Abstract: A process for heading of a blank (30) formed from a length of wire stock to form a brush contact (10) having a different diameter ends, (12,14) and an intermediate shoulder (16) with a relatively great reduction in the length of the blank (30) occurring during successive heading steps, including clamping the blank in one of a plurality of holders (166), each having a counter bore (46) opening onto an end face against which a respective one of a series of coning dies (32,50,56,64) are brought into abutment. Each coning die is formed with an opening (38,50,58,66) of successively larger diameters receiving a protruding end of the blank. Respective punches (40,52,60,68) are axially advanced in a respective coning die against the blank and during forming of the blanks, simultaneously forcing the blank material against the interior of the coning die opening and outward into the counterbore.

Abstract: An apparatus (100) and process for multistep heading of elongated stock to form a brush contact (10) with a relatively great reduction in the length of the wire stock material (386) achieved during successive heading steps, including a rotary holder plate (112) mounting a series of blank clamping holders (166) indexed through a series of stations and a series of coning dies (240) and punches (244) carried by independently actuated tooling plates (114, 116) which are axially advanced during forming of the blanks. A final forming step involves a reverse extrusion to create an endwise axial opening (26). The apparatus (100) also includes a feed mechanism (148) and a cutoff mechanism (160) for forming blanks from wire stock (386). A clamping member (178) is associated with each holder (166) for clamping the blank for securement during the forming steps, which is unlocked at an ejection station to enable removal of the formed article by an ejection mechanism (610).