Flaring and swaging bits, and methods using same

Abstract

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

Description

RELATED APPLICATION

This FIG. 20 is a perspective view of a rotary insert embodying features disclosed herein.Inserted herein is text from certified English language translation of the Specification of PCT Application No. PCT/BR2013/00379, filed 30 Sep. 2013 (published as WO 2015/042674 on 2 Apr. 2015), which was incorporated by reference in U.S. patent application Ser. No. 14/947,537, as noted above. References to the FIGS. 5-10 have been amended to refer to FIGS. 20-25.

The present invention refers to a metal insert that must be coupled to a rotary drive mechanism, for flanging/widening the ends of metal tubes. The insert drive can be made by using “drills” or “screwdrivers” and, as a final result, it is capable of making flanges in specially applied metal tubes, and “split” type air conditioning system connections, refrigeration systems connections and liquefied petroleum gas transport systems connections and similar, being faster than the current state of the art, due to the heating generated by the rotation of the insert inside the metal tube.

Therefore, the insert is intended to form:

• • 1) a flange opening at the tube ends at an angle of 45°, or;
  • 2) widening of the metal tube for coupling with a tube of the same gauge, or
  • 3) widening with the flange opening, for coupling of another metal tube of the same diameter.

The industrial sectors, notably the industry and commerce of refrigeration, demand equipment that simplifies, optimizes and reduces production and labor time. As an example, the need for widening and shaping flange in metal tubes of heat exchangers, such as copper tubes and aluminum tubes, for the manufacture of condensing and evaporation units, in home applications, commercial and industrial lines can be highlighted.

The present patent application is directly related to patent PI0902047-0 A2, which clearly denotes the characteristics of the connection where flanged tubes are applied. However, it differs in that it refers to the method of obtaining the shape of the flanged tube or, as denoted in patent PI0902047-0 A2 cited above, “angled tube.”

Currently, there are several mechanisms of obtaining a flanged tube. However, they are differentials of the object of the present invention:

• • 1) the operating tool design;
  • 2) application mode, which can be performed using a “drill” or “screwdriver”;
  • 3) ability to make, with the same insert, multiple flanges in tubes of different gauges, due to the different diameters in a single insert;
  • 4) it does not require a tailstock system, “mordant,” to fix the metal pipe to be flanged;
  • 5) the hot formation of the flange, in order to avoid the hardening of the flanged material; and
  • 6) the characteristic of the final flange obtained, with its homogeneous and resistant microstructure, due to its formation through a heated medium.

Initially, referring to the current state of the art, there are two models of flanging tools present on the market, called a) “conventional flanging tool” and b) “eccentric flanging tool”:

• • a) The conventional flanging tools (FIG. 1) are characterized by having a “mordant” for fixing the tubes (1) and a flanging mechanism, the latter, in turn, comprising a body for fixing the “mordant” (2), a threaded spindle (3), which is coupled to the body, a 45-degree conical tip (4) coupled to one end of the spindle and a drive crank (5) at the other end of the spindle. This system is characterized by the concentric alignment (FIG. 2), between the spindle shaft (6) and the conical tip shaft (7). During the flange execution, the contact zone between the tip and the tube is set through the entire surface of the cone.
  • b) The eccentric flanging tools (FIG. 3) are characterized by having a “mordant” for fixing the tubes (8) and a flanging mechanism, the latter, in turn, comprising a body for fixing the “mordant” (9), a threaded spindle (10), which is coupled to the body, a 45-degree conical tip (11) coupled to one end of the spindle and a drive crank (12) at the other end of the spindle. This system is characterized by the eccentric misalignment (FIG. 4) between the spindle shaft (13) and the conical tip shaft (14). During the flange execution, the contact zone between the tip and the tube is set through a linear contact of the cone.

Although both promote the final shape of the flange, the current state of the art requires the use of a “mordant” (tailstock) for shaping the flange. The coupling of the tube to the “mordant” and the flange execution takes a long time to execute because, in the case of split type air conditioning applications, it is necessary, for example, to make a total of four flanges per equipment. That is, two flanges per tube, these tubes being necessarily of two different gauges. In addition, due to their conception, both make the cold tube conformation, hardening the flanged material, incurring the risk of cracks in the flange wall.

Referring now to the rotating Insert for flanging and widening of metal tubes, called drill for flanging, it allows the execution of the widening and/or flanging of metal tubes through a system of interchangeable inserts. These inserts can be coupled to drills (whether with a chuck or pneumatic coupling) or even to electric screwdrivers.

Insert (FIG. 20) can be subdivided into the following parts:

• • a) A cylindrical body (15), for coupling with a drill or a screwdriver, through chuck.
  • b) A flanging tip (16), to properly fit in the metal tube (FIG. 21) and give to its tip (17) a flanged (18) metal tube shape (FIG. 22) at an angle of approximately 45°. The flanging tip (FIG. 23) can contain one stage (19) or (FIG. 24) more stages (20) to make the flange in one or more tubes without the need to change the insert for another one of different size and gauge. For instance, the same tip can have a diameter of 6.35 mm at the end close to its tip and 12.05 mm at the end closest to the cylindrical body. In addition, it (FIG. 25) has a slim shape (21) and rounded corners (22), reducing only two points the contact with the metal tube, thus reducing friction and the amount of burrs.

Therefore, the invention differs from the current state of the art in several aspects. First, because the insert does not need a tailstock (“mordant”) system to perform the flange in the metal tube. Since the strength required to hold the pipe in the working position is low, the user himself can maintain the positioning of the flanged pipe by hands. Second, as it works through a high rotation system, it is present friction and heating generation in the pipe, facilitating the hot shaping of the flange, without hardening in the region of the tube flange. The absence of hardening in the flange region avoids cracking problems during the tightening of the connection, a problem that is recurrent in the current state of the art. Third, the invention allows the presence of one or more gauges within the same insert, with different diameters, reducing the time of flanges execution, especially in the installation of split type air conditioners, being able of flanging different tube sizes using only one single insert.

The main objective of the insert in question is, therefore, to optimize the working time, due to its speed and ease of operation and to bring a higher quality result, considering the heating of the tube when flanged with the insert and its best microstructural result with greater strength.

Regarding the applicability of the product, the present invention aims to optimize the process and time of a flange in metal tubes for split type air conditioning systems, but it is not restricted to them. It can also be applied in flange type connections, in tubes for refrigeration applications or even in tube connections for systems that use liquefied petroleum gas.

Claims

1. A rotary insert, comprising:

a shank portion;

a stopper portion coupled to the shank portion such that a T-shape is formed thereby; and

a tip opposite the shank portion, the tip having a base coupled to the stopper portion, the tip extending away from the stopper portion along an axis of symmetry, the tip having a tip end spaced apart from the stopper portion, the tip comprising a first face disposed opposite a second face, the first face and the second face defining a continuous outer edge, the continuous outer edge extending from the tip end to the base; the continuous outer edge intersecting the axis of symmetry at the tip end; the outer edge having a maximum radius relative to the axis of symmetry at the base, the continuous outer edge from the tip end to the base tapering outward relative to the axis of symmetry; from the tip end to the base the tip having at least one stage portion, the continuous outer edge curved toward the tip end in the at least one stage portion; and the stopper portion having a stopper radius greater than the maximum radius of the tip,

wherein,

the tip widens an open end portion of a metal tube when (1) the shank portion is inserted into a chuck of a drill or an electric screwdriver, (2) spun via the drill or the electric screwdriver, and (3) inserted into the open end portion of the metal tube while spinning so as to sufficiently heat the open end portion of the metal tube via friction generated between the tip that is spinning and the open end portion of the metal tube and thereby widen the open end portion of the metal tube using a hot process,

the drill or the electric screwdriver is not a tailstock, and

the tip is insertable into the open end portion of the metal tube up to the stopper portion.

2. The rotary insert of claim 1, wherein the continuous outer edge comprising at least two stage portions, in each of the at least two stage portions the continuous outer edge having different curvature.

3. The rotary insert of claim 1, wherein the rotary insert formed as is a single element.

4. The rotary insert of claim 1, wherein the rotary insert comprising metal.

5. The rotary insert of claim 1, wherein the rotary insert comprising ceramic.

6. The rotary insert of claim 1, wherein the tip further comprising a flared bottom portion, the flared bottom portion affixed between the stopper portion and the at least one stage portion, at least two edges of the flared bottom portion sloping from the tip to the stopper portion.

7. The rotary insert of claim 1, wherein the tip has rounded edges being which are equal in diameter.

8. The rotary insert of claim 1, wherein the at least one stage portion comprising only one stage portion.

9. The rotary insert of claim 1, wherein the at least one stage portion comprising two stage portions.

10. A system, comprising:

a rotary insert comprising:

a shank portion;

a stopper portion coupled to the shank portion such that a T-shape is formed thereby; and

a tip opposite the shank portion, the tip having a base coupled to the stopper portion, the tip extending away from the stopper portion along an axis of symmetry, the tip having a tip end spaced apart from the stopper portion, the tip comprising a first face disposed opposite a second face, the first face and the second face defining a continuous outer edge, the continuous outer edge extending from the tip end to the base; the continuous outer edge intersecting the axis of symmetry at the tip end; the outer edge having a maximum radius relative to the axis of symmetry at the base, the continuous outer edge from the tip end to the base tapering outward relative to the axis of symmetry; from the tip end to the base the tip having at least one stage portion, the continuous outer edge curved toward the tip end in the at least one stage portion; the stopper portion having a stopper radius greater than the maximum radius of the tip; and

a drill or an electric screwdriver having a chuck engaging the shank portion to enable the tip to widen an open end portion of a metal tube when (1) the shank portion is inserted into the chuck of the drill or the electric screwdriver, (2) spun via the drill or the electric screwdriver, and (3) inserted into the open end portion of the metal tube while spinning so as to sufficiently heat the open end portion of the metal tube via friction generated between the tip that is spinning and the open end portion of the metal tube and thereby widen the open end portion of the metal tube using a hot process,

wherein,

the drill or the electric screwdriver is not a tailstock, and

the tip is insertable into the open end portion of the metal tube up to the stopper portion.

11. The system of claim 10, wherein the continuous outer edge comprising at least two stage portions, in each of the at least two stage portions the continuous outer edge having different curvature.

12. The system of claim 10, wherein the rotary insert formed as is a single element.

13. The system of claim 10, wherein the rotary insert comprising metal.

14. The system of claim 10, wherein the rotary insert comprising ceramic.

15. The system of claim 10, further comprising a flared bottom portion, the flared bottom portion affixed between the stopper portion and the tip, at least two edges of the flared bottom portion sloping from the tip to the stopper portion.

16. The system of claim 10, wherein the tip has rounded edges being which are equal in diameter.

17. The system of claim 10, wherein the at least one stage portion comprising only one stage portion.

18. The system of claim 10, wherein the at least one stage portion comprising two stage portions.

19. A method for flaring a an open end portion of a metal tube, the method comprising:

coupling a rotary insert to a chuck of a rotary power tool, wherein the rotary power tool is a drill or an electric screwdriver, wherein the rotary power tool is not a tailstock, wherein the rotary insert comprising:

a shank portion;

a stopper portion coupled to the shank portion such that a T-shape is formed thereby;

a tip opposite the shank portion, the tip having a base coupled to the stopper portion, the tip extending away from the stopper portion along an axis of symmetry, the tip having a tip end spaced apart from the stopper portion, the tip comprising a first face disposed opposite a second face, the first face and the second face defining a continuous outer edge, the continuous outer edge extending from the tip end to the base; the continuous outer edge intersecting the axis of symmetry at the tip end; the outer edge having a maximum radius relative to the axis of symmetry at the base, the continuous outer edge from the tip end to the base tapering outward relative to the axis of symmetry; from the tip end to the base the tip having at least one stage portion, the continuous outer edge curved toward the tip end in the at least one stage portion; and the stopper portion having a stopper radius greater than the maximum radius of the tip;

inserting the tip of the rotary insert into a cavity defined by an interior surface of a the open end portion of the metal tube while the rotary insert is coupled to the chuck of the rotary power tool; and

rotating the rotary insert by spinning the shank portion via the chuck of the rotary power tool to cause friction between the tip and the interior surface of the open end portion of the metal tube, to increase the diameter of at least a portion of the metal tube including the open end portion, to create a flare of the open end portion of the metal tube, and to increase structural quality of the metal tube from heat provided to the metal tube via friction generated between the tip that is spinning and the open end portion of the metal tube using a hot process,

wherein,

rotating the rotary insert occurs as the tip of the rotary insert is inserted into the cavity defined by the interior surface of the open end portion of the metal tube, and

the tip is insertable into the open end portion of the metal tube up to the stopper portion.

20. A method for swaging a an open end portion of a metal tube, the method comprising:

coupling a rotary insert coupled to a chuck of a rotary power tool, wherein the rotary power tool is a drill or an electric screwdriver, wherein the rotary power tool is not a tailstock, wherein the rotary insert comprising:

a shank portion;

a stopper portion coupled to the shank portion such that a T-shape is formed thereby;

a tip opposite the shank portion, the tip having a base coupled to the stopper portion, the tip extending away from the stopper portion along an axis of symmetry, the tip having a tip end spaced apart from the stopper portion, the tip comprising a first face disposed opposite a second face, the first face and the second face defining a continuous outer edge, the continuous outer edge extending from the tip end to the base; the continuous outer edge intersecting the axis of symmetry at the tip end; the outer edge having a maximum radius relative to the axis of symmetry at the base, the continuous outer edge from the tip end to the base tapering outward relative to the axis of symmetry; from the tip end to the base the tip having at least one stage portion, the continuous outer edge curved toward the tip end in the at least one stage portion; and the stopper portion having a stopper radius greater than the maximum radius of the tip;

inserting the tip of the rotary insert into a cavity defined by an interior surface of a the open end portion of the metal tube while the rotary insert is coupled to the chuck of the rotary power tool; and

rotating the rotary insert by spinning the shank portion via the chuck of the rotary power tool to cause friction between the tip and the interior surface of the open end portion of the metal tube, to increase the diameter of at least a portion of the metal tube including the open end portion, to create a swage of the open end portion of the metal tube, and to increase structural quality of the metal tube from heat provided to the metal tube via friction generated between the tip that is spinning and the open end portion of the metal tube using a hot process,

wherein,

rotating the rotary insert occurs as the tip of the rotary insert is inserted into the cavity defined by the interior surface of the open end portion of the metal tube, and

the tip is insertable into the open end portion of the metal tube up to the stopper portion.

21. The rotary insert of claim 1, wherein the tip widens the open end portion of the metal tube by or including flanging.

22. The system of claim 10, wherein the tip is enabled to widen the open end portion of the metal tube by or including flanging.

23. The method of claim 19, wherein the tip has only one stage portion.

24. The method of claim 19, wherein the tip has two stage portions.

25. The method of claim 19, wherein the rotary insert is a single element.

26. The method of claim 19, wherein each of the shank, the stopper, and the tip includes metal.

27. The method of claim 19, wherein each of the shank, the stopper, and the tip includes ceramic.

28. The method of claim 20, wherein the tip has only one stage portion.

29. The method of claim 20, wherein the tip has two stage portions.

30. The method of claim 20, wherein the rotary insert is a single element.

31. The method of claim 20, wherein each of the shank, the stopper, and the tip includes metal.

32. The method of claim 20, wherein each of the shank, the stopper, and the tip includes ceramic.

33. A rotary insert, comprising:

a shank portion;

a stopper portion coupled to the shank portion such that a T-shape is formed thereby; and

a tip opposite the shank portion, the tip having a base coupled to the stopper portion, the tip extending away from the stopper portion along an axis of symmetry, the tip having a tip end spaced apart from the stopper portion, the tip comprising a first face disposed opposite a second face, the first face and the second face defining a continuous outer edge, the continuous outer edge extending from the tip end to the base; the continuous outer edge intersecting the axis of symmetry at the tip end; the outer edge having a maximum radius relative to the axis of symmetry at the base, the continuous outer edge from the tip end to the base tapering outward relative to the axis of symmetry; from the tip end to the base the tip having at least one stage portion, the continuous outer edge curved toward the tip end in the at least one stage portion; and the stopper portion having a stopper radius greater than the maximum radius of the tip,

wherein,

the tip widens an open end portion of a metal tube when (1) the shank portion is inserted into a chuck of a drill or an electric screwdriver, (2) spun via the drill or the electric screwdriver, and (3) inserted into the open end portion of the metal tube while spinning so as to sufficiently heat the open end portion of the metal tube via friction generated between the tip that is spinning and the open end portion of the metal tube and thereby widen the open end portion of the metal tube using a hot process,

the drill or the electric screwdriver is not a tailstock,

the tip is insertable into the open end portion of the metal tube up to the stopper portion,

the rotary insert is a single element,

the rotary insert comprises metal, and

the at least one stage portion comprises only one stage portion.

34. The rotary insert of claim 33, wherein the tip widens the open end portion of the metal tube by or including flanging.