Systems and methods for coldworking metal are described that reduce the axial flow of metal and increase the radial/tangential flow, thereby improving the fatigue life at an aperture. A tool is inserted through an aperture and its travel speed is reduced when in contact with the metal to reduce axial plastic flow. A sensor as part of the motive system moving the mandrel can sense when the tool contacts the metal and reduces the speed of the tool. The tool may move more quickly when not in contact with the metal to reduce working time than when the mandrel is working the metal. The coldworking tool engages the metal at the aperture at a speed of less than the speed which results in the time duration for the mandrel engaging the metal at the aperture for 35 second per inch of metal thickness at the aperture.

A method of manufacturing a flaring-processed metal pipe from a hollow shell including a plurality of portions having different deformation resistances in a circumferential direction is provided, the method includes: among the plurality of portions, specifying a portion having a relatively small deformation resistance as a low deformation resistance section, and a portion having a relatively large deformation resistance as a high deformation resistance section; and press-fitting a pipe expansion punch into the hollow shell such that a thickness reduction rate of the low deformation resistance section is smaller than a thickness reduction rate of the high deformation resistance section.

A method of manufacturing a flaring-processed metal pipe from a hollow shell including a plurality of portions having different deformation resistances in a circumferential direction is provided, the method includes: among the plurality of portions, specifying a portion having a relatively small deformation resistance as a low deformation resistance section, and a portion having a relatively large deformation resistance as a high deformation resistance section; and press-fitting a pipe expansion punch into the hollow shell such that a thickness reduction rate of the low deformation resistance section is smaller than a thickness reduction rate of the high deformation resistance section.

A hand expansion device is capable of expanding pipe ends. The device includes an expanding head, which can be actuated by an electric motor and/or by a hydraulic medium and which has a plurality of segments. The segments can be actuated by an expanding mandrel that can be moved in the direction of a longitudinal axis of the expanding head. The segments are expanded in a direction which is transverse to the movement direction of the expanding mandrel as the result of a first triggering of an expansion process. A second activation of the hand expansion device is only allowed if it is determined that the hand expansion device was rotated around the longitudinal axis a predetermined angle.

A lubrication ring for a mechanical expander (1) for sizing large pipes comprises a conventionally manufactured ring (12) made of steel, in particular construction steel. Fluid bores are provided in the ring (12). A part (13) of the lubrication ring (6) is manufactured by an additive manufacturing technology.

Tube flaring tool comprising a tube receiving region comprising first and second gripping dies retractable with respect to each other and positionable to cooperatively define an opening for receiving a tube; a first clutch shaft; a support housing having a bore for receiving a second clutch shaft; a clutch plate; a flare forming head operable to flare the free end of the tube; and a biasing member urging the flare forming head axially. The first clutch shaft may have an outer configuration adapted to be engaged by a 12 point or 3/8″ square drive SAE ratchet wrench for creating mechanical advantage to actuate the flare forming head. When the force that the biasing member urges the flare forming head axially is overcome, the clutch plate disengages from the second clutch shaft such that further actuation of the first clutch shaft does not rotate the flare forming head shaft, preventing over-flaring.

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 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.

An expansion tool for expanding an article. The expansion tool includes a lead-in portion extending outwardly from a first end of the expansion tool and a first pilot portion extending from the lead-in portion. The first pilot portion has a first diameter. The expansion tool further includes a second pilot portion being generally parallel with the first pilot portion. The second pilot portion has a second diameter larger than the first diameter. The expansion tool further includes a forming portion bridging the first pilot portion and the second pilot portion. The forming portion is generally sloped. The expansion tool further includes an expansion portion extending from the second pilot portion toward a second end of the expansion tool. The expansion portion has a third diameter larger than the second diameter.

An expansion tool for expanding an article. The expansion tool includes a lead-in portion extending outwardly from a first end of the expansion tool and a first pilot portion extending from the lead-in portion. The first pilot portion has a first diameter. The expansion tool further includes a second pilot portion being generally parallel with the first pilot portion. The second pilot portion has a second diameter larger than the first diameter. The expansion tool further includes a forming portion bridging the first pilot portion and the second pilot portion. The forming portion is generally sloped. The expansion tool further includes an expansion portion extending from the second pilot portion toward a second end of the expansion tool. The expansion portion has a third diameter larger than the second diameter.