END FORMING TOOL FOR FORMING A PROTRUSION ON A TUBE

Abstract

An end forming tool assembly, including a body including a through-hole extending in a first axial direction, a plunger slidingly engaged with the first hole, a clamp, a first arm pivotably connected to the body, the first arm operatively arranged to engage the clamp, and a die connected to the plunger, and wherein when the plunger is displaced in the first axial direction the first arm applies a force to the clamp.

Claims

1. An end forming tool assembly, comprising: a body including a through-hole extending in a first axial direction; a plunger slidingly engaged with the through-hole; a clamp; a first arm pivotably connected to the body, the first arm operatively arranged to engage the clamp; and a die connected to the plunger; and wherein when the plunger is displaced in the first axial direction the first arm applies a force to the clamp.

2. The end forming tool assembly as recited in claim 1, wherein as the plunger is displaced in the first axial direction, the first arm is displaced in a first radial direction.

3. The end forming tool assembly as recited in claim 1, wherein the clamp is fixedly secured to the first arm.

4. The end forming tool assembly as recited in claim 1, wherein the die is removably connected to the plunger.

5. The end forming tool assembly as recited in claim 4, wherein: the plunger comprises a first end and a second end, the first end comprising a hole; and the die comprises a protrusion operatively arranged to engage the hole to connect the die to the plunger.

6. The end forming tool assembly as recited in claim 1, further comprising a biasing member operatively arranged to apply a radially inward force to the clamp.

7. The end forming tool assembly as recited in claim 1, wherein the plunger comprises: a first end engaged with the die; a second end; and at least one leg extending from the second end and including a slot.

8. The end forming tool assembly as recited in claim 7, wherein the at least one leg comprises a first leg and a second leg spaced apart from the first leg along the second end.

9. The end forming tool assembly as recited in claim 8, wherein: the body comprises a flange; the first leg is arranged on a first side of the flange; and the second leg is arranged on a second side of the flange.

10. The end forming tool assembly as recited in claim 1, wherein: the plunger further comprises a wedging member; and when the plunger is displaced in the first axial direction the wedging member displaces the first arm in a first circumferential direction with respect to the body.

11. The end forming tool assembly as recited in claim 1, further comprising a biasing element arranged around the die and operatively arranged to engage the plunger.

12. The end forming tool assembly as recited in claim 1, further comprising a second arm pivotably connected to the body and operatively arranged to engage the clamp, wherein the first arm engages a first side of the clamp and the second arm engages a second side of the clamp, opposite the first side of the clamp.

13. A tool for end forming a tube, the tool comprising: a body including: a first end; a second end; a through-hole extending from the first end to the second end in a first axial direction; and a flange extending in the first axial direction from the second end; a plunger slidingly engaged with the through-hole; a clamp including a first portion and a second portion; a first arm pivotably connected to the body, the first arm including a first proximal end and a first distal end arranged to engage the first portion; and a second arm pivotably connected to the body, the second arm including a second proximal end and a second distal end arranged to engage the second portion; wherein when the plunger is displaced in the second axial direction, opposite the first axial direction, the first arm and the second arm apply a radially inward force to the clamp.

14. The tool as recited in claim 13, further comprising a die connected to the plunger.

15. The tool as recited in claim 14, wherein the plunger comprises: a third end engaged with the die; a fourth end; and at least one leg extending from the fourth end and including a slot.

16. The tool as recited in claim 15, wherein: the third end comprises a hole; the die comprises a protrusion; and the protrusion engages the hole to connect the die to the plunger.

17. The tool as recited in claim 15, wherein the at least one leg comprises a first leg and a second leg spaced apart from the first leg along the second end.

18. The tool as recited in claim 17, wherein: the first leg is arranged on a first side of the flange; and the second leg is arranged on a second side of the flange.

19. The tool as recited in claim 13, wherein: the plunger further comprises a wedging member; and when the plunger is displaced in the first axial direction the wedging member displaces the first arm in a first circumferential direction with respect to the body and the second arm in a second circumferential direction with respect to the body.

20. The tool as recited in claim 13, further comprising a biasing member operatively arranged to bias the first portion and the second portion radially inward.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0027] The accompanying drawings are incorporated herein as part of the specification. The drawings described herein illustrate embodiments of the presently disclosed subject matter and are illustrative of selected principles and teachings of the present disclosure, in which corresponding reference symbols indicate corresponding parts. However, the drawings do not illustrate all possible implementations of the presently disclosed subject matter and are not intended to limit the scope of the present disclosure in any way.

[0028] FIG. 1 is a front perspective view of an end forming tool assembly, in a non-engaged state.

[0029] FIG. 2A is a front perspective view of the end forming tool assembly shown in FIG. 1.

[0030] FIG. 2B is a rear perspective view of the end forming tool assembly shown in FIG. 1.

[0031] FIG. 3A is a front perspective exploded view of the end forming tool assembly shown in FIG. 1.

[0032] FIG. 3B is a rear perspective exploded view of the end forming tool assembly shown in FIG. 1.

[0033] FIG. 4 is a cross-sectional view of the end forming tool assembly taken generally along line 4-4 in FIG. 1.

[0034] FIG. 5 is a cross-sectional view of the end forming tool assembly taken generally along line 5-5 in FIG. 1.

[0035] FIG. 6 is a cross-sectional view of the end forming tool assembly taken generally along line 6-6 in FIG. 2A.

[0036] FIG. 7 is a front perspective view of an end forming tool assembly, in an engaged state.

[0037] FIG. 8 is a partial front perspective exploded view of the end forming tool assembly shown in FIG. 7.

[0038] FIG. 9 is a cross-sectional view of the end forming tool assembly taken generally along line 9-9 in FIG. 7.

[0039] FIG. 10A is a front perspective view of an end forming tool assembly, in an engaged state.

[0040] FIG. 10B is a rear perspective view of the end forming tool assembly shown in FIG. 10A.

[0041] FIG. 11 is a front perspective exploded view of the end forming tool assembly shown in FIG. 10A.

[0042] FIG. 12 is a cross-sectional view of the end forming tool assembly taken generally along line 11-11 in FIG. 10A.

[0043] FIG. 13 is a front perspective view of an end forming tool assembly, in a non-engaged state.

[0044] FIG. 14A is a front perspective view of the end forming tool assembly shown in FIG. 13.

[0045] FIG. 14B is a rear perspective view of the end forming tool assembly shown in FIG. 13.

[0046] FIG. 15A is a front perspective exploded view of the end forming tool assembly shown in FIG. 13.

[0047] FIG. 15B is a rear perspective exploded view of the end forming tool assembly shown in FIG. 13.

[0048] FIG. 16 is a cross-sectional view of the end forming tool assembly taken generally along line 16-16 in FIG. 14A.

[0049] FIG. 17 is a cross-sectional view of the end forming tool assembly taken generally along line 17-17 in FIG. 14A.

[0050] FIG. 18A is a front perspective view of an end forming tool assembly.

[0051] FIG. 18B is a rear perspective view of the end forming tool assembly shown in FIG. 18A.

[0052] FIG. 19 is a front perspective exploded view of the end forming tool assembly shown in FIG. 18A.

[0053] FIG. 20 is a cross-sectional view of the end forming tool assembly taken generally along line 20-20 in FIG. 18A.

[0054] FIG. 21 is a cross-sectional view of the end forming tool assembly taken generally along line 21-21 in FIG. 18A.

DETAILED DESCRIPTION

[0055] It is to be understood that the invention may assume various alternative orientations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific assemblies and systems illustrated in the attached drawings and described in the following specification are simply exemplary embodiments of the inventive concepts defined herein. Hence, specific dimensions, directions, or other physical characteristics relating to the embodiments disclosed are not to be considered as limiting, unless expressly stated otherwise. Also, although they may not be, like elements in various embodiments described herein may be commonly referred to with like reference numerals within this section of the application.

[0056] Furthermore, it is understood that this disclosure is not limited to the particular methodology, materials and modifications described and as such may, of course, vary. It is also understood that the terminology used herein is for the purpose of describing particular aspects only, and is not intended to limit the scope of the claims.

[0057] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which this disclosure pertains. It should be understood that any methods, devices or materials similar or equivalent to those described herein can be used in the practice or testing of the example embodiments.

[0058] Where used herein, the terms first, second, and so on, do not necessarily denote any ordinal, sequential, or priority relation, but are simply used to more clearly distinguish one element or set of elements from another, unless specified otherwise.

[0059] Where used herein, the term about when applied to a value is intended to mean within the tolerance range of the equipment used to produce the value, or, in some examples, is intended to mean plus or minus 10%, or plus or minus 5%, or plus or minus 1%, unless otherwise expressly specified.

[0060] It should be appreciated that the term substantially is synonymous with terms such as nearly, very nearly, about, approximately, around, bordering on, close to, essentially, in the neighborhood of, in the vicinity of, etc., and such terms may be used interchangeably as appearing in the specification and claims. It should be appreciated that the term proximate is synonymous with terms such as nearby, close, adjacent, neighboring, immediate, adjoining, etc., and such terms may be used interchangeably as appearing in the specification and claims. The term substantially is intended to mean values within ten percent of the specified value.

[0061] Where used herein, the term exemplary is intended to mean an example of, serving as an example, or illustrative, and does not denote any preference or requirement with respect to a disclosed aspect or embodiment.

[0062] It should be understood that use of or in the present application is with respect to a non-exclusive arrangement, unless stated otherwise. For example, when saying that item x is A or B, it is understood that this can mean one of the following: (1) item x is only one or the other of A and B; (2) item x is both A and B. Alternately stated, the word or is not used to define an exclusive or arrangement. For example, an exclusive or arrangement for the statement item x is A or B would require that x can be only one of A and B. Furthermore, as used herein, and/or is intended to mean a grammatical conjunction used to indicate that one or more of the elements or conditions recited may be included or occur. For example, a device comprising a first element, a second element and/or a third element, is intended to be construed as any one of the following structural arrangements: a device comprising a first element; a device comprising a second element; a device comprising a third element; a device comprising a first element and a second element; a device comprising a first element and a third element; a device comprising a first element, a second element and a third element; or a device comprising a second element and a third element.

[0063] Moreover, as used herein, the phrases comprises at least one of and comprising at least one of in combination with a system or element is intended to mean that the system or element includes one or more of the elements listed after the phrase. For example, a device comprising at least one of: a first element; a second element; and a third element, is intended to be construed as any one of the following structural arrangements: a device comprising a first element; a device comprising a second element; a device comprising a third element; a device comprising a first element and a second element; a device comprising a first element and a third element; a device comprising a first element, a second element and a third element; or a device comprising a second element and a third element. A similar interpretation is intended when the phrase used in at least one of: is used herein.

[0064] It should be appreciated that the term tube as used herein is synonymous with hose, pipe, channel, conduit, tube end form, or any other suitable pipe flow used in hydraulics and fluid mechanics. It should further be appreciated that the term tube can mean a rigid or flexible conduit of any material suitable for containing and allowing the flow of a gas or a liquid.

[0065] By non-rotatably connected elements, it is meant that the elements are connected so that whenever one of the elements rotate, all the elements rotate, and relative rotation between the elements is not possible. Radial and/or axial movement of non-rotatably connected elements with respect to each other is possible, but not required. By rotatably connected elements, it is mean that the elements are rotatable with respect to each other.

[0066] Adverting now to the figures, FIG. 1 is a front perspective view of end forming tool assembly 10, in a non-engaged state. FIG. 2A is a front perspective view of end forming tool assembly 10. FIG. 2B is a rear perspective view of end forming tool assembly 10. FIG. 3A is a front perspective exploded view of end forming tool assembly 10. FIG. 3B is a rear perspective exploded view of end forming tool assembly 10. FIG. 4 is a cross-sectional view of end forming tool assembly 10 taken generally along line 4-4 in FIG. 1. FIG. 5 is a cross-sectional view of end forming tool assembly 10 taken generally along line 5-5 in FIG. 1. FIG. 6 is a cross-sectional view of end forming tool assembly 10 taken generally along line 6-6 in FIG. 2A.

[0067] End forming tool assembly 10 generally comprises body 20, link 70, at least one arm, for example, arms 100A-100B, clamp 120, and die 90. In an exemplary embodiment, end forming tool assembly 10 further comprises plunger 130. In an exemplary embodiment, end forming tool assembly 10 further comprises actuator 2. End forming tool assembly 10 is operatively arranged to end form tube 12. Prior to end forming, tube 12 comprises end 14, end 16, and radially outward facing surface 18.

[0068] Body 20 generally comprises a plate including end 22, end 24, and bracket assembly 30. In an exemplary embodiment, bracket assembly 30 is arranged proximate end 22 and generally comprises at least one protrusion or wall, for example, wall 32A and wall 32B. Wall 32A comprises hole 34A extending generally in a radial direction therethrough. Hole 34A is operatively arranged to allow arm 100A to engage clamp 120, as will be described in greater detail below. Wall 32B comprises hole 34B extending generally in a radial direction therethrough. Hole 34B is operatively arranged to allow arm 100B to engage clamp 120, as will be described in greater detail below.

[0069] In an exemplary embodiment, body 20 further comprises flange 36 arranged at or proximate to end 22. Flange 36 comprises hole 38 extending in an axial direction therethrough. Hole 38 is operatively arranged to engage tube 12, namely, such that tube 12 can pass through flange 36 in an axial direction. In an exemplary embodiment, body 20 further comprises flange 26 arranged proximate to end 24. Flange 26 comprises hole 28 extending in an axial direction therethrough. Hole 28 is operatively arranged to allow plunger 130 to extend axially therethrough to connect to link 70, as will be described in greater detail below.

[0070] In an exemplary embodiment, body 20 further comprises hole 40 and plate or tube holder 50. Plate 50 is operatively arranged to be removably engaged with body 20 via hole 40. As best shown in FIGS. 2B and 4-5, plate 50 is removably engaged with hole 40 to engage tube 12. Plate 50 comprises bottom surface 52 and top surface 54. Top surface 54 is arranged to engage end 14. In an exemplary embodiment, bottom surface 52 engages protrusions extending inward from walls 32A-32B. In an exemplary embodiment, plate 50 further comprises protrusion 56 extending from bottom surface 52 in axial direction AD2. Protrusion 56 is operatively arranged to engage body 20 to prevent over insertion of plate 50 in hole 40. In the disengaged state, plate 50 holds tube 12 in place. Plate 50 also provides an indicator of how far tube 12 needs to be inserted into hole 38, in axial direction AD2. Prior to engaging end forming tool assembly 10, plate 50 is removed to allow die 90 to engage end 14 of tube 12, as will be described in greater detail below.

[0071] In an exemplary embodiment, body 20 further comprises at least one hole, for example, hole 42A and hole 42B, and clip 60. Clip 60 comprises at least one arm, for example arms 62A-62B, operatively arranged to extend through holes 42A-42B and engage clamp 120. Arms 62A-62B may be clastic and comprise inward extending protrusions arranged thereon. As best shown in FIG. 6, arms 62A-62B engage outward facing surfaces 126A-126B of clamp 120 to hold clamp 120 in position within bracket assembly 30, prior to engaging end forming tool assembly 10. Clip 60 is removably connectable to body 20.

[0072] Arm 100A is rotatably connected to body 20, for example, via pin 114A. Arm 100A comprises hole 102A arranged to engage pin 114A, slot 104A, and engaging surface 108A. In an exemplary embodiment, and as best shown in FIG. 4, slot 104A is at least partially curvilinear and is operatively arranged to engage pin 112A. As pin 112A is displaced in slot 104A, engaging surface 108A of arm 100A is displaced radially, for example, in radial direction RD1 and radial direction RD2, to engage and disengage clamp 120, respectively. In an exemplary embodiment, arm 100A further comprises engaging member 110A displaceably and/or removably connected to engaging surface 108A. Engaging member 110A is engaged with hole 106A and is adjustable, for example, via a threaded connection therein. Engaging member 110A may be adjusted to increase or decrease the force with which arm 100A engages clamp portion 120A.

[0073] Arm 100B is rotatably connected to body 20, for example, via pin 114B. Arm 100B comprises hole 102B arranged to engage pin 114B, slot 104B, and engaging surface 108B. In an exemplary embodiment, and as best shown in FIG. 4, slot 104B is at least partially curvilinear and is operatively arranged to engage pin 112B. As pin 112B is displaced in slot 104B, engaging surface 108B of arm 100B is displaced radially, for example, in radial direction RD1 and radial direction RD2, to engage and disengage clamp 120, respectively. In an exemplary embodiment, arm 100B further comprises engaging member 110B displaceably and/or removably connected to engaging surface 108B. Engaging member 110B is engaged with hole 106B and is adjustable, for example, via a threaded connection therein. Engaging member 110B may be adjusted to increase or decrease the force with which arm 100B engages clamp portion 120B.

[0074] In an exemplary embodiment, end forming tool assembly 10 further comprises a linkage removably connectable to body 20, the linkage comprising one or more elements, for example, arm 46 and leg 48. Leg 48 is operatively arranged to be connected to body 20. For example, leg 48 is removably connectable to flange 26. Arm 46 is connected to leg 48 and is operatively arranged to maintain arms 100A-100B on body 20, for example, via pins 114A-114B. In an exemplary embodiment, leg 48 comprises hole 48A including a female component that engages a male connecting component of protrusion 44 on body 20. As shown, protrusion 44 extends from flange 26, for example, in an axial direction.

[0075] Clamp 120 comprises portion 120A and portion 120B. Portions 120A-120B are configured to be arranged radially around tube 12 and squeezed against radially outward facing surface 18 during engagement of end forming tool assembly 10. Clamp 120 is removably arranged in bracket assembly 30. Portion 120A comprises inward facing surface 122A, space 124A, and outward facing surface 126A. Inward facing surface 122A comprises a plurality of teeth or threading arranged to engage radially outward facing surface 18. Space 124A is arranged to engage die 90. Arm 100A engages outward facing surface 126A to apply radially inward force on portion 120A. Portion 120B comprises inward facing surface 122B, space 124B, and outward facing surface 126B. Inward facing surface 122B comprises a plurality of teeth or threading arranged to engage radially outward facing surface 18. Space 124B is arranged to engage die 90. Arm 100B engages outward facing surface 126B to apply radially inward force on portion 120B.

[0076] As best shown in FIG. 4, end 14 of tube 12 is spaced apart in axial direction AD2 from inward facing surfaces 122A-122B. Specifically, end 14 is arranged in or extends through spaces 124A-124B. Arms 100A-100B and/or engaging members 110A-110B extend through holes 34A-34B and engage outward facing surfaces 126A-126B to squeeze portions 120A-120B around tube 12, respectively. Die 90 is displaced in axial direction AD1 into spaces 124A-124B to engage end 14 of tube 12. It should be appreciated that the outer diameter of die 90 is less than or equal to the inner diameter formed by spaces 124A-124B. When die 90 is forced into end 14 a radially outward extending protrusion is formed on tube 12.

[0077] Link or body 70 comprises base 71 and at least one leg extending axially therefrom, for example, leg 72A and leg 72B. Leg 72B is spaced apart from leg 72A, for example, in radial direction RD2. In an exemplary embodiment, leg 72A comprises two portions that are spaced apart and engage opposite sides of arm 100A. Leg 72A comprises hole 74A and pin 112A extends through leg 72A and slot 104A of arm 100A. In an exemplary embodiment, leg 72B comprises two portions that are spaced apart and engage opposite sides of arm 100B. Leg 72B comprises hole 74B and pin 112B extends through leg 72B and slot 104B of arm 100B.

[0078] Link 70 is arranged to be connected to plunger 130. In an exemplary embodiment, plunger 130 generally comprises end 132, end 134, and groove 136 arranged proximate to end 134. End 134 is arranged to engage link 70 and end 132 is arranged to engage actuator 2. In an exemplary embodiment, and as best shown in FIG. 4, link 70 comprises hole 73 extending into base 71 in axial direction AD1 from the bottom thereof. Link 70 may further comprise hole 76. In an exemplary embodiment, hole 76 extends into base 71 in a direction perpendicular to axial direction AD1. End 134 of plunger 130 is engaged with hole 73 such that groove 136 is aligned with hole 76. Retainer 82 is then inserted into hole 76 and engages groove 136, for example via two legs, to connect plunger 130 to link 70. Retainer 82 can be removed from hole 76 to disconnect link 70 from plunger 130.

[0079] Link 70 may further comprise hole 78. In an exemplary embodiment, hole 78 extends into base 71 in axial direction AD1 from the top thereof. Link 70 comprises flange 80 extending radially into hole 78. Flange 80 is arranged to engage groove 96 to connect die 90 to link 70. Specifically, die 90 is inserted into hole 78 of link 70 such that flange 80 engages groove 96. Section 94 is arranged on a first side of (i.e., below) flange 80 and section 92 is arranged on a second side of (i.e., above) flange 80, opposite the first side. Die 90 further comprises hole or form 98 arranged to engage tube 12 to impart a radially outward projection and/or plastic deformation thereon. It should be appreciated that multiple dies 90 having different forms may be used. Arm 46 and/or leg 48 further enclose die 90 within link 70 thereby preventing die 90 from accidentally being removed from hole 78.

[0080] Actuator 2 is operatively arranged to displace plunger 130 in axial direction AD1 with respect to body 20. In an exemplary embodiment, actuator 2 is arranged to displace plunger 130 in axial direction AD1 and axial direction AD2 with respect to body 20. Actuator 2 is arranged to be connected to body 20. For example, and as best shown in FIGS. 4-5, actuator 2 is engaged with a hole in flange 26 that extends in axial direction AD1 with respect to end 24. In an exemplary embodiment, actuator 2 may comprise a radially outward extending flange that engages a radially inward extending flange on body 20 (see FIG. 5) to connect body 20 to actuator 2. In an exemplary embodiment, actuator 2 comprises a linear actuator. In an exemplary embodiment, actuator 2 comprises a hydraulic, pneumatic, screw, piezoelectric, ball, or telescoping actuator.

[0081] To assemble end forming tool assembly 10, arms 100A-100B are connected to link 70. Specifically, arm 100A is connected to leg 72A with pin 112A extending through hole 74A and slot 104A and arm 100B is connected to leg 72B with pin 112B extending through hole 74B and slot 104B. In an exemplary embodiment, engaging members 110A-110B are connected to arms 100A-100B. Arms 100A-100B are pivotably connected to body 20, for example via pins 114A-114B. Die 90 is connected to link 70. Plunger 130 is inserted through hole 28 of body 20 in axial direction AD2 and connected to link 70, for example via retainer 82. In an exemplary embodiment, arm 46 and/or leg 48 are connected to body 20. Actuator 2 is connected to and/or engages body 20.

[0082] Plate 50 is inserted into hole 40 (see FIG. 5). Clamp 120 is arranged in bracket assembly 30 such that inward facing surfaces 122A-122B face toward each other. In an exemplary embodiment, portions 120A-120B of clamp 120 rest on one or more inward extending ledges or protrusions of bracket assembly 30. For example, a ledge may extend radially inward from wall 32A and/or a ledge may extend radially inward from wall 32B. Tube 12 is inserted in axial direction AD2 through hole 38. In an exemplary embodiment, end 14 rests on top surface 54 of plate 50. Clip 60 is connected to body 20, and specifically arms 62A-62B are inserted through holes 42A-42B such that they are arranged within bracket assembly 30 and engage outward facing surfaces 126A-126B. In an exemplary embodiment, arms 62A-62B apply radially inward force on portions 120A-120B which further holds clamp 120 and tube 12 within bracket assembly 30. Prior to engaging end forming tool assembly 10, plate 50 is removed from body 20.

[0083] To engage end forming tool assembly 10, plunger 130 is displaced in axial direction AD1 with respect to body 20, which in turn displaces link 70 in axial direction AD1 with respect to body 20. As link 70 is displaced in axial direction AD1, link 70 simultaneously forces arms 100A-100B radially inward to squeeze portions 120A-120B radially inward around tube 12 and forces die 90 onto end 14. For example, arm 100A is displaced in circumferential direction CD1 such that surface 108A and engaging member 110A are displaced in radial direction RD1, and arm 100B is displaced in circumferential direction CD2 such that surface 108B and engaging member 110B are displaced in radial direction RD1. Thus, end forming tool assembly 10 simultaneously 1) radially clamps tube 12 (i.e., via clamp 120 and arms 100A-100B) and 2) plastically deforms tube 12 (i.e., by axially driving die 90 onto end 14).

[0084] FIG. 7 is a front perspective view of an embodiment of end forming tool assembly 10, in an engaged state. FIG. 8 is a partial front perspective exploded view of end forming tool assembly 10. FIG. 9 is a cross-sectional view of end forming tool assembly 10 taken generally along line 9-9 in FIG. 7. The embodiment of end forming tool assembly 10 shown in FIGS. 7-10 is substantially similar to the embodiment of end forming tool assembly 10 shown in FIGS. 1-6.

[0085] Arm 46 and leg 48 may be connected to body 20, and specifically flange 26, via pins, screws, dowels, welding, brazing, adhesive, etc. Similarly, plunger 130 may be connected to link 70 via pins, screws, dowels, welding, brazing, adhesive, etc. In an exemplary embodiment, and as shown, plunger 130 may comprise two legs separated by an elongate hole, the hole extending from end 134 in direction AD2. Each of the two legs engages with and is connected to two sides of link 70.

[0086] As best shown in FIG. 9, actuator 2 has displaced link 70 and thus die 90 in axial direction AD1 with respect to body 20. Die 90 has been forced into spaces 124A-124B to engage end 14 and form bead or shoulder or protrusion 19. At the same time, link 70 forces arms 100A-100B radially inward via pins 112A-112B such that engaging members 110A-110B squeeze clamp 120 around radially outward facing surface 18, thus securing tube 12 in place for engagement with die 90. Note that in the engaged state, pins 112A-112B are arranged proximate the top of slots 104A-104B, respectively (see FIG. 9), as compared with the disengaged state wherein pins 112A-112B are arranged proximate the bottom of slots 104A-104B, respectively (see FIG. 4).

[0087] FIG. 10A is a front perspective view of end forming tool assembly 210, in an engaged state. FIG. 10B is a rear perspective view of end forming tool assembly 210. FIG. 11 is a front perspective exploded view of end forming tool assembly 210. FIG. 12 is a cross-sectional view of end forming tool assembly 210 taken generally along line 11-11 in FIG. 10A.

[0088] End forming tool assembly 210 generally comprises body 220, link 270, at least one arm, for example, arms 300A-300B, clamp 320, and die 290. In an exemplary embodiment, end forming tool assembly 210 further comprises plunger 330. In an exemplary embodiment, end forming tool assembly 210 further comprises an actuator such as actuator 2 shown in FIG. 1. End forming tool assembly 210 is operatively arranged to end form a tube, for example tube 12.

[0089] Body 220 generally comprises a plate including end 222, end 224, and bracket assembly 230. In an exemplary embodiment, bracket assembly 230 is arranged proximate end 222 and generally comprises at least one protrusion or wall, for example, wall 232A and wall 232B. Wall 232A comprises hole 234A extending generally in a radial direction therethrough. Hole 234A is operatively arranged to allow arm 300A to engage clamp 320, as will be described in greater detail below. Wall 232B comprises hole 234B extending generally in a radial direction therethrough. Hole 234B is operatively arranged to allow arm 300B to engage clamp 320, as will be described in greater detail below.

[0090] In an exemplary embodiment, body 220 further comprises flange 236 arranged at or proximate to end 222. Flange 236 comprises hole 238 extending in an axial direction therethrough. Hole 238 is operatively arranged to engage tube 12, namely, such that tube 12 can pass through flange 236 in an axial direction. In an exemplary embodiment, body 220 further comprises base 226 arranged proximate to end 224. Base 226 comprises hole 228 extending in an axial direction therethrough. Hole 228 is operatively arranged to allow plunger 330 to extend axially therethrough to connect to link 270, as will be described in greater detail below.

[0091] In an exemplary embodiment, end forming tool assembly 210 further comprises plate 214. Plate 214 is connected to body 220 to maintain clamp 320 in body 220, as best shown in FIG. 10B. In an exemplary embodiment, end forming tool assembly 210 further comprises base 212. Base 212 is operatively arranged to engage base 226 and/or connect actuator 2 to body 220.

[0092] Arm 300A is rotatably connected to body 220, for example, via pin 312A and bearing 314A. Arm 300A comprises hole 302A arranged to engage pin 312A, engaging surface 304A, and engaging surface 308A. In an exemplary embodiment, and as best shown in FIG. 12, arm 300A is at least partially curvilinear. As link 270 engages surface 304A, arm 300A pivots about pin 312A such that surface 304A is displaced radially outward and surface 308A is displaced radially inward to engage portion 320A and squeeze clamp 320 around tube 12.

[0093] Arm 300B is rotatably connected to body 220, for example, via pin 312B and bearing 314B. Arm 300B comprises hole 302B arranged to engage pin 312B, engaging surface 304B, and engaging surface 308B. In an exemplary embodiment, and as best shown in FIG. 12, arm 300B is at least partially curvilinear. As link 270 engages surface 304B, arm 300B pivots about pin 312B such that surface 304B is displaced radially outward and surface 308B is displaced radially inward to engage portion 320B and squeeze clamp 320 around tube 12.

[0094] Clamp 320 comprises portion 320A and portion 320B. Portions 320A-320B are configured to be arranged radially around tube 12 and squeezed against radially outward facing surface 18 during engagement of end forming tool assembly 210. Clamp 320 is removably arranged in bracket assembly 230. Portion 320A comprises inward facing surface 322A, space 324A, and outward facing surface 326A. Inward facing surface 322A comprises a plurality of teeth or threading arranged to engage radially outward facing surface 18. Space 324A is arranged to engage die 290. Arm 300A engages outward facing surface 326A to apply radially inward force on portion 320A. In an exemplary embodiment, outward facing surface 326A comprises a groove. Portion 320B comprises inward facing surface 322B, space 324B, and outward facing surface 326B. Inward facing surface 322B comprises a plurality of teeth or threading arranged to engage radially outward facing surface 18. Space 324B is arranged to engage die 290. Arm 300B engages outward facing surface 326B to apply radially inward force on portion 320B. In an exemplary embodiment, outward facing surface 326B comprises a groove.

[0095] As best shown in FIG. 12, end 14 of tube 12 is spaced apart in axial direction AD2 from inward facing surfaces 322A-322B. Specifically, end 14 is arranged in or extends through spaces 324A-324B. Arms 300A-300B extend through holes 234A-234B and engage outward facing surfaces 326A-326B to squeeze portions 320A-320B around tube 12, respectively. Die 290 is displaced in axial direction AD1 into spaces 324A-324B to engage end 14 of tube 12. It should be appreciated that the outer diameter of die 290 is less than or equal to the inner diameter formed by spaces 324A-324B. When die 290 is forced into end 14 radially outward extending protrusion 19 is formed on tube 12.

[0096] Link or body 270 comprises base 271 and at least one leg extending axially therefrom, for example, leg 272A and leg 272B. Leg 272B is spaced apart from leg 272A, for example, in radial direction RD2. Link 270 is arranged to be connected to plunger 330. In an exemplary embodiment, plunger 330 generally comprises end 332, end 334, and groove 336 arranged proximate to end 334. End 334 is arranged to engage link 270 and end 332 is arranged to engage actuator 2. In an exemplary embodiment, and as best shown in FIG. 12, link 270 comprises hole 273 extending into and/or through base 271 in axial direction AD1 from the bottom thereof. End 334 of plunger 330 is fed through hole 273 in axial direction AD1 and a retainer (not shown), such as retainer 82 shown in FIGS. 3A-5, is engaged with groove 336, for example via two legs, to connect plunger 330 to link 270. The retainer can be removed from groove 336 to disconnect link 270 from plunger 330.

[0097] Link 270 may further comprise hole 278. In an exemplary embodiment, hole 278 extends into link 270 in axial direction AD1 from the top thereof. Link 270 comprises flange 280 extending radially into hole 278. Flange 280 is arranged to engage groove 296 to connect die 290 to link 270. Specifically, die 290 is inserted into hole 278 of link 270 such that flange 280 engages groove 296. Section 294 is arranged on a first side of (i.e., below) flange 280 and section 292 is arranged on a second side of (i.e., above) flange 280, opposite the first side. Die 290 further comprises hole or form 298 arranged to engage tube 12 to impart a radially outward projection and/or plastic deformation thereon. It should be appreciated that multiple dies 290 having different forms may be used.

[0098] Actuator 2 is operatively arranged to displace plunger 330 in axial direction AD1 with respect to body 220. In an exemplary embodiment, actuator 2 is arranged to displace plunger 330 in axial direction AD1 and axial direction AD2 with respect to body 220.

[0099] To assemble end forming tool assembly 210, arms 300A-300B are pivotably connected to base 220, for example via pins 312A-312B and bearings 314A-314B. In an exemplary embodiment, base 212 is connected to body 220. In an exemplary embodiment, plate 214 is connected to body 220. Die 290 is connected to link 270. Plunger 330 is inserted through hole 228 of body 220 in axial direction AD2 and connected to link 270, for example via a retainer (not shown). Actuator 2 is connected to and/or engages body 220.

[0100] Clamp 320 is arranged in bracket assembly 230 such that inward facing surfaces 322A-322B face toward each other. In an exemplary embodiment, portions 320A-320B of clamp 320 rest on radially inward extending projections 240A-240B. Tube 12 is inserted in axial direction AD2 through hole 238.

[0101] To engage end forming tool assembly 210, plunger 330 is displaced in axial direction AD1 with respect to body 220, which in turn displaces link 270 in axial direction AD1 with respect to body 220. As link 270 is displaced in axial direction AD1, link 270 simultaneously forces arms 300A-300B radially inward, by contact with surfaces 304A-304B, to squeeze portions 320A-320B radially inward around tube 12 and forces die 290 onto end 14. For example, arm 300A is displaced in circumferential direction CD1 such that surface 308A is displaced in radial direction RD1, and arm 300B is displaced in circumferential direction CD2 such that surface 308B is displaced in radial direction RD1. Thus, end forming tool assembly 210 simultaneously 1) radially clamps tube 12 (i.e., via clamp 320 and surfaces 308A-308B of arms 300A-300B) and 2) plastically deforms tube 12 (i.e., by axially driving die 290 onto end 14).

[0102] FIG. 13 is a front perspective view of end forming tool assembly 410, in a non-engaged state. FIG. 14A is a front perspective view of end forming tool assembly 410. FIG. 14B is a rear perspective view of end forming tool assembly 410. FIG. 15A is a front perspective exploded view of end forming tool assembly 410. FIG. 15B is a rear perspective exploded view of end forming tool assembly 410. FIG. 16 is a cross-sectional view of end forming tool assembly 410 taken generally along line 16-16 in FIG. 14A. FIG. 17 is a cross-sectional view of end forming tool assembly 410 taken generally along line 17-17 in FIG. 14A.

[0103] End forming tool assembly 410 generally comprises body 420, link 470, at least one arm, for example, arms 500A-500B, clamp 520, and die 490. In an exemplary embodiment, end forming tool assembly 410 further comprises plunger 530. In an exemplary embodiment, end forming tool assembly 410 further comprises actuator 2. In an exemplary embodiment, end forming tool assembly 410 further comprises case 412. End forming tool assembly 410 is operatively arranged to end form tube 12.

[0104] Body 420 generally comprises a plate including end 422, end 424, and bracket assembly 430. In an exemplary embodiment, bracket assembly 430 is arranged proximate end 422 and generally comprises at least one protrusion or wall, for example, wall 432A and wall 432B. Wall 432A comprises hole 434A extending generally in a radial direction therethrough. Hole 434A is operatively arranged to allow arm 500A to engage clamp 520, as will be described in greater detail below. Wall 432B comprises hole 434B extending generally in a radial direction therethrough. Hole 434B is operatively arranged to allow arm 500B to engage clamp 520, as will be described in greater detail below. In an exemplary embodiment, bracket assembly 430 is removably connected to body 420, for example, via one or more flanges extending radially outward from wall 432A and/or wall 432B.

[0105] In an exemplary embodiment, body 420 and/or bracket assembly 430 further comprises flange 436 arranged at or proximate to end 422. Flange 436 comprises hole 438 extending in an axial direction therethrough. Hole 438 is operatively arranged to engage tube 12, namely, such that tube 12 can pass through flange 436 in an axial direction. In an exemplary embodiment, body 420 further comprises flange 426 arranged proximate to end 424. Flange 426 comprises hole 428 extending in an axial direction therethrough. Hole 428 is operatively arranged to allow plunger 530 to extend axially therethrough to connect to link 470, as will be described in greater detail below.

[0106] In an exemplary embodiment, body 420 further comprises hole 440 and plate or tube holder 450. Plate 450 is operatively arranged to be removably engaged with body 420 via hole 440. As best shown in FIGS. 14B and 16-17, plate 450 is removably engaged with hole 440 to engage tube 12. Plate 450 comprises bottom surface 452 and top surface 454. Top surface 454 is arranged to engage end 14. In an exemplary embodiment, bottom surface 452 engages protrusions extending inward from walls 432A-432B. In an exemplary embodiment, plate 450 further comprises protrusion or arm 456 extending from top surface 454 in axial direction AD1. Protrusion 456 is operatively arranged to engage body 420 to prevent over insertion of plate 450 in hole 440. In the disengaged state, plate 450 holds tube 12 in place. Plate 450 also provides an indicator of how far tube 12 needs to be inserted into hole 438, in axial direction AD2. Prior to engaging end forming tool assembly 410, plate 450 is removed to allow die 490 to engage end 14 of tube 12, as will be described in greater detail below.

[0107] In an exemplary embodiment, body 420 further comprises at least one hole, for example, hole 442A and hole 442B, and arm 456 further comprise at least one pin, for example, pin 458A and pin 458B. Pins 458A-458B are operatively arranged to slidably extend through holes 442A-442B and engage arms 500A-500B. Specifically, pins 458A-458B engage holes 503A-503B of arms 500A-500B to maintain arms 500A-500B in a disengaged state. When pins 458A-458B are disengaged or removed from arms 500A-500B, springs 462A-462B pull arms 500A-500B radially inward to engage clamp 520, thereby holding it in place until end forming tool assembly 410 is engaged. Thus, plate 450 and pins 458A-458B form a chuck which maintains arms 500A-500B in a disengaged position and holds tube 12 in place. In an exemplary embodiment, pins 458A-458B are connected to arm 456. In an exemplary embodiment, plate 450 is connected to arm 456. It should be appreciated that, while pins 458A-458B are slidably engaged with holes 442A-442B and 503A-503B and can be completely removed therefrom in some embodiments, in other embodiments, pins 458A-458B are removable from holes 503A-503B but not holes 442A-442B.

[0108] Arm 500A is rotatably connected to body 420, for example, via pin 514A. Arm 500A comprises hole 502A arranged to engage pin 514A, slot 504A, and engaging surface 508A. In an exemplary embodiment, and as best shown in FIG. 16, slot 504A is at least partially curvilinear and is operatively arranged to engage pin 512A. As pin 512A is displaced in slot 504A, engaging surface 508A of arm 500A is displaced radially, for example, in radial direction RD1 and radial direction RD2, to engage and disengage clamp 120, respectively. In an exemplary embodiment, arm 500A further comprises engaging member 510A displaceably and/or removably connected to engaging surface 508A. Engaging member 510A is engaged with hole 506A and is adjustable, for example, via a threaded connection therein. Engaging member 510A may be adjusted to increase or decrease the force with which arm 500A engages clamp portion 520A. In an exemplary embodiment, and as previously described, arm 500A further comprises hole 503A operatively arranged to engage pin 458A.

[0109] Arm 500B is rotatably connected to body 420, for example, via pin 514B. Arm 500B comprises hole 502B arranged to engage pin 514B, slot 504B, and engaging surface 508B. In an exemplary embodiment, and as best shown in FIG. 16, slot 504B is at least partially curvilinear and is operatively arranged to engage pin 512B. As pin 512B is displaced in slot 504B, engaging surface 508B of arm 500B is displaced radially, for example, in radial direction RD1 and radial direction RD2, to engage and disengage clamp 520, respectively. In an exemplary embodiment, arm 500B further comprises engaging member 510B displaceably and/or removably connected to engaging surface 508B. Engaging member 510B is engaged with hole 506B and is adjustable, for example, via a threaded connection therein. Engaging member 510B may be adjusted to increase or decrease the force with which arm 500B engages clamp portion 520B. In an exemplary embodiment, and as previously described, arm 500B further comprises hole 503B operatively arranged to engage pin 458B.

[0110] In an exemplary embodiment, end forming tool assembly 410 further comprises at least one biasing element, for example spring 462A and spring 462B, operatively arranged to bias at least one of arm 500A and arm 500B in a radially inward direction. For example, spring 462A is connected at a first end to body 420, for example via strut 460A, and at a second end to arm 500A, for example via strut 464A. Strut 460A may be engaged with a hole in body 420 (e.g., strut 460A may be threadeably connected to a threaded hole in body 420). Strut 464A may be engaged with a hole in arm 500A (e.g., strut 464A may be threadeably connected to a threaded hole in body 420). In an exemplary embodiment, strut 464A is arranged in a hole on an opposite side of arm 500A as hole 506A. Spring 462B is connected at a first end to body 420, for example via strut 460B, and at a second end to arm 500B, for example via strut 464B. Strut 460B may be engaged with a hole in body 420 (e.g., strut 460B may be threadeably connected to a threaded hole in body 420). Strut 464B may be engaged with a hole in arm 500B (e.g., strut 464B may be threadeably connected to a threaded hole in body 420). In an exemplary embodiment, strut 464B is arranged in a hole on an opposite side of arm 500B as hole 506B.

[0111] Springs 462A-462B bias arms 500A-500B in a radially inward direction such that arms 500A-500B and/or engaging elements 510A-510B preliminarily engage clamp portions 520A-520B and hold tube 12 in position prior to engagement of end forming tool assembly 410. When arms 500A-500B are held in the disengaged position by pins 458A-458B, a user may easily insert clamp 520 and tube 12 into end forming tool 410. Then pins 458A-458B are disengaged from holes 503A-503B, and springs 462A-462B snap arms 500A-500B inward such that engaging members 510A-510B firmly hold tube 12 within clamp 520.

[0112] In an exemplary embodiment, end forming tool assembly 410 further comprises a linkage removably connectable to body 420, the linkage comprising one or more elements, for example, arm 446 and leg 448. Leg 448 is operatively arranged to be connected to body 420. For example, leg 448 is removably connectable to flange 426. Arm 446 is connected to leg 448 and is operatively arranged to maintain arms 500A-500B on body 420, for example, via pins 514A-514B. In an exemplary embodiment, leg 448 comprises hole 448A including a female component that engages a male connecting component of protrusion 444 on body 420. As shown, protrusion 444 extends from flange 426, for example, in an axial direction.

[0113] Clamp 520 comprises portion 520A and portion 520B. Portions 520A-520B are configured to be arranged radially around tube 12 and squeezed against radially outward facing surface 18 during engagement of end forming tool assembly 410. Clamp 520 is removably arranged in bracket assembly 430. Portion 520A comprises inward facing surface 522A, space 524A, and outward facing surface 526A. Inward facing surface 522A comprises a plurality of teeth or threading arranged to engage radially outward facing surface 18. Space 524A is arranged to engage die 490. Arm 500A engages outward facing surface 526A to apply radially inward force on portion 520A. Portion 520B comprises inward facing surface 522B, space 524B, and outward facing surface 526B. Inward facing surface 522B comprises a plurality of teeth or threading arranged to engage radially outward facing surface 18. Space 524B is arranged to engage die 490. Arm 500B engages outward facing surface 526B to apply radially inward force on portion 520B.

[0114] As best shown in FIG. 16, end 14 of tube 12 is spaced apart in axial direction AD2 from inward facing surfaces 522A-522B. Specifically, end 14 is arranged in or extends through spaces 524A-524B. Arms 500A-500B and/or engaging members 510A-510B extend through holes 434A-434B and engage outward facing surfaces 526A-526B to squeeze portions 520A-520B around tube 12, respectively. Die 490 is displaced in axial direction AD1 into spaces 524A-524B to engage end 14 of tube 12. It should be appreciated that the outer diameter of die 490 is less than or equal to the inner diameter formed by spaces 524A-524B. When die 490 is forced into end 14 a radially outward extending protrusion is formed on tube 12.

[0115] Link or body 470 comprises base 471 and at least one leg extending axially therefrom, for example, leg 472A and leg 472B. Leg 472B is spaced apart from leg 472A, for example, in radial direction RD2. In an exemplary embodiment, leg 472A comprises two portions that are spaced apart and engage opposite sides of arm 500A. Leg 472A comprises hole 474A and pin 512A extends through leg 472A and slot 504A of arm 500A. In an exemplary embodiment, leg 472B comprises two portions that are spaced apart and engage opposite sides of arm 500B. Leg 472B comprises hole 474B and pin 512B extends through leg 472B and slot 504B of arm 500B. In an exemplary embodiment, at least one of pin 512A and pin 512B comprises a bearing (e.g., a roller within a bushing).

[0116] Link 470 is arranged to be connected to plunger 530. In an exemplary embodiment, plunger 530 generally comprises end 532, end 534, and groove 536 arranged proximate to end 534. End 534 is arranged to engage link 470 and end 532 is arranged to engage actuator 2. In an exemplary embodiment, and as best shown in FIG. 16, link 470 comprises hole 473 extending into base 471 in axial direction AD1 from the bottom thereof. Link 470 may further comprise hole 476. In an exemplary embodiment, hole 476 extends into base 471 in a direction perpendicular to axial direction AD1. End 534 of plunger 530 is engaged with hole 473 such that groove 536 is aligned with hole 476. Retainer 482 is then inserted into hole 476 and engages groove 536, for example via two legs, to connect plunger 530 to link 470. Retainer 482 can be removed from hole 476 to disconnect link 470 from plunger 530.

[0117] Link 470 may further comprise hole 478. In an exemplary embodiment, hole 478 extends into base 471 in axial direction AD1 from the top thereof. Link 470 comprises flange 480 extending radially into hole 478. Flange 480 is arranged to engage groove 496 to connect die 490 to link 470. Specifically, die 490 is inserted into hole 478 of link 470 such that flange 480 engages groove 496. Section 494 is arranged on a first side of (i.e., below) flange 480 and section 492 is arranged on a second side of (i.e., above) flange 480, opposite the first side. Die 490 further comprises hole or form 498 arranged to engage tube 12 to impart a radially outward projection and/or plastic deformation thereon. It should be appreciated that multiple dies 490 having different forms may be used. Arm 446 and/or leg 448 further enclose die 490 within link 470 thereby preventing die 490 from accidentally being removed from hole 478.

[0118] Actuator 2 is operatively arranged to displace plunger 530 in axial direction AD1 with respect to body 420. In an exemplary embodiment, actuator 2 is arranged to displace plunger 530 in axial direction AD1 and axial direction AD2 with respect to body 420. Actuator 2 is arranged to be connected to body 420. For example, and as best shown in FIGS. 16-17, actuator 2 may be engaged with a hole in flange 426 that extends in axial direction AD1 with respect to end 424. In an exemplary embodiment, actuator 2 may comprise a radially outward extending flange that engages a radially inward extending flange on body 420 (see FIG. 17) to connect body 420 to actuator 2. In an exemplary embodiment, actuator 2 comprises a linear actuator. In an exemplary embodiment, actuator 2 comprises a hydraulic, pneumatic, screw, piezoelectric, ball, or telescoping actuator.

[0119] To assemble end forming tool assembly 410, arms 500A-500B are connected to link 470. Specifically, arm 500A is connected to leg 472A with pin 512A extending through hole 474A and slot 504A and arm 500B is connected to leg 472B with pin 512B extending through hole 474B and slot 504B. In an exemplary embodiment, engaging members 510A-510B are connected to arms 500A-500B. Arms 500A-500B are pivotably connected to body 420, for example via pins 514A-514B. Die 490 is connected to link 470. Plunger 530 is inserted through hole 428 of body 420 in axial direction AD2 and connected to link 470, for example via retainer 482. In an exemplary embodiment, arm 446 and/or leg 448 are connected to body 420. Actuator 2 is connected to and/or engages body 420.

[0120] Plate 450 is inserted into hole 440 (see FIG. 17). Clamp 520 is arranged in bracket assembly 430 such that inward facing surfaces 522A-522B face toward each other. In an exemplary embodiment, portions 520A-520B of clamp 120 rest on one or more inward extending ledges or protrusions of bracket assembly 430. For example, a ledge may extend radially inward from wall 432A and/or a ledge may extend radially inward from wall 432B. Tube 12 is inserted in axial direction AD2 through hole 438. In an exemplary embodiment, end 14 rests on top surface 454 of plate 450. Pins 458A-458B are inserted through holes 442A-442B and into holes 503A-503B. In an exemplary embodiment, spring 462A is connected to arm 500A at a first end and body 420 at a second end, and spring 462B is connected to arm 500B at a first end and body 420 at a second end. Prior to engaging end forming tool assembly 410, plate 450 is removed from body 420.

[0121] To engage end forming tool assembly 410, pins 458A-458B are disengaged from holes 503A-503B. Springs 462A-462B cause arms 500A-500B to apply force to outward facing surfaces 526A-526B. Plate 450 is at least partially removed from body 420 and/or bracket assembly 430. Plunger 530 is displaced in axial direction AD1 with respect to body 420, which in turn displaces link 470 in axial direction AD1 with respect to body 420. As link 470 is displaced in axial direction AD1, link 470 simultaneously forces arms 500A-500B radially inward to squeeze portions 520A-120B radially inward around tube 12 and forces die 490 onto end 14. For example, arm 500A is displaced in circumferential direction CD1 such that surface 508A and engaging member 510A are displaced in radial direction RD1, and arm 500B is displaced in circumferential direction CD2 such that surface 508B and engaging member 510B are displaced in radial direction RD1. Thus, end forming tool assembly 410 simultaneously 1) radially clamps tube 12 (i.e., via clamp 520 and arms 500A-500B) and 2) plastically deforms tube 12 (i.e., by axially driving die 490 onto end 14).

[0122] FIG. 18A is a front perspective view of end forming tool assembly 610. FIG. 18B is a rear perspective view of end forming tool assembly 610. FIG. 19 is a front perspective exploded view of end forming tool assembly 610. FIG. 20 is a cross-sectional view of end forming tool assembly 610 taken generally along line 20-20 in FIG. 18A. FIG. 21 is a cross-sectional view of end forming tool assembly 610 taken generally along line 21-21 in FIG. 18A.

[0123] End forming tool assembly 610 generally comprises body 620, at least one arm, for example, arms 670A-670B, clamp 690, and die 720. In an exemplary embodiment, end forming tool assembly 610 further comprises plunger 650. In an exemplary embodiment, end forming tool assembly 610 further comprises actuator 2 (see FIGS. 1, 7-8, and 13). End forming tool assembly 610 is operatively arranged to end form tube 12.

[0124] Body 620 generally comprises end 622, end 624, and through-hole 626 extending from end 622 to end 624 in axial direction AD2. In an exemplary embodiment, body 620 comprises one or more radially inward extending channels or holes, for example, channel 628A-628B, operatively arranged to engage arms 670A-670B, as will be described in greater detail below. Body 620 further comprises through-bores 630A-630B. In an exemplary embodiment, through-bores 630A-630B may be aligned with channels 628A-628B, respectively. Body 620 further comprises flange 632 extending in axial direction AD2 from surface 624. Flange 632 comprises hole 634 arranged to engage pin or dowel or bolt 636 to connect the actuator to body 620. In an exemplary embodiment, hole 638 extends through body 620 in a direction perpendicular to axial direction AD1 and axial direction AD2. Hole 638 may extend at least partially through flange 632.

[0125] Plunger 650 comprises end 652, end 654, and at least one leg extending from end 654 in axial direction AD2, for example, legs 656A-656B. Leg 656B is spaced apart from leg 656A, for example, in a direction perpendicular to axial direction AD1 and axial direction AD2. Slot or hole 658 extends through legs 656A-656B and is arranged to slidingly engage pin 636. Thus, plunger 650 is slidingly connected to body 620 via pin 636 which extends through slot 658 and through-hole 634 in flange 632. In an exemplary embodiment, and as shown, leg 656A is arranged on a first side of flange 632 and leg 656B is arranged on a second side of flange 632. End 652 comprises hole 660 extending into plunger 650 in axial direction AD2. In an exemplary embodiment, hole 660 is threaded and arranged to engage protrusion 724 to secure die 720 to plunger 650.

[0126] Plunger 650 further comprises wedging member 662 connected to leg 656A and/or leg 656B. In an exemplary embodiment, wedging member 662 is fixedly secured to a distal end of leg 656A and/or leg 656B. Wedging member 662 comprises support 664 and at least one curvilinear member or wheel, for example, curvilinear members 666A-666B. In an exemplary embodiment, curvilinear member 666A is fixedly secured to support 664 and/or curvilinear member 666B is fixedly secured to support 664. In an exemplary embodiment, curvilinear member 666A is rotatably connected to support 664 and/or curvilinear member 666B is rotatably connected to support 664. Wedging member 666 is operatively arranged to engage arms 670A-670B such that arms 670A-670B apply radially inward force to clamp 690 about tube 12. Specifically, curvilinear member 666A is arranged to engage surface 676A to displace arm in circumferential direction CD1 with respect to body 620 and curvilinear member 666B is operatively arranged to engage surface 676B to displace arm in circumferential direction CD2 with respect to body 620.

[0127] Plunger 650 and die 720 are operatively arranged to be slidably displaceable, and translatable, in axial direction AD1 and axial direction AD2 with respect to body 620. FIGS. 18A-18B and 20-21 show end forming tool assembly 610 in a non-engaged state. By non-engaged state it is meant that plunger 650, and thus die 720, are retracted in axial direction AD2 with respect to body 620, for example, such that bottom surface 654 is engaged with, abuts against, or is arranged proximate to flange 632. To form the engaged state of end forming tool assembly 610, plunger 650 is displaced in axial direction AD1 with respect to body 620 such that wedging member 662 engages surfaces 676A-676B and die 720 engages end 14 of tube 12.

[0128] Die 720 comprises section or outward facing surface 722 and protrusion 724 extending from section 722 in axial direction AD2. Protrusion 724 is arranged to engage plunger 650 to connect die 720 thereto. For example, protrusion 724 may comprise threading arranged to engage threading in hole 660 to secure die 720 to plunger 650. Die 720 further comprises hole or form 726 arranged to engage tube 12 to impart a radially outward projection and/or plastic deformation thereon. It should be appreciated that multiple dies 720 having different forms may be used. Section 722 is arranged to engage spaces 694A-694B in clamp portions 690A-690B to engage end 14 of tube 12.

[0129] In an exemplary embodiment, end forming tool assembly 610 further comprises biasing element of spring 730 concentrically arranged around and aligned with section 722. Biasing element 730 comprises a first end operatively arranged to engage end 652 of plunger 650 and a second end operatively arranged to engage clamp portions 690A-690B. In the engaged state, wherein die 720 is engaged with tube 12 to form shoulder 19, biasing element 730 is in a compressed or partially compressed state wherein it biases plunger 650 and die 720 in axial direction AD2 with respect to tube 12. This provides a release mechanism and aid in preventing die 720 from getting stuck to tube 12. In an exemplary embodiment, biasing element 730 comprises a coil spring. In an exemplary embodiment, biasing element 730 comprises a wave spring.

[0130] Arm 670A is rotatably connected to body 620, for example via fastener or pin 640A. Arm 670A comprises end 672A, end 674A, and one or more holes, for example, hole 678A, 680A, and 682A. Hole 678A is arranged to engage fastener 640A to rotatably connect arm 670A to body 620. In an exemplary embodiment, fastener 640A extends through hole 678A and through-bore 630A and is secured via fastener 642A. Surface 676A is arranged proximate end 672A and faces radially inward, for example, in radial direction RD1. As previously described, wedging member 662 is arranged to engage surface 676A to displace arm 670A in circumferential direction CD1 with respect to body 620 such that end 674A, and thus clamp portion 690A, apply force to tube 12 in radial direction RD1. In an exemplary embodiment, arm 670A comprises a channel extending radially outward from surface 676A. In an exemplary embodiment, through-hole 680A and through-hole 682A are arranged proximate end 674A. In an exemplary embodiment, arm 670A is engaged with and/or arranged in channel 628A of body 620.

[0131] Arm 670B is rotatably connected to body 620, for example via fastener or pin 640B. Arm 670B comprises end 672B, end 674B, and one or more holes, for example, hole 678B, 680B, and 682B. Hole 678B is arranged to engage fastener 640B to rotatably connect arm 670B to body 620. In an exemplary embodiment, fastener 640B extends through hole 678B and through-bore 630B and is secured via fastener 642B. Surface 676B is arranged proximate end 672B and faces radially inward, for example, in radial direction RD1. As previously described, wedging member 662 is arranged to engage surface 676B to displace arm 670B in circumferential direction CD2 with respect to body 620 such that end 674B, and thus clamp portion 690B, apply force to tube 12 in radial direction RD1. In an exemplary embodiment, arm 670B comprises a channel extending radially outward from surface 676B. In an exemplary embodiment, through-hole 680B and through-hole 682B are arranged proximate end 674B. In an exemplary embodiment, arm 670B is engaged with and/or arranged in channel 628B of body 620.

[0132] Clamp 690 comprises portion 690A and portion 690B. Portions 690A-690B are configured to be arranged radially around tube 12 and squeezed against radially outward facing surface 18 during engagement of end forming tool assembly 610. Portion 690A comprises inward facing surface 692A, space 694A, and outward facing surface 696A. Inward facing surface 692A comprises a plurality of teeth or threading arranged to engage radially outward facing surface 18. Space 694A is arranged to engage die 720. Arm 670A engages outward facing surface 696A and/or channel or hole 698A extending radially inward therefrom to apply radially inward force on portion 690A. In an exemplary embodiment, portion 690A comprises one or more holes operatively arranged to connect portion 690A to arm 670A, for example, holes 700A and 702A. Fastener 684A is arranged to engage hole 700A and hole 680A to connect portion 690A to arm 670A proximate end 674A. Fastener 686A is arranged to engage hole 702A and hole 682A to connect portion 690A to arm 670A proximate end 674A.

[0133] Portion 690B comprises inward facing surface 692B, space 694B, and outward facing surface 696B. Inward facing surface 692B comprises a plurality of teeth or threading arranged to engage radially outward facing surface 18. Space 694B is arranged to engage die 720. Arm 670B engages outward facing surface 696B and/or channel or hole 698B extending radially inward therefrom to apply radially inward force on portion 690B. In an exemplary embodiment, portion 690B comprises one or more holes operatively arranged to connect portion 690B to arm 670B, for example, holes 700B and 702B. Fastener 684B is arranged to engage hole 700B and hole 680B to connect portion 690B to arm 670B proximate end 674B. Fastener 686B is arranged to engage hole 702B and hole 682B to connect portion 690B to arm 670B proximate end 674B.

[0134] In an exemplary embodiment, end forming tool assembly 610 further comprises at least one biasing member or spring, for example biasing member 710, operatively arranged to bias arms 670A-670B, and thus clamp portions 690A-690B, in a radially inward direction. For example, biasing member 710 comprises first end 712A connected to portion 690A, for example via fastener 706A, and second end 712B connected to portion 690B, for example via fastener 706B. Fastener 706A may be engaged with hole 704A in portion 690A and/or fastener 706B may be engaged with hole 704B in portion 690B. Biasing member 710 biases arms 670A-670B in a radially inward direction such that arms 670A-670B and/or clamping portions 690A-690B preliminarily hold tube 12 in position prior to engagement of end forming tool assembly 610. As end forming tool assembly 610 is moved to the engaged position, wedging member 662 engages surfaces 676A-676B resulting in added radial inward force on radially outward facing surface 18 from arms 670A-670B and/or clamp portions 690A-690B such that tube 12 can be deformed by die 720.

[0135] As best shown in FIG. 20, end 14 of tube 12 is spaced apart in axial direction AD2 from inward facing surfaces 692A-692B. Specifically, end 14 is arranged in or extends through spaces 694A-694B. Arms 670A-670B squeeze portions 690A-690B around tube 12, respectively. Die 720 is displaced in axial direction AD1 into spaces 694A-694B to engage end 14 of tube 12. It should be appreciated that the outer diameter of die 720 is less than or equal to the inner diameter formed by spaces 694A-694B. When die 720 is forced into end 14 radially outward extending protrusion 19 is formed on tube 12.

[0136] Actuator 2 is operatively arranged to displace plunger 650 in axial direction AD1 with respect to body 620. In an exemplary embodiment, actuator 2 is arranged to displace plunger 650 in axial direction AD1 and axial direction AD2 with respect to body 620. Actuator 2 is arranged to be connected to body 620. For example, actuator 2 is fixedly secured to flange 632 via pin 636 and hole 634. A plunger element in actuator 2 displaces plunger 650, including wedging component 662, in axial direction AD1 with respect to body 620 to engage end forming tool assembly 610, and in axial direction AD2 with respect to body 620 to disengage end forming tool assembly 610. In an exemplary embodiment, actuator 2 comprises a linear actuator. In an exemplary embodiment, actuator 2 comprises a hydraulic, pneumatic, screw, piezoelectric, ball, or telescoping actuator.

[0137] To assemble end forming tool assembly 610, legs 656A-656B of plunger 650 are inserted into hole 626 of body 620 in axial direction AD2. Die 720 is connected to end 652 of plunger 650, for example, by screwing protrusion 724 into hole 660. Wedging member 662 is connected to plunger 650, for example at the distal end of leg 656A, 656B. Pin 636 is engaged with slot 658 and hole 634. Biasing element 730 is arranged around section 722 of die 720. Arm 670A is engaged with channel 628A and rotatably connected to body 620 via fastener 640A. Arm 670B is engaged with channel 628B and rotatably connected to body 620 via fastener 640B. Portion 690A of clamp 690 is connected to arm 670A, for example via fasteners 684A and 686A. Portion 690B of clamp 690 is connected to arm 670B, for example via fasteners 684B and 686B. Biasing member 710 is connected at first end 712A to portion 690A, for example via fastener 706A, and at second end 712B to portion 690B, for example via fastener 706B. Actuator 2 is connected to body 620, for example via pin 626, and a plunger within actuator 2 is connected to and/or engaged with plunger 650. In the disengaged state, as shown in FIGS. 18A-18B and 20-21, end 654 of plunger 650 is engaged with or arranged substantially proximate to flange 623 and die 720 is spaced apart from portions 690A-690B in axial direction AD2.

[0138] To engage end forming tool assembly 610, tube 12 is arranged radially between portions 690A-690B and is preliminarily held in position via biasing member 710. Plunger 650 is displaced, for example via actuator 2, in axial direct AD1 with respect to body 620. Wedging member 662 engages surfaces 676A-676B forcing ends 674A-674B of arms 670A-670B radially inward to squeeze tube 12 between portions 690A-690B. For example, arm 670A is displaced in circumferential direction CD1 such that end 674A and portion 690A are displaced in radial direction RD1, and arm 674B is displaced in circumferential direction CD2 such that end 674B and portion 690B are displaced in radial direction RD1. At the same time that radially inward force is being exerted on tube 12, die 720 is displaced in axial direction AD1 into engagement with end 14 of tube 12, and hole 726 forms shoulder 19 on radially outward facing surface 18. Thus, end forming tool assembly 610 simultaneously 1) radially clamps tube 12 (i.e., via clamp 690 and arms 670A-670B) and 2) plastically deforms tube 12 (i.e., by axially driving die 720 onto end 14).

[0139] It will be appreciated that various aspects of the disclosure above and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.

REFERENCE NUMERALS

[0140] 2 Actuator [0141] 10 End forming tool assembly [0142] 12 Tube [0143] 14 End [0144] 16 End [0145] 18 Radially outward facing surface [0146] 19 Bead or shoulder or protrusion [0147] 20 Body [0148] 22 End [0149] 24 End [0150] 26 Flange [0151] 28 Hole [0152] 30 Bracket assembly [0153] 32A Protrusion or wall [0154] 32B Protrusion or wall [0155] 34A Hole [0156] 34B Hole [0157] 36 Flange [0158] 38 Hole [0159] 40 Hole [0160] 42A Hole [0161] 42B Hole [0162] 44 Protrusion [0163] 46 Arm [0164] 48 Leg [0165] 48A Hole [0166] 50 Plate or tube holder [0167] 52 Surface [0168] 54 Surface [0169] 56 Protrusion [0170] 60 Clip [0171] 62A Arm [0172] 62B Arm [0173] 70 Link or body [0174] 71 Base [0175] 72A Leg [0176] 72B Leg [0177] 73 Hole [0178] 74A Hole [0179] 74B Hole [0180] 76 Hole [0181] 78 Hole [0182] 80 Flange [0183] 82 Retainer [0184] 90 Die [0185] 92 Section [0186] 94 Section [0187] 96 Groove [0188] 98 Hole [0189] 100A Arm [0190] 100B Arm [0191] 102A Hole [0192] 102B Hole [0193] 104A Slot [0194] 104B Slot [0195] 106A Hole [0196] 106B Hole [0197] 108A Surface [0198] 108B Surface [0199] 110A Engaging member [0200] 110B Engaging member [0201] 112A Pin [0202] 112B Pin [0203] 114A Pin [0204] 114B Pin [0205] 120 Clamp [0206] 120A Portion [0207] 120B Portion [0208] 122A Inward facing surface [0209] 122B Inward facing surface [0210] 124A Space [0211] 124B Space [0212] 126A Outward facing surface [0213] 126B Outward facing surface [0214] 130 Plunger [0215] 132 End [0216] 134 End [0217] 136 Groove [0218] 210 End forming tool assembly [0219] 212 Base [0220] 214 Plate [0221] 220 Body [0222] 222 End [0223] 224 End [0224] 226 Base [0225] 228 Hole [0226] 230 Bracket assembly [0227] 232A Protrusion or wall [0228] 232B Protrusion or wall [0229] 234A Hole [0230] 234B Hole [0231] 236 Flange [0232] 238 Hole [0233] 240A Projection [0234] 240B Projection [0235] 270 Link [0236] 271 Base [0237] 272A Leg [0238] 272B Leg [0239] 273 Hole [0240] 278 Hole [0241] 280 Flange [0242] 290 Die [0243] 292 Section [0244] 294 Section [0245] 296 Groove [0246] 298 Hole [0247] 300A Arm [0248] 300B Arm [0249] 302A Hole [0250] 302B Hole [0251] 304A Surface [0252] 304B Surface [0253] 308A Surface [0254] 308B Surface [0255] 312A Pin [0256] 312B Pin [0257] 314A Bearing [0258] 314B Bearing [0259] 320 Clamp [0260] 320A Portion [0261] 320B Portion [0262] 322A Inward facing surface [0263] 322B Inward facing surface [0264] 324A Space [0265] 324B Space [0266] 326A Outward facing surface [0267] 326B Outward facing surface [0268] 330 Plunger [0269] 332 End [0270] 334 End [0271] 336 Groove [0272] 410 End forming tool assembly [0273] 412 Cover [0274] 420 Body [0275] 422 End [0276] 424 End [0277] 426 Flange [0278] 428 Hole [0279] 430 Bracket assembly [0280] 432A Protrusion or wall [0281] 432B Protrusion or wall [0282] 434A Hole [0283] 434B Hole [0284] 436 Flange [0285] 438 Hole [0286] 440 Hole [0287] 442A Hole [0288] 442B Hole [0289] 444 Protrusion [0290] 446 Arm [0291] 448 Leg [0292] 448A Hole [0293] 450 Plate or tube holder [0294] 452 Surface [0295] 454 Surface [0296] 456 Protrusion [0297] 458A Pin [0298] 458B Pin [0299] 460A Connector [0300] 460B Connector [0301] 462A Spring [0302] 462B Spring [0303] 464A Connector [0304] 464B Connector [0305] 470 Link or body [0306] 471 Base [0307] 472A Leg [0308] 472B Leg [0309] 473 Hole [0310] 474A Hole [0311] 474B Hole [0312] 476 Hole [0313] 478 Hole [0314] 480 Flange [0315] 482 Retainer [0316] 490 Die [0317] 492 Section [0318] 494 Section [0319] 496 Groove [0320] 498 Hole [0321] 500A Arm [0322] 500B Arm [0323] 502A Hole [0324] 502B Hole [0325] 503A Hole [0326] 503B Hole [0327] 504A Slot [0328] 504B Slot [0329] 506A Hole [0330] 506B Hole [0331] 508A Surface [0332] 508B Surface [0333] 510A Engaging member [0334] 510B Engaging member [0335] 512A Pin [0336] 512B Pin [0337] 514A Pin [0338] 514B Pin [0339] 520 Clamp [0340] 520A Portion [0341] 520B Portion [0342] 522A Inward facing surface [0343] 522B Inward facing surface [0344] 524A Space [0345] 524B Space [0346] 526A Outward facing surface [0347] 526B Outward facing surface [0348] 530 Plunger [0349] 532 End [0350] 534 End [0351] 536 Groove [0352] 610 End forming tool assembly [0353] 620 Body [0354] 622 End [0355] 624 End [0356] 626 Hole [0357] 628A Channel or hole [0358] 628B Channel or hole [0359] 630A Through-bore [0360] 630B Through-bore [0361] 632 Flange [0362] 634 Hole [0363] 636 Pin or dowel or bolt [0364] 638 Hole [0365] 640A Fastener [0366] 640B Fastener [0367] 642A Fastener [0368] 642B Fastener [0369] 650 Plunger [0370] 652 End [0371] 654 End [0372] 656A Leg [0373] 656B Leg [0374] 658 Slot or hole [0375] 660 Hole [0376] 662 Wedging member [0377] 664 Support [0378] 666A Wheel or curvilinear member [0379] 666B Wheel or curvilinear member [0380] 670A Arm [0381] 670B Arm [0382] 672A End [0383] 672B End [0384] 674A End [0385] 674B End [0386] 676A Surface [0387] 676B Surface [0388] 678A Through-bore [0389] 678B Through-bore [0390] 680A Through-hole [0391] 680B Through-hole [0392] 682A Through-hole [0393] 682B Through-hole [0394] 684A Fastener [0395] 684B Fastener [0396] 686A Fastener [0397] 686B Fastener [0398] 690 Clamp [0399] 690A Portion [0400] 690B Portion [0401] 692A Inward facing surface [0402] 692B Inward facing surface [0403] 694A Space [0404] 694B Space [0405] 696A Outward facing surface [0406] 696B Outward facing surface [0407] 698A Channel or hole [0408] 698B Channel or hole [0409] 700A Through-bore [0410] 700B Through-bore [0411] 702A Through-bore [0412] 702B Through-bore [0413] 704A Hole [0414] 704B Hole [0415] 706A Fastener [0416] 706B Fastener [0417] 710 Biasing member or spring [0418] 712A End [0419] 712B End [0420] 720 Die [0421] 722 Outward facing surface [0422] 724 Protrusion [0423] 726 Hole [0424] 730 Biasing element [0425] AD1 Axial direction [0426] AD2 Axial direction [0427] CD1 Circumferential direction [0428] CD2 Circumferential direction [0429] RD1 Radial direction [0430] RD2 Radial direction