Abstract: A method for manufacturing a multi-functional fastener includes a preparing operation, a forming operation and a threading operation. The preparing operation prepares a metal blank cut from a length of a metal material. The forming operation is executed so that the metal blank forms a shank, a head, and a drilling portion connected to the shank. The threading operation is executed to roll the metal blank with a thread rolling set having two opposite rolling plates. Each rolling plate has slit grooves and convex units arranged in alternation. Each of the convex units has protrusions each situated between two adjacent slit grooves, which allows the threading operation to equip the shank of the metal blank with thread convolutions, slots formed between the thread convolutions for helping quick removal of chips, and main ribs formed between any two adjacent slots for increasing cutting efficiency.

Abstract: A reciprocating die roll forming machine for forming a pattern such as a thread form on the outer surface of a cylindrical blank includes at least one set of reciprocating dies operating upon the blank which rotates in place. The machine includes a slide and bearing combination to support the dies belt driven by a servo-motor controlled by a central processing unit. Mechanism is provided to deliver and position a blank for engagement by the dies. In one form, the machine includes multiple die sets to produce multiple parts during one die reciprocation cycle. In another form, the machine employs separate drive mechanisms to independently drive each die of a set.

Abstract: A method for manufacturing a rotationally symmetrical shaped article, which has a cylindrical, concentric hub axially closed on one side, in a shaping process is performed such that at least one pressure roll is in contact with a rotating, closed, planar circular blank sheet and presses the material of the blank radially from the outside inward against a projecting part that runs upright on the circular blank such that the thickness of the circular blank decreases and the hub including a blind hole is formed.

Abstract: A form-rolling die structure with die members which are pressed against a material to be threaded and which have rigid surfaces that are relatively displaced. The die members are equipped with a plurality of independent concave portions which form a substantially parallelogram shape when viewed from the normal of a virtual surface obtained by connecting the outermost portions of each of the rigid surfaces, and which are recessed from the virtual surface. Two of the corners at the sites corresponding to the four corners of the substantially parallelogram-shape of the concave portions are rounded. The periphery of each concave portion in the cross-section along the direction of the normal is rounded along the periphery of the substantially parallelogram shape. The concave portions form a substantially truncated-pyramid shape.

Abstract: A thread-rolling flat die for a threaded fastener, includes a thread-rolling surface including at least a bite surface to which a workpiece of the threaded fastener is supplied, a finishing surface formed adjacent to the bite surface, and a roll-off surface formed adjacent to the finishing surface. The bite surface includes at least: a first partial bite surface having an inclination and a second partial bite surface formed continuously from the first partial bite surface and having an inclination. A length L1 along a thread-rolling direction in the first partial bite surface, a length L3 along the thread-rolling direction in the finishing surface, a length L4 along the thread-rolling direction in the roll-off surface, and a diameter of a processed portion of the workpiece of the threaded fastener have a relationship of L1>L3>L4> the diameter of the processed portion.

Abstract: An electric discharge machining electrode is shaped to form a die for roll forming a dual threaded screw. The electrode is oriented with a face thereof adjacent to a forming surface of the die and placed within an electric discharge machine to cause electric discharge via the electrode to the forming surface of the die, to shape the die to have the geometry required for roll forming of the dual threaded screw. The EDM electrode face has a plurality of troughs and tips substantially matching coarse threads of the screw. Grooves are formed in the tips. The grooves are angled relative the tips and have a geometry substantially matching the fine threads of the screw. The face of the electrode has a form which shapes the forming surface of the die so that the die can roll form the dual threaded screw.

Abstract: A reciprocating die roll forming machine for forming a pattern such as a thread form on the outer surface of a cylindrical blank includes at least one set of reciprocating dies operating upon the blank which rotates in place. The machine includes a slide and bearing combination to support the dies belt driven by a servo-motor controlled by a central processing unit. Mechanism is provided to deliver and position a blank for engagement by the dies. In one form, the machine includes multiple die sets to produce multiple parts during one die reciprocation cycle. In another form, the machine employs separate drive mechanisms to independently drive each die of a set.

Abstract: A thread rolling die includes a thread rolling region comprising a working surface including a thread form. The thread rolling region of the thread rolling die comprises a sintered cemented carbide material having a hardness in the range of 78 HRA to 89 HRA. In certain embodiments, the thread rolling die may further include at least one non-cemented carbide piece metallurgically bonded to the thread rolling region in an area of the thread rolling region that does not prevent a workpiece from contacting the working surface, and wherein the non-cemented carbide piece comprises at least one of a metallic region and a metal matrix composite region. Methods of forming a thread rolling die as embodied herein are also disclosed.

Abstract: [Problem] The purpose of the present invention is to provide a form-rolling die and form-rolling method for a compound screw that use a cylindrical material to be threaded, enable the high-precision mass production of compound screws having a right-hand thread portion and a left-hand thread portion on the same region, do not cause rolling defects such as slips, and in which blockages do not occur even in the unlikely event of shavings being generated. [Solution] A form-rolling die structure is provided with die members which are pressed against a material to be threaded and which have rigid surfaces that are relatively displaced. The die members are equipped with a plurality of independent concave portions which form a substantially parallelogram shape when viewed from the normal of a virtual surface obtained by connecting the outermost portions of each of the rigid surfaces, and which are recessed from the virtual surface.

Abstract: A manufacturing method for a toothed part including a bottom surface portion and a side wall portion provided to extend upright from an outer peripheral end portion of the bottom surface portion, the side wall portion being formed with teeth. The manufacturing method includes a half drawing process of performing draw shaping on a material having a disk shape to form the bottom surface portion and the side wall portion, an inside diameter of which becomes larger in a direction away from the bottom surface portion; and a tooth shaping process of forming the teeth in the side wall portion.

Abstract: A portable handheld device for introducing an external profile into a longitudinal workpiece by noncutting shaping includes a locking element and a profiling tool having a pitchless profile disposed opposite the locking element and disposable at an adjustable angle as a function of a desired lead angle of the external profile within a force transmission plane, wherein the workpiece is disposable and removable between the profiling tool and the locking element, and wherein the profile tool and the locking element are configured to execute a feed movement relative to one another and to be adjustable to a neutral position.

Abstract: In order to develop a surgical needle comprising an elongate needle body and a needle point formed on a distal end of the needle body, wherein the needle body is manufactured in particular from an elongate cylindrical blank, in a way that improves the handling ability of the surgical needle, it is proposed that the needle body has at least one textured-profile lateral face, which comprises at least one textured-profile lateral-face region provided with a textured profile, wherein the textured profile comprises a plurality of indentations and wherein the at least one textured-profile lateral-face region extends as far as the needle point. An improved method of manufacturing a surgical needle is also provided.

Abstract: A hot forming die that includes a first die and a second die. The first die has a first die structure that is formed of a tool steel. The first die structure has a first die surface and a plurality of first cooling apertures. The first die surface has a complex shape. The first cooling apertures are spaced apart from the die surface by a first predetermined distance. The second die has a second die surface. The first and second die surfaces cooperate to form a die cavity. Related methods for forming a hot forming die and for hot forming a workpiece are also provided.

Abstract: A die for use in a sheet metal forming process includes a die material having a surface. A plurality of depressions is formed in a predetermined portion of the surface, where each of the plurality of depressions has a predetermined diameter and depth. Interaction of a surface of a sheet metal blank with i) the plurality of depressions, and ii) a solid forming lubricant, including particles of an average predetermined size and distribution, disposed on one of the die material surface or the sheet metal blank surface substantially reduces adhesion between the sheet metal blank surface and the die material surface during the sheet metal forming process.

Abstract: A method for manufacturing a toothing on a component of a shaft/hub connection is disclosed. The component may be held permanently in a chucking while it receives an at least two-stage toothing in this chucking. A special draw die for carrying out the method is also proposed, a first toothing-forming region with a first height and at least one following second toothing-forming region with at least one second height being arranged between a first and a second end face, and the first height being designed to be lower than the second height.

Abstract: The present invention includes a bar having a maximum cross section region smaller than a minimum cross section region of a hollow portion of a pipe P, and projected portions mounted along an axial direction of the bar and including a projected portion with maximum extent Hb, extent Ha of the projected portion positioned at a leading end side of the bar is set to be smaller than extent Hb of the projected portion positioned at a center side in the axial direction, and extent Hc of the projected portion positioned at a base end side of the bar is set to be less than or equal to extent Hb of the projected portion.

Abstract: In a machining tool, multiple tooth forming portions for plastically forming spline teeth on an axial end face of a vehicle hub unit, the axial end face facing inward in the vehicle lateral direction, are formed in a circular pattern about the central axis of the machining tool. In the machining tool, a rounded-portion forming portion is formed to form a rounded portion between a tooth flank and a top land of each spline tooth, and the radius of the rounded-portion forming portion gradually changes in the radial direction about the central axis.

Abstract: A manufacturing method for a toothed part including a bottom surface portion and a side wall portion provided to extend upright from an outer peripheral end portion of the bottom surface portion, the side wall portion being fanned with teeth. The manufacturing method includes a half drawing process of performing draw shaping on a material having a disk shape to form the bottom surface portion and the side wall portion, an inside diameter of which becomes larger in a direction away from the bottom surface portion; and a tooth shaping process of forming the teeth in the side wall portion.

Abstract: A self-attaching fastener and panel assembly wherein the free open end of the tubular barrel portion is coined, collapsed axially, flattened and deformed radially inwardly and outwardly and axially against a panel surrounding the panel opening. The method of installation includes driving the free end of the tubular barrel portion against a substantially planar die surface, deforming an end portion radially, then collapsing an intermediate portion over the radially deformed end portion, flattening the end portion, substantially thickening the tubular barrel portion and forming an annular surface engaging and supporting the panel surrounding the opening. The die member includes an annular moat surrounding a central die post and a planar die surface extending generally perpendicular to the axis of the die button.

Abstract: A hot forming die that includes a first die and a second die. The first die has a first die structure that is formed of a tool steel. The first die structure has a first die surface and a plurality of first cooling apertures. The first die surface has a complex shape. The first cooling apertures are spaced apart from the die surface by a first predetermined distance. The second die has a second die surface. The first and second die surfaces cooperate to form a die cavity. Related methods for forming a hot forming die and for hot forming a workpiece are also provided.

Abstract: A thread forming screw thread fastener for fastening into a hole formed by the fastener in a work piece, the fastener comprising: a head having a drive to be engaged with a driver bit; and a shank with threads having a symmetrical thread profile with a minor diameter and a major diameter, the major diameter defining a thread crest of the screw thread, and the minor diameter defining the thread root of the screw thread, the profile of the screw thread defined by the surface of the screw thread between adjacent thread crests forming a thread flank, the thread flank having a first central portion of constant radius along the thread root, the radius common at the thread root, at each adjacent thread crests, and at two transition intersection points, the profile of the thread flank having second and third portions defined by surfaces having different radii of curvature between each transition intersection point and each adjacent thread crest.

Abstract: A surgical staple assembly is disclosed and can include a surgical staple. The surgical staple assembly can be moved between a first configuration and a second configuration. In the first configuration, the surgical staple can be in an original shape. Moreover, in the second configuration, the surgical staple can be in a deformed configuration.

Abstract: A thread rolling die includes a thread rolling region comprising a working surface including a thread form. The thread rolling region of the thread rolling die comprises a sintered cemented carbide material having a hardness in the range of 78 HRA to 89 HRA. In certain embodiments, the thread rolling die may further include at least one non-cemented carbide piece metallurgically bonded to the thread rolling region in an area of the thread rolling region that does not prevent a workpiece from contacting the working surface, and wherein the non-cemented carbide piece comprises at least one of a metallic region and a metal matrix composite region. Methods of forming a thread rolling die as embodied herein are also disclosed.

Abstract: A spline rolling tool including a plurality of forming teeth that are to bite into a cylindrical workpiece so as to roll splines in the workpiece. Each of the forming teeth has an incomplete toothed region in which a crest of each forming tooth is removed such that an upper end of each forming tooth in the incomplete toothed region is defined by an incomplete-toothed region surface that includes a curved surface portion, a flat surface portion and a slant surface portion. The incomplete-toothed region surface is defined at its periphery by a chamfered edge that has a surface roughness of not larger than about 3.2 ?m. Also disclosed is a process of manufacturing the spline rolling tool, which includes a chamfering step of forming the chamfered edge by using a wire brush having abrasive grains that are fixed to bristles of the wire brush.

Abstract: A rolling-circle machine for rolling a workpiece includes at least one first rolling portion, a second rolling portion connected to the first rolling portion, and at least one adjusting screw. The first rolling portion includes one or more first concaved sections for rolling the workpiece and at least a through hole. The second rolling portion includes one or more second concaved sections for rolling the workpiece. The second concaved section forms one or more rolling slots in cooperation with the first concaved section. The adjusting screw includes a threaded post passing through the through hole of the first rolling portion and one end of the threaded post is fixed in the second rolling portion. The adjusting screw is configured for adjusting a distance between the first and the second rolling portion to roll workpieces that have different dimensions.

Abstract: A split die adapted for threads of a bolt may include a first die member and a second die member being detachably connected to the first die member. The first die member and the second die member may include a radially inward extending member having a radial thread to cooperate with the thread of the bolt. The first die member may include a first discontinuous circular interior surface, and the second die member may include a first discontinuous circular interior surface. The first die member may include a guiding pin, and the second die member may include a guiding pin aperture to cooperate with the guiding pin. The split die may include a retaining pin to detachably connect with the first die member to the second die member, and the split die may be six sided. The split die may be five sided, and the split die may be four sided.

Abstract: The invention concerns an embossing plate for a hot-cold-laminating press with a three-dimensional structure based on an essentially flawless metal plate with a hardened surface of appropriate thickness and dimensions and a suitable surface, specifically a highly polished surface, into which or onto which the three-dimensional structure is incorporated by a process with at least two steps. An embossing plate produced by this process is used for the production of documents, specifically security documents, such as personal identity cards, passports, identification cards, credit cards, customer cards, driving licenses and similar sheet and/or card and/or book-like documents by means of hot-cold-lamination and/or embossing and/or item-by-item embossing.

Abstract: A thread rolling die having a nitride diffusion layer formed in a surface layer portion of a form rolling surface portion for thread rolling to plastically deform a surface of a workpiece, the nitride diffusion layer being formed in an ion nitriding treatment such that a compound layer depth is 1 ?m or smaller, a practical nitride layer depth ranges from 5 to 40 ?m, and either of that a surface hardness is 1300 HV or larger or that a surface hardened amount is 400 HV or larger.

Abstract: A method of manufacturing a catalyst, a catalyst precursor, or a catalyst support comprising: (a) mixing a refractory metal oxide or precursor thereof with a liquid to form a paste; (b) adding said paste to an extruder, the extruder having a die plate comprising one or more dies, each die having a plurality of apertures, the outlet of each aperture having a cross sectional area of 6 mm2 or less; (c) extruding the paste through the apertures to form catalyst support extrudates; wherein the inlet of the apertures has a greater cross sectional area than the outlet of said apertures; and wherein for at least one die the combined cross sectional area of all apertures at the inlet relative to the total cross sectional area of the die at the inlet is higher than 50%.

Abstract: The object of the present invention is to provide a bolt that effectively prevents gouging, seizure and racing between the bolt and nut without the aid of a guide boss and is effective when combined with the case nut. The object can be attained by providing a bolt having a threaded shank portion wherein a plural number of notched faces slanting toward the end of the threaded shank portion at an angle ranging from ±15° to ±80° toward the axis of the threaded shank portion, are formed at the beginning of the thread part of the threaded shank portion.

Abstract: There is provided a rolling die and a method for forming a thread or worm and a spline having a small number of teeth whose number is thirteen or less simultaneously by rolling. By use of rolling dies, the formation of a worm by rolling by use of a thread rolling die starts, and after that, the formation of a spline having a small number of teeth by rolling starts by use of a spline rolling die while continuing the formation of the worm. Accordingly, a rolled material can be rolled forcibly by a driving source from the worm rolled using the thread rolling die. As a result, the spline having a small number of teeth whose number is thirteen or less can be formed by rolling onto the rolled material at the same time as the formation of the worm.

Abstract: A rolling die is provided for forming a rod member with a ball portion. The rolling die includes a first die member and a second die member facing the first die member. Each of the first die member and the second die member has a process surface. The process surface has a start forming portion having a process tooth configured to bite the rod member and an arc surface portion proximate the process tooth, an intermediate forming portion having the process tooth and a curved surface proximate the process tooth, the curved surfaced being configured to press the rod member to form an arched shape, and a finish forming portion having the process tooth and a hemispheric groove configured to press the rod member into the arched shape to form the ball portion.

Abstract: A new and improved thread rolling die, for forming a new and improved threaded fastener, comprises a plurality of first, primary thread rolling die threads, and a plurality of sets of second, auxiliary thread rolling die threads alternatively interposed between successive threads of the first, primary thread rolling die threads, so as to render the manufacturing process more cost effective by reducing the the number of revolutions, through which a blank member must be rotated in order to complete the formation of the thread leads upon the blank member, to be accordingly reduced which, in turn, permits the axial length of the thread rolling dies, and the thread rolling machines, to be reduced in size.

Abstract: A new and improved thread rolling die for forming a new and improved threaded fastener, and a new and improved method or technique of manufacturing the new and improved threaded fastener, is disclosed wherein the new and improved threaded fastener comprises a first, primary thread lead, and a pair of second, auxiliary thread leads alternatively interposed between successive threads of the first, primary thread lead. As a result of the provision of the pair of second, auxiliary thread leads being interposed between successive ones of the threads of the first, primary thread lead, not only is additional axial reinforcement provided for the threaded fastener, but more importantly, the lateral or transverse distance through which the material comprising the blank member must be displaced or moved in order to form the successive threads of the first, primary thread lead is substantially reduced.

Abstract: The invention relates to a wheel bearing assembly for motor vehicles with a bearing provided with an inner ring and an outer ring, the bearing being fitted with its outer ring into a bearing casing and the outer ring being mechanically supported in axial direction on a first side by a supporting surface provided on the bearing casing. Discrete and preferably evenly arranged stop protrusions are formed on the inner circumference of the bearing casing, the outer ring abutting thereon in axial direction on its second side, and the stop protrusions being formed by locally plastic forming the bearing casing.

Abstract: A threaded fastener includes a lead having bosses separated from one another by bases along the thread crest. Two such leads may be formed such that lead-in profiles for of one lead are disposed at locations corresponding to locations of lead-out profiles for the other lead. The lead-in and lead-out profiles of the bossed, and other features of the bosses and bases may differ from one another along the fastener shank. The boss profiles may be selected to reduce insertion torque and to provide excellent resistance to pullout. The fastener may be formed by roll threading via a tool made by a plunge EDM process.

Abstract: A tooth rolling flat die and a method for forming a tooth are provided. The die has the same service life as those of the conventional tooth rolling flat dies using oil coolant even if conducted by semi-dry forming. A first substantially quarter length portion of the leading teeth section of the die has a first surface roughness Rz of maximum height ranging from 20 to 35 &mgr;m, and a second substantially quarter length portion of the leading teeth section of the die has a second surface roughness Rz of maximum height ranging from 5 to 20 &mgr;m. The die is adapted for semi-dry forming the tooth.

Abstract: A thread rolling dies for producing dog point threads is capable of preventing slips of an outer surface of screw blank when rolling, thereby avoiding breakage of the dog point thread. The dog point thread has a thread portion provided with external threads and a dog point having an outer diameter smaller than an outer diameter of the thread portion. The thread rolling dies is configured with a thread portion rolling surface having a thread portion dies ridge for forming a groove of the thread portion of the dog point thread and a thread portion dies groove for forming a ridge of the thread portion of the dog point thread, and a dog point rolling surface provided in parallel with the thread rolling surface and having a dog point dies ridge for forming a groove on the dog point of the dog point thread and a dog point dies groove for forming a ridge on the dog point of the dog point thread.

Abstract: A punch and die tool for cutting a slug from a sheet of material that is retained in the opening of the die and does not adhere to or follow the punch on its upward stroke, and a method for retaining a slug in a die, are disclosed. The die is formed with one or more irregularities or grooves on the edge of the die face so that the slug cut by the operation of the punch and die will have a burr on its edge. The burr causes the slug to lodge in the inside surface of the die and prevents the slug from following the punch on its upward stroke.

Abstract: The present invention is directed at an improved thread rolling die, comprising flat parallel longitudinal top and bottom edges, flat tapered die ends, and a vertical face that is used in producing the thread. Formed on the face is a series of parallel ridges which include a plurality of flanks positioned at a pre-determined angle. The ridges are complementary to the thread to be produced and are at an acute angle relative to the top and bottom edges. The ridges are configured for producing a thread helix when a blank is rolled between a set of dies. The thread roll dies have flat narrow surfaces at an angle of less than 60 degrees from the vertical face of the die, rather than being perpendicular to the longitudinal axes of the ridges. The top edge of the die leading to the ends of the vertical face of the die and leading away from the top surface of the die at a 60 degree angle. The ends of the die are positioned approximately 30 degrees from the perpendicular position to create smoother threads.

Abstract: A tooth rolling flat die and a method for forming a tooth are provided. The die has the same service life as those of the conventional tooth rolling flat dies using oil coolant even if conducted by semi-dry forming. Wherein the die comprises the surface roughness Rz of the first substantially quarter length portion of the leading teeth section wherein heights of the tops of the teeth are gradually increasing, ranging 20 to 35 &mgr;m, and that Rz of the second substantially quarter length portion of the leading teeth section, ranging 5 to 20 &mgr;m. The die is adapted for semi-dry forming the tooth.

Abstract: Thread forming dies to form a continuous helical thread for a metal fastener. The dies are designed and constructed to eliminate laps and discontinuities in the thread form particularly in larger diameter fastener blanks. The dies are constructed by calculating a roll-off section which tapers down to expel the threaded fastener then determining the length of a dwell section having a full depth grooves to create a well-defined and stable thread. Finally, a roll-up ramp section is calculated along which the grooves of the die become deeper along its length until reaching the desired thread angle and depth. The thread forming dies include a stationary die and a moving die. The fastener blank is rolled therebetween causing the die faces to form the thread as the blank moves from the roll-up section, through the dwell section and out the roll-off section.

Abstract: In a rolling die as a tool for thread-rolling screws, an electrode exhaustion-melted substance or its reactive substance of a discharge electrode (5) generated by discharge energy based on an in-liquid gap discharging is adhered to an deposited onto a rolling cutting-edge surface (100b). Thus, a hard film (110) of the electrode exhaustion-melted substance or its reactive substance is formed on the rolling cutting-edge surface (100b).

Abstract: A power transmission member (20) is provided by a spline rolling method and apparatus (36) that includes a pair of racks (38) for providing splines (24) with ends (34) opposing each other in a precisely spaced relationship at an annular groove (30) that is utilized to provide snap ring or other fastener positioning for axially locating the member during use.

Abstract: The present invention is to a lightweight threaded bolt type fastener having a shank with a large diameter portion and small diameter portion connected by a transition portion; a thread is roll formed on the small diameter portion and terminates in a run-out section where the thread gradually decreases in root depth and width and with the run-out section being of minimal axial length and being located closely adjacent the transition portion to produce a run-out zone of minimal axial length. A rolling die for forming the thread with minimal thread run-out having ridge segments with tapered end surfaces for providing the run-out thread with an end wall parallel to the transition portion and a method of making the bolt type fastener.

Abstract: The specification and drawings describe and show a thread-rolling die whose thread-forming lands are modified at their points of emergence along the side edge of die so that the crest of the ramp formed by the emerging end of the land remains parallel to the crest of the adjacent land.

Abstract: The present invention provides an improved, lightweight, compact threaded fastener that has a relatively shortened transition thread rollout zone between the grip of the fastener and the threaded shank of the fastener. This transition zone is shortened due to the fact that the runout (or inner end) of the rolled thread on the fastener extends no more than one-third the circumference of the rolled thread at its pitch diameter. The short runout of the rolled thread does not compromise the strength of the fastener, because the runout does not have a relatively abrupt transition. Instead, the depth of the runout of the rolled thread of the fastener gradually decreases along its length from a depth equal to the uniform depth of the rolled thread throughout the length of the threaded shaft of the fastener to no depth at the very end of the runout. The invention further provides a pair of thread rolling dies for producing such an improved, lightweight, compact threaded fastener.

Abstract: An apparatus for attaching a surgical needle of the type having an end portion with an elongated aperture defined therein and a suture having a generally elongated end portion which is to be positioned in the elongated aperture of the needle includes a pair of dies, each die having at least two generally planar engaging surfaces with a recessed portion disposed between adjacent engaging surfaces. The engaging surfaces of the dies each define a plane which is in general parallel relation to a longitudinal axis of the respective die.

Abstract: Apparatus for attaching a surgical needle having an end portion with an elongated aperture defined therein and a suture having a generally elongated end portion to be positioned in the elongated aperture of the needle, includes a pair of dies, each die defining a longitudinal axis and having an inner die surface. The inner die surface includes at least two raised swaging portions extending generally along the longitudinal axis of the die and a generally recessed portion defined between adjacent swaging portions and extending substantially along the lengths thereof. The swaging portions each have an engaging surface defining a plane angularly oriented relative to a longitudinal bisecting plane of the dies.

Abstract: An improved spline rack for use on a spline rack cutter is disclosed wherein the spline rack includes a plurality of teeth each having a top land surface that curves toward the inner tooth edge region, and the inner tooth edge region of each tooth includes a chamfer connecting the inner tooth edge region with the curved portion of the top land surface. In this manner, the exit radius of curvature of the inner top land surface may be maximized, while the chamfer prevents interference between the inner tooth edge region and the workpiece. A method of forming an improved spline rack is also disclosed.