Abstract: A process for forming a radially upset tube flange particularly suitable for securing a connector on an end of a tube, and a connector assembly formed thereby. A connector is provided, having an end face and an away face. A desired length of tube is provided, having an end portion and a tube end. The connector is passed over the end portion of the tube, with the end face of the connector nearest the tube end and the away face of the connector farthest from the tube end. The tube is gripped with a fixture, and positioned with the away face of the connector against the fixture. A preferred length of the tube end portion extends axially beyond the end face of the connector. Force is applied axially to the tube end, causing a major radially outward upset of the tube against the end face of the connector and a minor radially outward upset of the tube against the away face of the connector. A tapered punch is forced into the tube end axially, causing the tube end to flare outwardly.

Abstract: A method of forming a collar backed doubly upset tubing end includes positioning the collar on the tube, gripping the tube in a die and finally positioning the collar coplanar with the die and with a preferred length of tube extending axially beyond the coplanar collar and die faces. The tube end is axially impacted by a frustoconical punch forcing the tube end axially toward the collar while allowing a tube portion intermediate the tube end and the collar to expand radially outwardly. The tube end is then axially impacted for a second and final time with a recessed flat punch to flatten the tube end. Apparatus for performing the method as well as the product produced thereby are also disclosed.