Method of making a mandrel comprising a drill section

Abstract: A method of making an elongate mandrel (1) having an end integral with a drill section (4), the method comprising the steps of: subjecting a single columnar piece of material to the heading process so as to make a blank "N" composed of the mandrel, a short stem (2) having one end integral with the end of the mandrel and having a diameter "D" greater than the diameter "d" of the mandrel, and a flange (3) formed integrally with the other end of the stem; then cold forging the stem to produce the drill section having end edges (7a) and (7b) facing the flange; and subsequently trimming the drill section so as to remove the flange (3) together with scrap (10) resulting from the cold forging of the stem, in such a manner that the mandrel having the integral drill section can be mass produced from the single raw piece, efficiently at a reduced cost.

Description: The prior art "self-drilling blind rivet" comprises a tubular rivet body and an elongate mandrel inserted through the rivet body. The mandrel has at its one end a drill section capable of self-drilling an object in which the blind rivet is to be attached. The drill section has an outer diameter comparatively greater than that of the tubular rivet body. However, there has not been offered any effective method to form in a mass-production manner such a drill section at the end of said elongate mandrel. Consequently, a great demand for this type of blind rivet has not been met with a sufficient supply. The present inventor, who had made best efforts to supply such an unsatisfied demand, already proposed a method as disclosed in the Japanese Patent Laying-Open Gazette Hei. 2-197347 ( corresponding to the Unites States Patent No. 4,998,853 ). In this method, a short drill tip is adjoined or welded to one end of a mandrel. This previous method has however proved not necessarily satisfactory due to a certain difficulty in ensuring an coaxial relationship between each mandrel and each drill tip jointed thereto. Thus, the mass production of the blind rivet according to the previous method proposed by the present inventor has not been realized yet, because a specially designed automatic welder is needed therefor but has not been offered. GB-A-1 392 601 describes a method of forming an elongate mandrel having an end integral with a drill section by cold forging a short stem integral with the end of the mandrel and having a diameter greater than the diameter of the mandrel, to form the drill section, and trimming the drill section to remove therefrom the scrap resulting from the cold forging. According to the present invention there is provided a method of making an elongate mandrel having an end integral with a drill section does comprise the steps of: subjecting a single columnar piece of material to a heading process so as to make a blank composed of the elongate mandrel having a diameter "d", a short stem integral with the end of the mandrel and having a diameter "D" greater than the diameter "d" of the mandrel, and a flange integral with the short stem and extending from one end thereof opposite to the mandrel; then cold forging the stem to produce the drill section having end edges disposed to face the flange; and subsequently trimming the drill section so as to remove therefrom the flange together with scrap possibly resulting from the cold forging of the short stem. Thus the present invention provides a highly efficient method for the mass production of a mandrel comprising a drill section and adapted to construct a self-drilling blind rivet, wherein the drill section is not a separate tip jointed to the mandrel but is formed in one piece together with the mandrel from a single piece of raw material. The blank mentioned above may be a piece of hardenable steel so that only its drill section is hardened in a high-frequency heating apparatus. Alternatively, the blank may be made of a low carbon steel and subsequently carburized before only the drill section is selectively hardened in the high-frequency heating apparatus. The method proposed herein will enable not only the mass production of the blank by using any conventional type of the headers, but also the efficient forming of the drill section by a conventional cold forging technique. The invention will be described, by way of example only, with reference to the accompanying drawings, in which: Figures 1(a) to 1(c) show the step of making a blank in an embodiment of the method proposed herein; Figures 2(a) to 2(c) show the step of forming a drill section from the blank in the embodiment; Figure 3 is a front elevation of a pair of molds used for the cold forging of the drill section; Figure 4 is a plan view showing the molds disposed vis-a-vis; Figure 5 shows the step of forming a breakable annular groove on a mandrel as a portion of the blank; Figure 6 shows the step of heating and hardening the drill section; Figure 7 is a front elevation showing partly in cross section a self-drilling blind rivet which comprises the mandrel having the drill section; Figures 8(a) to 8(c) show the step of forming the drill section in a modified embodiment; and Figures 9(a) and 9(b) are a front elevation and a bottom view, respectively, showing the mandrel with the drill section which are manufactured in a further modified embodiment. An embodiment of the present invention will now be described referring to the drawings. Figures 1(a) to 1(c) illustrate the step of producing a blank "N". A columnar piece "M" shown in FIG. 1(a) is a raw material used to prepare the blank "N", and is a length severed from a raw coil of a hardenable carbon steel. The diameter "D" of the columnar piece "M" is slightly smaller than that of a drill section which will be described below in detail. The heading process is carried out using at first a pressing punch 16 to force the columnar piece downwardly into a diameter-reducing die 15. A thin and elongate mandrel 1, which is formed in this way from a lower portion of the columnar piece "M", will have a diameter "d" substantially equal to a half of the diameter "D" of said piece "M". At the same time as the mandrel is formed, a short stem 2 for the drill section will also be formed thicker from an upper portion of the columnar piece. The stem 2 integral with the mandrel 1 is of a diameter substantially equal to the diameter "D" of the piece "M", such that a reduced and curved zone 1a appears between the short stem and the mandrel, thus providing a transitional blank "M1". Subsequently, this transitional blank "M1" will be transferred into a finishing die 17 shown in Figure 1(c). At this stage, another punch 18 forces the blank "M1" downwards so that the curved zone 1a disappears, and a flange 3 is formed integral with the short stem 2 at its end opposite to the mandrel. A lower end of the mandrel 1 is chamfered simultaneously by the die 17, thus providing a finished blank "N". The flange 3 disposed at an extremity of this blank will facilitate the automatic control of the following step of cold forging the drill section 4. In particular the transportation and positioning of the blank "N" at that step can be done easily and smoothly by virtue of this flange 3. The reference numeral 19 denotes a knocking-out pin. Figures 2(a) to 2(c) illustrate the step of cold forging the drill section 4 previously mentioned above. A pair of molds 21A and 21B of a pinch pointer as shown in Figures 3 and 4 will forcibly grip the short stem 2 so as to cold forge it. The contour of the drill section 4 is produced by the inner engraved surfaces of the molds, and swelling excessive material will bulge out of the molds to form scrap 10 along and around the outer periphery of the thus forged drill section. The configuration of the mating molds 21A and 21B are as follows. They are of the same shape and arranged symmetrical with each other as shown in FIGS. 3 and 4, and each mold has the inner surface composed of two ( or "first" and "second" ) flat zones 22 and 23 extending stepwise and in parallel with one another. A recess 24 for forming one of a number of lands 5 on the drill section 4 is engraved to extend or initiate from the first one of the flat zones 22. A protrusion 25 for forming a ( chip-discharging ) vertical groove 6 on the drill section extends or initiates from the other, i.e., "second", flat zone 23. A first sharp ridge 26a defining one of the end edges 7a of the drill section is disposed, together with a third sharp ridge 27a defining one of side the edges 8a, to terminate at the first flat zone 22. A second sharp ridge 26b defining the other end edges 7b of the drill section is disposed, together with a fourth sharp ridge 27b defining the other side edges 8b, to similarly terminate at the second flat zone 23. A top end of the first sharp ridge 26a is connected by a short straight line to a top end of the second sharp ridge 26b, in such a manner that the straight line provides a fifth ridge for forming a chisel edge on the drill section 4. The drill section 4 will be produced in the following manner using the pair of the molds 21A and 21B. At first, the blank "N" will be supported at its flange 3 on a support ing end 31 of a feeder disc 30, and then transported into and positioned between the molds 21A and 21B. Then, the flange 3 will be urged downwards by a retainer pin 32 in a direction indicated by the arrow in FIG. 3 by means of a spring not shown, while the molds 21A and 21B are strongly pressed towards each other to cold forge the stem 2 to give the drill section 4. This drill section 4 produced in this way will have the end edges 7a and 7b as well as the chisel edge 9, which edges are in such a position as to face the flange 3 as shown in Figure 2(b). The scrap 10 extends along, around and integral with the periphery of the drill section. Subsequent to this stage, any conventional trimming die not shown may be used to remove from the drill section the scrap 10 together with the flange. As a result, a drilling mandrel 11 composed of the elongate mandrel 1 integral with the thicker drill section 4 will be obtained as illustrated in Figure 2(c). In a modification of the embodiment, an annular recess 12 may be formed prior to the cold forging step at a boundary between a major portion and a minor portion of the short stem 2, so that only the former is forged, with the latter portion 2a being left unforged. Such an additional step is effective to prevent any possible flash 10a from remaining unremoved from the ends of side edges 8a and 8b of the drill section 4, as indicated by the phantom line in Figure 2(c), when the trimming of the scrap 10 is done. Even if any residual portion of the flash 10a would remain, it will be accommodated in the recess 12 so as not to impair the drilling performance. In a further modification, some radially extending protrusions 14 may be formed on a shoulder surface 13 between the stem 2 and the mandrel 1 in a manner shown in FIGS. 9(a) and 9(b), when the blank "N" is made. Those protrusions will play a certain important role when the blind rivet is used, which rivet will be composed of the mandrel 1 inserted through a tubular rivet body 40 ( shown in FIG. 7 ). Such protrusions will claw the end surface of the rivet body 40 so that a torque can be transmitted to the drill section 4 not only through the mandrel 1 but also from the rivet body through the protrusions 14, thus enabling the drill section to be driven with a sufficient force. The mandrel 11 having the drill portion integral therewith will then be rolled between a pair of rolling dies 35 opposed to each other, as shown in Figure 5. Ridges 36 on the rolling dies will thus produce a breakable annular groove 37 of a reduced diameter and extending around the periphery of the mandrel portion near the drill section 4. Instead of such a groove, it may also be possible to produce a breakable recessed zone by the pinch pointer while it grips and cold forges the mandrel 1. Figure 6 illustrates a further step of selectively hardening only the drill section 4 in a high-frequency heating coil apparatus 38. In a case wherein the raw material "M" for the blank "N" is a low carbon steel, an appropriate step of carburizing the material must be effected before the selective hardening step. FIG. 7 shows a self-drilling blind rivet which is assembled by fitting the tubular rivet body 40 on the finished mandrel 11 having the hardened drill section. The rivet body has a central bore 41 for receiving the mandrel 1 as well as a flange-like portion 42 integral with an end of said body 40. Usually, the rivet body 40 is made of a softer metal such as an aluminum alloy. According to the above described method provided herein, the elongate mandrel having its one end formed integral with the drill section of a larger diameter can be manufactured from a single piece of a raw material, efficiently at a mass production scale and a reduced cost, by using any conventional heading machine and cold forging apparatus

Claims: A method of making an elongate mandrel (1) having an end integral with a drill section (4), the method comprising the steps of: subjecting a single columnar piece of material to a heading process so as to make a blank composed of the elongate mandrel having a diameter "d", a short stem (2) integral with the end of the mandrel and having a diameter "D" greater than the diameter "d" of the mandrel, and a flange (3) integral with the short stem and extending from one end thereof opposite to the mandrel; then cold forging the stem to produce the drill section having end edges (7a, 7b) disposed to face the flange; and subsequently trimming the drill section so as to remove therefrom the flange together with scrap (10) possibly resulting from the cold forging of the short stem. A method according to claim 1, further comprising the step of forming a breakable annular groove (37) or recessed zone on a portion intermediate the opposite ends of the mandrel. A method according to claim 1 or claim 2, further comprising the step of preliminarily forming an anuular recess (37) at a boundary between the stem's portion from which the drill section is to be cold forged and the stem's other portion which is to remain unforged, wherein the step is conducted before the following step of cold forging. A method according to any one of claims 1 to 3, wherein a plurality of radially extending protrusions (14) are formed on a shoulder surface between the stem and the mandrel at the same time as the blank is formed in the heading process. A method acccording to any one of claims 1 to 4, and further comprising the step of selectively hardening the drill section of the blank by using a high-frequency heating apparatus, wherein the blank is made of a hardenable steel. A method according to any one of claims 1 to 4, and further comprising the step of selectively hardening the drill section of the blank by using a high-frequency heating apparatus, after previously carburizing the blank, wherein the blank is made of a low carbon steel.

Inventors: SHINJO KATSUMI, SHINJO, KATSUMI
Applicants: SHINJO SEISAKUSHO YK, YUGENKAISHA SHINJO SEISAKUSHO
Application year: 1993
Main classification: B21K1
IPC codes: B21K1, C23C8, C21D1, B21K5, C21D9, F16B19, B21J15, B21J9