Flaring and swaging bits, and methods using same

Abstract

Embodiments provide improved flaring and swaging bits, and methods for flaring and swaging.

What is claimed is: 
     
       1. A rotary insert, comprising:
 a shank portion; 
 a stopper portion coupled to the shank portion such that a T-shape is formed thereby; and 
 a tip opposite the shank portion, the tip having a base coupled to the stopper portion, the tip extending away from the stopper portion along an axis of symmetry, the tip having a tip end spaced apart from the stopper portion, the tip comprising a first face disposed opposite a second face, the first face and the second face defining a continuous outer edge, the continuous outer edge extending from the tip end to the base; the continuous outer edge intersecting the axis of symmetry at the tip end; the outer edge having a maximum radius relative to the axis of symmetry at the base, the continuous outer edge from the tip end to the base tapering outward relative to the axis of symmetry; from the tip end to the base the tip having at least one stage portion, the continuous outer edge curved toward the tip end in the at least one stage portion; and the stopper portion having a stopper radius greater than the maximum radius of the tip, 
 wherein,
 the tip widens an open end portion of a metal tube when (1) the shank portion is inserted into a chuck of a drill or an electric screwdriver, (2) spun via the drill or the electric screwdriver, and (3) inserted into the open end portion of the metal tube while spinning so as to sufficiently heat the open end portion of the metal tube via friction generated between the tip that is spinning and the open end portion of the metal tube and thereby widen the open end portion of the metal tube using a hot process, 
 the drill or the electric screwdriver is not a tailstock, and 
 the tip is insertable into the open end portion of the metal tube up to the stopper portion. 
 
 
     
     
       2. The rotary insert of  claim 1 , wherein the continuous outer edge comprising at least two stage portions, in each of the at least two stage portions the continuous outer edge having different curvature. 
     
     
       3. The rotary insert of  claim 1 , wherein the rotary insert formed as is a single element. 
     
     
       4. The rotary insert of  claim 1 , wherein the rotary insert comprising metal. 
     
     
       5. The rotary insert of  claim 1 , wherein the rotary insert comprising ceramic. 
     
     
       6. The rotary insert of  claim 1 , wherein the tip further comprising a flared bottom portion, the flared bottom portion affixed between the stopper portion and the at least one stage portion, at least two edges of the flared bottom portion sloping from the tip to the stopper portion. 
     
     
       7. The rotary insert of  claim 1 , wherein the tip has rounded edges being which are equal in diameter. 
     
     
       8. The rotary insert of  claim 1 , wherein the at least one stage portion comprising only one stage portion. 
     
     
       9. The rotary insert of  claim 1 , wherein the at least one stage portion comprising two stage portions. 
     
     
       10. A system, comprising:
 a rotary insert comprising:
 a shank portion; 
 a stopper portion coupled to the shank portion such that a T-shape is formed thereby; and 
 a tip opposite the shank portion, the tip having a base coupled to the stopper portion, the tip extending away from the stopper portion along an axis of symmetry, the tip having a tip end spaced apart from the stopper portion, the tip comprising a first face disposed opposite a second face, the first face and the second face defining a continuous outer edge, the continuous outer edge extending from the tip end to the base; the continuous outer edge intersecting the axis of symmetry at the tip end; the outer edge having a maximum radius relative to the axis of symmetry at the base, the continuous outer edge from the tip end to the base tapering outward relative to the axis of symmetry; from the tip end to the base the tip having at least one stage portion, the continuous outer edge curved toward the tip end in the at least one stage portion; the stopper portion having a stopper radius greater than the maximum radius of the tip; and 
 
 a drill or an electric screwdriver having a chuck engaging the shank portion to enable the tip to widen an open end portion of a metal tube when (1) the shank portion is inserted into the chuck of the drill or the electric screwdriver, (2) spun via the drill or the electric screwdriver, and (3) inserted into the open end portion of the metal tube while spinning so as to sufficiently heat the open end portion of the metal tube via friction generated between the tip that is spinning and the open end portion of the metal tube and thereby widen the open end portion of the metal tube using a hot process, 
 wherein,
 the drill or the electric screwdriver is not a tailstock, and 
 the tip is insertable into the open end portion of the metal tube up to the stopper portion. 
 
 
     
     
       11. The system of  claim 10 , wherein the continuous outer edge comprising at least two stage portions, in each of the at least two stage portions the continuous outer edge having different curvature. 
     
     
       12. The system of  claim 10 , wherein the rotary insert formed as is a single element. 
     
     
       13. The system of  claim 10 , wherein the rotary insert comprising metal. 
     
     
       14. The system of  claim 10 , wherein the rotary insert comprising ceramic. 
     
     
       15. The system of  claim 10 , further comprising a flared bottom portion, the flared bottom portion affixed between the stopper portion and the tip, at least two edges of the flared bottom portion sloping from the tip to the stopper portion. 
     
     
       16. The system of  claim 10 , wherein the tip has rounded edges being which are equal in diameter. 
     
     
       17. The system of  claim 10 , wherein the at least one stage portion comprising only one stage portion. 
     
     
       18. The system of  claim 10 , wherein the at least one stage portion comprising two stage portions. 
     
     
       19. A method for flaring a an open end portion of a metal tube, the method comprising:
 coupling a rotary insert to a chuck of a rotary power tool, wherein the rotary power tool is a drill or an electric screwdriver, wherein the rotary power tool is not a tailstock, wherein the rotary insert comprising:
 a shank portion; 
 a stopper portion coupled to the shank portion such that a T-shape is formed thereby;  
 a tip opposite the shank portion, the tip having a base coupled to the stopper portion, the tip extending away from the stopper portion along an axis of symmetry, the tip having a tip end spaced apart from the stopper portion, the tip comprising a first face disposed opposite a second face, the first face and the second face defining a continuous outer edge, the continuous outer edge extending from the tip end to the base; the continuous outer edge intersecting the axis of symmetry at the tip end; the outer edge having a maximum radius relative to the axis of symmetry at the base, the continuous outer edge from the tip end to the base tapering outward relative to the axis of symmetry; from the tip end to the base the tip having at least one stage portion, the continuous outer edge curved toward the tip end in the at least one stage portion; and the stopper portion having a stopper radius greater than the maximum radius of the tip; 
 
 inserting the tip of the rotary insert into a cavity defined by an interior surface of a the open end portion of the metal tube while the rotary insert is coupled to the chuck of the rotary power tool; and 
 rotating the rotary insert by spinning the shank portion via the chuck of the rotary power tool to cause friction between the tip and the interior surface of the open end portion of the metal tube, to increase the diameter of at least a portion of the metal tube including the open end portion, to create a flare of the open end portion of the metal tube, and to increase structural quality of the metal tube from heat provided to the metal tube via friction generated between the tip that is spinning and the open end portion of the metal tube using a hot process, 
 wherein,
 rotating the rotary insert occurs as the tip of the rotary insert is inserted into the cavity defined by the interior surface of the open end portion of the metal tube, and 
 the tip is insertable into the open end portion of the metal tube up to the stopper portion. 
 
 
     
     
       20. A method for swaging a an open end portion of a metal tube, the method comprising:
 coupling a rotary insert coupled to a chuck of a rotary power tool, wherein the rotary power tool is a drill or an electric screwdriver, wherein the rotary power tool is not a tailstock, wherein the rotary insert comprising:
 a shank portion; 
 a stopper portion coupled to the shank portion such that a T-shape is formed thereby;  
 a tip opposite the shank portion, the tip having a base coupled to the stopper portion, the tip extending away from the stopper portion along an axis of symmetry, the tip having a tip end spaced apart from the stopper portion, the tip comprising a first face disposed opposite a second face, the first face and the second face defining a continuous outer edge, the continuous outer edge extending from the tip end to the base; the continuous outer edge intersecting the axis of symmetry at the tip end; the outer edge having a maximum radius relative to the axis of symmetry at the base, the continuous outer edge from the tip end to the base tapering outward relative to the axis of symmetry; from the tip end to the base the tip having at least one stage portion, the continuous outer edge curved toward the tip end in the at least one stage portion; and the stopper portion having a stopper radius greater than the maximum radius of the tip; 
 
 inserting the tip of the rotary insert into a cavity defined by an interior surface of a the open end portion of the metal tube while the rotary insert is coupled to the chuck of the rotary power tool; and 
 rotating the rotary insert by spinning the shank portion via the chuck of the rotary power tool to cause friction between the tip and the interior surface of the open end portion of the metal tube, to increase the diameter of at least a portion of the metal tube including the open end portion, to create a swage of the open end portion of the metal tube, and to increase structural quality of the metal tube from heat provided to the metal tube via friction generated between the tip that is spinning and the open end portion of the metal tube using a hot process, 
 wherein,
 rotating the rotary insert occurs as the tip of the rotary insert is inserted into the cavity defined by the interior surface of the open end portion of the metal tube, and 
 the tip is insertable into the open end portion of the metal tube up to the stopper portion. 
 
 
     
     
       21. The rotary insert of claim 1, wherein the tip widens the open end portion of the metal tube by or including flanging. 
     
     
       22. The system of claim 10, wherein the tip is enabled to widen the open end portion of the metal tube by or including flanging. 
     
     
       23. The method of claim 19, wherein the tip has only one stage portion. 
     
     
       24. The method of claim 19, wherein the tip has two stage portions. 
     
     
       25. The method of claim 19, wherein the rotary insert is a single element. 
     
     
       26. The method of claim 19, wherein each of the shank, the stopper, and the tip includes metal. 
     
     
       27. The method of claim 19, wherein each of the shank, the stopper, and the tip includes ceramic. 
     
     
       28. The method of claim 20, wherein the tip has only one stage portion. 
     
     
       29. The method of claim 20, wherein the tip has two stage portions. 
     
     
       30. The method of claim 20, wherein the rotary insert is a single element. 
     
     
       31. The method of claim 20, wherein each of the shank, the stopper, and the tip includes metal. 
     
     
       32. The method of claim 20, wherein each of the shank, the stopper, and the tip includes ceramic. 
     
     
       33. A rotary insert, comprising:
 a shank portion;   a stopper portion coupled to the shank portion such that a T-shape is formed thereby; and   a tip opposite the shank portion, the tip having a base coupled to the stopper portion, the tip extending away from the stopper portion along an axis of symmetry, the tip having a tip end spaced apart from the stopper portion, the tip comprising a first face disposed opposite a second face, the first face and the second face defining a continuous outer edge, the continuous outer edge extending from the tip end to the base; the continuous outer edge intersecting the axis of symmetry at the tip end; the outer edge having a maximum radius relative to the axis of symmetry at the base, the continuous outer edge from the tip end to the base tapering outward relative to the axis of symmetry; from the tip end to the base the tip having at least one stage portion, the continuous outer edge curved toward the tip end in the at least one stage portion; and the stopper portion having a stopper radius greater than the maximum radius of the tip,   wherein,
 the tip widens an open end portion of a metal tube when (1) the shank portion is inserted into a chuck of a drill or an electric screwdriver, (2) spun via the drill or the electric screwdriver, and (3) inserted into the open end portion of the metal tube while spinning so as to sufficiently heat the open end portion of the metal tube via friction generated between the tip that is spinning and the open end portion of the metal tube and thereby widen the open end portion of the metal tube using a hot process, 
 the drill or the electric screwdriver is not a tailstock, 
 the tip is insertable into the open end portion of the metal tube up to the stopper portion, 
 the rotary insert is a single element, 
 the rotary insert comprises metal, and 
 the at least one stage portion comprises only one stage portion. 
   
     
     
       34. The rotary insert of claim 33, wherein the tip widens the open end portion of the metal tube by or including flanging.