Method of making folding hand tool set for bicycles

Abstract

A method for producing a tool for use in a folding hand tool set includes the following steps. Firstly, a metallic rod is provided. Next, a working end and a shank portion are formed on opposite ends of the metallic rod. The shank portion has a regular polygonal cross-section. The working end has a maximum external diameter (Z) is smaller than a maximum external diameter (Y) of the shank portion. Then, the shank portion is flattened into a flat, generally oblong portion by a stamping press, wherein the flattened shank portion has a thickness (X) more than or equal to a half of the maximum external diameter (Y) of the original shank portion. And the thickness (X) of the flattened shank portion is greater than the maximum external diameter (Z) of the working end. Finally, a hole is punched in an end of the flattened shank portion opposite the working end to complete the tool.

What is claimed is: 
     
         1 . A method for producing a tool for use in a folding hand tool set, the method comprising:
 (a). providing a metallic rod;   (b). forming the metallic rod with a working end with a maximum external diameter (Z) and a shank portion opposite the working end with a regular polygonal cross-section and a maximum external diameter (Y) greater than that of the working end;   (c). flattening the shank portion into a flat, generally oblong shank portion by a stamping press, wherein the flattened shank portion has a thickness (X) more than or equal to a half of the maximum external diameter (Y) of the original shank portion, and the thickness (X) of the flattened shank portion is greater than the maximum external diameter (Z) of the working end; and   (d). punching a hole in an end of the flattened shank portion opposite the working end.   
     
     
         2 . A method as recited in  claim 1 , wherein the regular polygonal cross-section of the metallic rod is a circle with an infinite number of sides. 
     
     
         3 . A method as recited in  claim 1 , wherein the step (d) further including trimming the flattened shank portion, and the trimming and the punching the hole are performed at the same time in a single punch process. 
     
     
         4 . A method as recited in  claim 1 , wherein the step (c) further including trimming the shank portion, and the trimming and flattening the shank portion are performed at the same time in a single punch process. 
     
     
         5 . A method as recited in  claim 4 , wherein in the step (c), the shank portion is punched and trimmed to include an rounded end. 
     
     
         6 . A method as recited in  claim 1 , wherein the step (b) further including forming the metallic portion with a transition portion between the working end and the shank portion. 
     
     
         7 . A method as recited in  claim 6 , wherein the transition portion includes a cylindrical section proximate to the working end with a diameter greater than the maximum external diameter (Z) of the working end, and a conical frustum disposed in between the cylindrical section and the flattened shank portion. 
     
     
         8 . A method as recited in  claim 1 , wherein in the step (b), the forming of the working end is performed by a lathe. 
     
     
         9 . A method as recited in  claim 8 , wherein in the step (b), the working end is a hex-head key.