J). Typical useage of the device requires a tip to be fitted into the holder, the tip being then offered against the workpiece using the flank faces for guidance. The land radius determines the contact area. The tip impacts against the workpiece and bends the protrusions over. The flank radii then beat the protrusions thin enough for them to break off or be driven off. The tip continues to impact until the finished edge conforms to the root radius.

Abstract: A straightening device (16) for bent fuel assembly alignment pins (12) in an upper core plate (10) comprises elongated mast (22) having an upper and lower portion, bail (25) secured to the upper portion and cross member (28) secured to the lower portion. At one end of the cross member (28) is attached pin straightening assembly (19), the other end having counterweight (31) to assure a horizontal orientation of the cross member (28). Pin straightening assembly (19) is further comprised of housing (37) having wedge-shaped adjustable shim (61) connected to its top surface, the housing (37) secured to the cross member (28) by baseplate (34). Four axially compressible and laterally deformable compression springs (41) are connected between baseplate (34) and housing (37) to provide angular and translational compliance for housing (37).

Abstract: A bolt head reforming tool for extracting bolts that have had their head stripped such that they cannot be removed with a wrench. A hollow tool has a central opening which has a lower portion large enough to pass over the head of the bolt and an inner portion which is smaller than the head of the bolt such that the tool can be driven onto the head of the bolt with a hammer such that the smaller portion cuts the head of the bolt to reform it to its original position. The tool may have a staggered inside cutting edge so that as the tool is driven further onto the head of the bolt, a third inner surface also cuts the head of the bolt. The outer surface of the tool is formed such that a wrench can be connected thereto so as to turn the tool and the bolt to thus remove the head.

Abstract: A cast iron core provides inertia and a thick rubber covering affords comfort and freedom from marring when a new door skin is installed on a vehicle door framework. The covering over the planar bottom surface of the core is especially thick and serves to absorb and dissipate the impact energy of the body hammer.

Abstract: A die particularly adapted to drive a rivet, where the head of the rivet has a relatively steep circumferential side surface. The die engages the rivet head in a manner that initially the middle portion of the die driving surface exerts substantial force into the shank portion of the rivet, after which the die driving surface comes in greater overall driving engagement with the entire rivet head. Further, the die has a circumferential lip which limits lateral movement of the die relative to the rivet head.

Abstract: A can and seaming tool for use in seaming a can end to a can body and having a seaming chuck and a seaming roll, said seaming chuck being adapted to fit said can end while said seaming roll is adapted to simultaneously press and seam the curling portion of said can end and the flanging portion of said can body, wherein the improvement comprises that at least one of said seaming chuck contacting said can end and the portion of said seaming roll frictionally contacting at least said can end is made from cermet of titanium carbonitride system (a composite sintered material composed of a metal and ceramics containing titanium carbides and titanium nitrides).

Abstract: Metal-working dies which are typically made of steel are provided with substantially enhanced life by receiving a plasma-sprayed refractory metal coating which is subsequently compacted under conditions of minimum shear stress. The number of working cycles which can be obtained from a die before it is necessary to rework the die can be improved by as much as 3500%.