A bead forming method includes the steps of preparing a bumper stay having a partition wall that partitions an internal space and extends in a longitudinal direction, an elastic body that can be inserted into the bumper stay, and a pusher that presses the elastic body; inserting the elastic body into the bumper stay and arranging the elastic body in the bumper stay so as not to come into contact with the partition wall; and forming a buckling bead by compressing the elastic body in the longitudinal direction of the bumper stay by the pusher to expand the elastic body outward in a radial direction without coming into contact with the partition wall, thereby bulging a part of an outer wall of the bumper stay outward in the radial direction without deforming the partition wall.

A heat exchanger includes a tube expansion portion formed by expanding a heat transfer tube so that an outer peripheral surface of the heat transfer tube is pressed against an inner peripheral surface of a hole provided in a side wall portion of a case. The tube expansion portion includes first and second bulge portions positioned respectively on the inside and the outside of the side wall portion so as to sandwich the side wall portion in an axial length direction of the heat transfer tube and configured such that respective outer peripheral surfaces thereof partially bulge outward in a radial direction of the heat transfer tube, an end portion tip end of the heat transfer tube is positioned apart from the second bulge portion, and the end portion tip end and a part in the vicinity thereof are expanded so as to be included in a part of the tube expansion portion. Thus, effects such as improving the precision with which the side wall portion of the case, the heat transfer tube, and a connecting tube are fitted to each other can be achieved, and as a result, the respective parts can be brazed easily and appropriately.

A heat exchanger includes tube expansion portions provided respectively on a plurality of heat transfer tubes such that outer peripheral surfaces of the heat transfer tubes are respectively pressed against inner peripheral surfaces of a plurality of first holes provided in a side wall portion of a case, and a plurality of first concave surface portions provided in an outer surface of the tube expansion portion so that first gaps, into which brazing material of a first brazed portion advances, are formed between the outer surface of the tube expansion portion and the inner peripheral surface of the first hole. At least one of the plurality of first concave surface portions is positioned in an outside peripheral surface portion of the outer peripheral surface of the heat transfer tube. According to this configuration, the strength with which the heat transfer tubes are attached to the case can be increased while simplifying a manufacturing operation and reducing the manufacturing cost.

A method for permanently fastening a cam on a cam carrier may involve positioning the cam on the cam carrier in a predefined axial and angular position. By way of the positioning, an end face of the cam carrier is aligned with an end face of the cam. The method may also involve positioning a cam segment formed by the cam carrier and the cam in an assembly device. The cam carrier may then be deformed such that the cam is secured at least in a form-fitting or force-fitting manner against movement in an axial direction on the cam carrier. A deformation tool of the assembly device may be advanced in an axial direction onto the end face of the cam carrier, and the cam carrier may be deformed such that material of the cam carrier is forced outward in a radial direction against the cam.

A method for permanently fastening a cam on a cam carrier may involve positioning the cam on the cam carrier in a predefined axial and angular position. By way of the positioning, an end face of the cam carrier is aligned with an end face of the cam. The method may also involve positioning a cam segment formed by the cam carrier and the cam in an assembly device. The cam carrier may then be deformed such that the cam is secured at least in a form-fitting or force-fitting manner against movement in an axial direction on the cam carrier. A deformation tool of the assembly device may be advanced in an axial direction onto the end face of the cam carrier, and the cam carrier may be deformed such that material of the cam carrier is forced outward in a radial direction against the cam.

An electromagnetic forming method includes: a step of setting pipe periphery members at plural positions along an axial direction of a pipe material; a step of setting a coil unit on a side of one end, in the axial direction, of the pipe material, the coil unit including a conductor wound portion, conductor extension portions, and a resin-made conductor support portion; a step of setting a support member on a side of the other end, in the axial direction, of the pipe material; a coil unit holding step; a coil setting step; and a swaging step. The coil setting step and the swaging step are performed in this order at each of the plural positions of the pipe material while the coil unit is kept held by the support member.

An electromagnetic forming method includes: a step of setting pipe periphery members at plural positions along an axial direction of a pipe material; a step of setting a coil unit on a side of one end, in the axial direction, of the pipe material, the coil unit including a conductor wound portion, conductor extension portions, and a resin-made conductor support portion; a step of setting a support member on a side of the other end, in the axial direction, of the pipe material; a coil unit holding step; a coil setting step; and a swaging step. The coil setting step and the swaging step are performed in this order at each of the plural positions of the pipe material while the coil unit is kept held by the support member.

A forming die system and method is used in end forming a pipe or tube for connecting the pipe or tube with a fitting without a sleeve therebetween. The forming die system includes engageable outer dies that together define a bore having a longitudinal axis, die forming surfaces formed on each outer die, grip dies supported in each of the outer dies and configured to hold the pipe or tube, a biasing member that is engageable between a corresponding one of the outer dies and a corresponding one of the grip dies, and a forming pin that is configured to roll around the longitudinal axis in a circular motion at a predetermined angle relative to the longitudinal axis.

A forming die system and method is used in end forming a pipe or tube for connecting the pipe or tube with a fitting without a sleeve therebetween. The forming die system includes engageable outer dies that together define a bore having a longitudinal axis, die forming surfaces formed on each outer die, grip dies supported in each of the outer dies and configured to hold the pipe or tube, a biasing member that is engageable between a corresponding one of the outer dies and a corresponding one of the grip dies, and a forming pin that is configured to roll around the longitudinal axis in a circular motion at a predetermined angle relative to the longitudinal axis.

Techniques for implementing and/or deploying a swage machine, which includes a die plate that enables a die to be used to conformally deform a pipe fitting around pipe segment tubing to be loaded in the swage machine, a grab plate having grab plate sections that are pivotably connected, and grab adapter sections. Each grab adapter sections includes a base sub-section connected to a corresponding grab plate section, in which an inner surface of the base sub-section includes an alignment notch, and a modular sub-section to be secured to the base sub-section, in which an outer surface of the modular sub-section includes an alignment tab to be disposed within the alignment notch in the base sub-section and an inner surface of the modular sub-section includes a grab tab section that matingly interlocks with a fitting grab notch on the pipe fitting to facilitate securing the swage machine to the pipe fitting.