Abstract:
A method for swaging a suspension assembly to an actuator arm of a data storage device is disclosed. The method includes steps of inserting a deformable tubular stake into an aperture of an actuator arm and inserting an expandable swaging member into a channel of the tubular stake within the aperture of the actuator arm. Thereafter, the method includes the step of expanding the swaging member to deform the tubular stake to swage the tubular stake to the actuator arm of the data storage device.

Description:
CROSS-REFERENCE TO RELATED APPLICATION  
       [0001]    The invention claims priority to Provisional Application Serial No. 60/045,820, filed May 5, 1997, and entitled “SWAGING FLEXURES TO E-BLOCK ARMS”. 
     
    
     
       FIELD OF THE INVENTION  
         [0002]    The present invention relates to a disc drive storage system. In particular, the present invention relates to a swaging device for coupling a suspension system supporting a head gimbal assembly relative to an actuator arm.  
         BACKGROUND OF THE INVENTION  
         [0003]    Disc drives are well-known in the industry. Disc drives are used to store digital information on rigid discs coated with a magnetizable material in a plurality of circular, concentric data tracks. Discs are mounted on a spindle motor which rotate the discs for operation. Information is read from or written to the disc surface via transducers carried on a slider supported relative to the disc surface via a suspension system.  
           [0004]    The suspension assembly includes a load beam and a gimbal spring for supporting the slider. The slider is coupled to the gimbal spring at an upper surface of the slider. The gimbal spring is also coupled to the load beam. The lower surface of the slider defines an air bearing surface. Rotation of a disc via the spindle motor interacts with the air bearing surface of the slider to create a hydrodynamic lifting force to lift the slider to fly above the disc surface for reading information from and writing information to the disc surface. The gimbal spring supports the slider to allow the slider to pitch and roll relative to the disc surface for operation. The load beam supplies a preload force to counteract the hydrodynamic lifting force of the slider. The preload force supplied by the load beam and the hydrodynamic lifting force created by the air bearing surface and rotation of the disc define the fly characteristics of the slider (and transducers) above the disc surface.  
           [0005]    The slider is positioned relative to various concentric data tracks via an actuator mechanism. The actuator mechanism typically includes an “E-block” assembly, which is rotationally coupled to a base of the disc drive to define a rotary-type actuator. The E-block includes a plurality of spaced actuator arms and is rotationally operated via an actuator drive under the control of electronic circuitry. In particular, the suspension assemblies supporting the sliders are coupled to actuator arms of an E-block in alignment with upper and lower surfaces of discs supported by the spindle motor.  
           [0006]    The suspension assemblies are coupled to the actuator arms via a swaging technique. The suspension assemblies include a tubular-shaped stake having an opened central channel extending therethrough. The outer dimension of the stake is sized for insertion into a hole extending through an actuator arm of the E-block. After the stake is inserted into the hole, the stake is swaged to the hole of the actuator arm via the central channel to secure the suspension assembly to the actuator arm.  
           [0007]    Typically, suspension assemblies are coupled to opposed surfaces of an actuator arm for alignment relative to lower and upper disc surfaces. In particular, a tubular-shaped stake of a first suspension assembly is inserted into an upper portion of the hole such that extended ends of the stake extend downwardly from a fixed end. The stake is coupled to the upper portion of the hole for alignment relative to an upper disc surface. A stake of a second suspension system is inserted into a lower portion of the hole such that extended ends of the stake extend upwardly from a fixed end. The stake is coupled to the lower portion of the hole for alignment relative to a lower disc surface. A swaging device is inserted through the central channel of stakes positioned in the hole to impart a swaging force to deform the stakes against a wall of the hole for permanently connecting suspension assemblies to actuator arms.  
           [0008]    Fixed diameter swaging ball devices are known for deforming or pressing stakes into the hole of the actuator arm to connect the suspension assemblies. The diameter of the ball is sized larger than the diameter of the channel to impart a swaging force to the stakes. The swaging ball is typically inserted in a single direction to swage both stakes position in upper and lower portions of the hole. For example, the swaging ball is initially inserted through the first stake at the upper portion of the hole. Due to the alignment of the first stake and insertion direction of the swaging ball, the swaging ball is inserted into the stake channel at the fixed end of the stake and exits at the extended end of the stake. Thus, the swaging ball supplies a tension force to the stake which may increase the preload force of the suspension assembly.  
           [0009]    Thereafter, the swaging ball is inserted through the stake at the lower portion of the hole. Due to the alignment of the second stake and insertion direction of the swaging ball, the swaging ball is inserted into the stake channel at the extended end of the stake and advanced along the channel to exit at the fixed end of the stake. Thus the swaging ball supplies a compressive force to the stake which may decrease the preload force of the suspension assembly. Thus, as described, different preload characteristics are introduced by known fixed-diameter swaging devices to suspension assemblies aligned with upper and lower disc surfaces.  
           [0010]    The stressing forces described influence the flying characteristics of the slider and have a greater impact or influence on the fly characteristics of smaller and lighter suspension assemblies which require less preload force in the flexure to fly at a correct height. Since the first and second suspension assemblies have different preloads supplied during assembly, each has different fly characteristics. It is desirable to reduce variations in preload characteristics introduced during assembly so that consistent fly characteristics may be provided for each data head for operation of the disc drive. The present invention provides a solution to this and other problems, and offers other advantages over the prior art.  
         SUMMARY OF THE INVENTION  
         [0011]    The present invention relates to a swaging device for connecting suspension assemblies to actuator arms of a disc drive. Suspension assemblies may be coupled to actuator arms by tubular stakes extending from a mounting plate of the suspension assembly. The tubular stake is inserted into a hole extending into the actuator arm. The tubular stake is swaged by a swaging device to secure the tubular stake within the hole.  
           [0012]    The swaging device of the present invention includes an expandable member which is expandable between an insertion dimension and a swaging dimension. In the insertion dimension, the expandable member is sized for insertion into a channel of a tubular stake. The expandable member is expanded to the swaging dimension to impart a swaging force to the tubular stake to swage the tubular stake relative to the hole of the actuator arm. Features and advantages which characterize the present invention will be apparent upon reading of the following detailed description and review of the associated drawings. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0013]    [0013]FIG. 1 is a schematic view of a disc drive.  
         [0014]    [0014]FIG. 2 is a perspective view of an “E-Block” for supporting data heads for reading information from and writing information to selected data tracks.  
         [0015]    [0015]FIG. 3 is an exploded view of suspension assemblies coupled to an actuator arm of an “E-Block”.  
         [0016]    [0016]FIG. 4 is a plan view illustrating swaging of suspension assemblies to an actuator arm using a swaging ball of the prior art.  
         [0017]    [0017]FIG. 5 is a detailed view illustrating the swaging ball of the prior art being inserted into an upper stake of a suspension assembly.  
         [0018]    [0018]FIG. 6 is a detailed view illustrating the swaging ball of the prior art being inserted into a lower stake of a suspension assembly.  
         [0019]    [0019]FIG. 7 is a plan view of an embodiment of the swaging assembly of the present invention including an expandable swaging device and actuating device.  
         [0020]    [0020]FIG. 8 is a cross-sectional view taken along line  8 - 8  of FIG. 7.  
         [0021]    FIGS.  9 - 11  are illustrative views illustrating operation of an embodiment of the swaging assembly of present invention.  
         [0022]    [0022]FIG. 12 is an illustrative view of an operating device for an embodiment of the swaging assembly.  
         [0023]    [0023]FIG. 13 is a flow chart illustrating steps of operation for use of an embodiment of a swaging device to swage suspension assemblies to multiple actuator arms.  
         [0024]    [0024]FIG. 14 is a plan view of an alternate embodiment of a swaging device according to the present invention.  
         [0025]    [0025]FIG. 15 is a plan view of an alternate embodiment of a swaging device according to the present invention. 
     
    
       [0026]    It should be noted that the drawings are not to scale and that certain features have been exaggerated for clarity.  
       DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0027]    [0027]FIG. 1 is a schematic view illustrating a disc drive  50 . As shown, disc drive  50  includes a housing  52  (shown schematically), disc stack  54 , and a plurality of head gimbal assemblies (HGA)  56 , which are supported relative to disc stack  54  and actuated by actuator assembly  58 . Disc stack  54  includes a plurality of discs  60 ,  62 ,  64 , and  66  supported for co-rotation about spindle axis  68  by a spindle motor  70 . The head gimbal assemblies  56  support a disc head slider via a gimbal spring (not shown) for reading information from and writing information to upper and lower disc surfaces in a known manner.  
         [0028]    The actuator assembly  58  includes an actuator block  72  and actuator drive  74 . Actuator block  72  is rotationally coupled to housing  52  for operation about a pivot axis  76  in a known manner. Although a rotary-type actuator is described, it should be understood that the invention is not limited to a rotary actuator system and that other actuators, such as a linear actuator, may be employed. A plurality of spaced stacked actuator arms  78 ,  80 ,  82 , and  84  extend from the actuator block  72  in alignment with lower and upper disc surfaces of discs  60 ,  62 ,  64 , and  66 . The HGAs  56  are coupled to actuator arms  78 ,  80 ,  82 , and  84  via load beams  86 .  
         [0029]    As shown, a first actuator arm, such as actuator arm  78 , supports HGA  56  in alignment with an upper disc surface of disc  62 , and an adjacent actuator arm, such as actuator arm  80 , supports HGA  56  in alignment with a lower disc surface of disc  62 . Actuator drive  74 , which is typically a voice coil motor, pivots actuator block  72  about the pivot axis  76  for alignment with selected data tracks of discs  60 ,  62 ,  64 , and  66 . Operation of the spindle motor  70  and actuator drive  74  are controlled via control circuitry  88  of disc drive  50 . Although the disc stack  54  shown includes four (4) discs, it should be understood that the disc stack  54  may include any number of discs, and the disc drive is not limited to the specific embodiment described.  
         [0030]    [0030]FIG. 2 illustrates the actuator block  72  for supporting HGAs  56 . The actuator block  72  is rotationally coupled to housing  52 , as previously described, and includes a main portion  90  supporting the plurality of actuator arms  78 ,  80 ,  82 , and  84 , which are typically integrally formed with the main portion  90  and extend from main portion  90  to define an “E-block” shaped structure. The actuator arms  78 ,  80 ,  82 , and  84  are supported in a spaced relation to define gaps  92 ,  94 , and  96  therebetween, respectively. The actuator arms  78 ,  80 ,  82 , and  84  include a mounting hole  98 . As previously explained, the HGAs  56  are coupled to load beam  86  and are supported thereby. The load beam  86  and HGA  56  define a suspension assembly. The HGAs  56  include a slider  100  carrying transducers (not shown) for reading data from and writing data to discs. Suspension assemblies are coupled to the actuator arms  78 ,  80 ,  82 , and  84  for flexibly supporting sliders  100 .  
         [0031]    [0031]FIG. 3 is an exploded view illustrating assembly of first and second suspension assemblies  102 ,  104  to an actuator arm to support suspension assemblies  102 ,  104  for operation. Sliders  100  of HGAs  56  are supported relative to the load beam via a gimbal spring  106  in a known manner. As shown, suspension assemblies  102 ,  104  include a mounting plate  108  which is generally fixedly coupled to an elongated flexible portion defining the load beam  86  in a known manner. Mounting plate  108  includes a mounting opening  110 . Tubular shaped stakes  112  having a central opened channel  114  extends from mounting plate  108  with channel  114  in alignment with mounting opening  110 . Stakes  112  may be separately or integrally formed with mounting plate  108 . In particular, a fixed end of stake  112  is coupled to mounting plate  108  and an extended end of stake  112  is spaced from mounting plate  108 . Preferably, the diameter of the mounting opening  110  is similar to the diameter of channel  114  to define an opened single diameter channel extending through mounting plate  108  and stake  112 .  
         [0032]    The outer circumference of the tubular stake  112  is sized for insertion into hole  98  of actuator arms  78 ,  80 ,  82 , and  84 . As shown in FIG. 3, the first suspension assembly  102  is aligned to position slider  100  upwardly and stake  112  (i.e. extended end) extends downwardly for insertion into the upper portion of hole  98  to define an upper stake  112 - 1  for supporting the head (slider  100 ) to read information from and write information to a lower disc surface. The second suspension assembly  104  is aligned to position slider  100  downwardly and stake  112  (i.e. extended ends) upwardly for insertion into the lower portion of hole  98  to define a lower stake  112 - 2  for supporting the head to read information from and write information to an upper disc surface.  
         [0033]    The length of stakes  112 - 1 ,  112 - 2  is designed for partial insertion into mounting hole  98  such that there is a gap between extended ends of inserted stakes  112 - 1  and  112 - 2 . Stakes  112 - 1  and  112 - 2  are formed of a malleable material, such as metal, and after stakes  112 - 1  and  112 - 2  are inserted into hole  98 , stakes  112 - 1  and  112 - 2  are deformed (i.e. essentially at extended ends) by a swaging technique to secure stakes  112 - 1  and  112 - 2  to actuator arms  78 ,  80 ,  82 , and  84 . As shown, depending upon the arrangement of the actuator arms and discs, not all actuator arms include first and second suspension assemblies. For example, actuator arm  84  supports a suspension assembly for alignment with a lower surface of disc  66  via stake  112 - 1  and does not support a second suspension assembly.  
         [0034]    [0034]FIG. 4 illustrates a swaging technique of the prior art for securing stakes  112 - 1  and  112 - 2  to actuator arms  78 ,  80 ,  82 , and  84 . A support fixture (not shown) is used to support the “E”-block  72  for swaging stakes  112  to actuator arms  78 ,  80 ,  82 , and  84 . Spacers  116 - 1 ,  116 - 2 , which are sized for insertion into gaps  92 ,  94 , and  96 , are inserted into gaps  92 ,  94 , and  96 , to support suspension assemblies  102 ,  104  relative to actuator arms  78 ,  80 ,  82 , and  84 . Spacers  116 - 1 ,  116 - 2  include holes  120 , preferably sized similar to channel  114 . As previously explained, stakes  112 - 1  and  112 - 2  are inserted into holes  98  of actuator arms and spacers  116 - 1  and  116 - 2 , and are positioned in gaps  92 ,  94 ,  96  between adjacent actuator arms  78 ,  80 ,  82 , and  84 . Thereafter, a fixed diameter swaging ball  122  is forced through the holes  120  in spacers  116 - 1 ,  116 - 2 , through channel  114  and hole  98  to deform or swage stakes  112  relative to an actuator arm.  
         [0035]    The round shape of the swaging ball  122  defines a smaller dimensioned leading portion for facilitating insertion of swaging ball  122  through channel  114  and a larger dimensioned portion sized to provide sufficient force to the tubular stakes  112  to force the tubular stakes  112  against walls of hole  98  of the actuator arm. The swaging ball  122  is inserted in a single direction and progressively advanced to sequential actuator arms to swage suspension assemblies to multiple actuator arms of an E-block. In particular, the swaging ball  122  may be forced through multiple spacers  116 - 1 ,  116 - 2  positioned between gaps  92 ,  94 ,  96  and may be progressively positioned relative to extended ends of stakes  112 - 1 ,  112 - 2  to secure multiple suspension assemblies to multiple actuator arms of an E-block.  
         [0036]    As previously explained, it is important that first and second suspension assemblies are assembled to actuator arms so that the first and second suspension assemblies have consistent preload forces for consistent fly characteristics. As shown in FIGS. 5 and 6, the swaging ball  122  is inserted through first and second stakes  112 - 1  and  112 - 2  in a single insertion direction. As the swaging ball  122  is inserted through channel  114  of stake  112 - 1  from the fixed end of the stake  112 - 1  at mounting opening  110  to the extended end, the swaging ball  122  essentially supplies a tension force to stake  112 - 1 , as illustrated by arrows  126 . This tension force influences the preload characteristics of the suspension assembly  102  (essentially increases the preload force). It is noted that stake  112 - 1  includes notch  124  at mounting opening  110  to facilitate insertion of ball  122 .  
         [0037]    As shown in FIG. 6, the swaging ball  122  is further advanced into and through stake  112 - 2  from the extended end of stake  112 - 2  to the fixed end of stake  112 - 2  at mounting opening  110 . Since the swaging ball  122  is forced through extended ends to the fixed end, a compressive force, as illustrated by arrow  128 , is supplied to stake  112 - 2  to provide an opposite influence to the load characteristics of suspension assembly  104  from the tension force supplied to stake  112 - 1 . In particular, since stakes  112 - 1  and  112 - 2  are inserted into hole  98  in opposed relation with extended ends extending towards one another and the swaging ball  122  is inserted in a single direction to swage stakes  112 - 1  and  112 - 2 , the swaging ball supplies different preload characteristics to suspension assemblies  102 ,  104 , thus affecting the fly characteristics of the slider  100  of each suspension assembly  102 ,  104 .  
         [0038]    FIGS.  7 - 8  illustrate an embodiment of a swaging assembly  130  of the present invention for connecting suspension assemblies  102 ,  104  to actuator arms. FIG. 7 is a plan view and FIG. 8 is a cross-sectional view taken along lines  8 - 8  of FIG. 7. As shown, the swaging assembly  130  includes an expandable swaging device  132  and an actuating device  134 . The expandable swaging device  132  includes a shaft  136 , an expandable extent  138 , and a swaging ridge  140  positioned along the expandable extent  138  and expandable therewith. The expandable extent  138  is preferably formed a hollow cylindrical member defining a central channel  142  and preferably includes a plurality of circumferentially-spaced slits  144  (only one shown in FIG. 7 for clarity) extending therealong between the outer surface and channel  142 , as illustrated in FIG. 8. The slits allow for expansion of the expandable extent  138  between an insertion diameter (shown) and a swaging diameter (not shown).  
         [0039]    In the embodiment shown, the actuating device  134  is formed of an elongated rod member  146  having a conically-shaped tip  148 . The diameter of the actuating device  134  is sized so that the actuating device  134  is inserted into channel  142  along the expandable extent to expand extent  138  to a swaging diameter. The conical-shaped tip  148  facilitates insertion of the actuating device  134  into channel  142  of the swaging device  132 . It should be understood that alternately shaped and designed swaging members and actuating members may be used and the invention is not limited to the exact configuration shown.  
         [0040]    The expandable extent  138  is sized for insertion through channels  114  of stakes  112  for swaging stakes  112  to actuator arms. In particular, the expandable extent  138  includes a collar segment  149  extending along a portion of the expandable extent  138 . The collar segment  149  has a slightly larger diameter than the remaining expandable extent  138  and shaft  136 . The swaging ridge  140  extends from the collar segment  149 . The insertion diameter of the collar segment  149  (and expandable extent  138  and shaft  136 ) is sized smaller than channel  114  of stake  112 . Preferably, the swaging ridge  140  extending about collar segment  149 , which forms a swaging portion, has a slightly larger insertion diameter than the channel  114  to provide a slight force to the walls of the stakes  112  during insertion. For example, if the diameter of the channel  114  is approximately 0.084 inches (2.134 millimeters), the collar segment of expandable extent  138  is 0.08 inches (2.032 millimeters) and the diameter of the swaging ridge  140  is 0.90 inches (22.86 millimeters). However, it should be understood that the swaging ridge  140  may be dimensioned smaller than channel  114 .  
         [0041]    In the embodiment illustrated above, rod member  146  and tip  148  of the actuating device  134  are sized smaller than channel  114  for insertion through channels  114  and mounting holes  98  for alignment and insertion into channel  142  of swaging device  134 . The dimension of the rod member  146  is sized to expand swaging device  132  along expandable extent  138  when inserted into channel  142 . For example, the diameter of rod  146  is approximately 0.072 inches (1.83 millimeters). As previously explained, the diameter of stake channel  114  is approximately 0.084 inches (2.134 millimeters) and thus rod  146  may be easily maneuvered relative to various actuator arms through stake channels  114  and hole  98  without applying force thereto. The diameter of channel  142  is approximately 0.06 inches (1.52 millimeters) and thus insertion of rod  146  into channel  142  expands swaging device  132  to provide sufficient swaging force to stakes  112 . Thus, no swaging force is supplied by the rod  146  until rod  146  is inserted into swaging device  132 , positioned relative to extended ends of stakes  112 . Preferably, the swaging diameter of the swaging ridge  140  in the embodiment described is 0.10 inches (2.54 millimeters).  
         [0042]    Slits  144  extend from an insertion end  150  of the swaging device  132  to a fulcrum position  152  distal of swaging ridge  140 . The distance between insertion end  150  and fulcrum  152  defines the expandable extent  138 . The swaging ridge  140  is positioned distal of the insertion end  150  into which actuating device  134  is inserted for expansion. The distance between insertion end  150  and swaging ridge  140  is designed to provide sufficient swaging force (via expansion of expandable extent  138  at swaging ridge  140 ) to stakes  112 - 1  and  112 - 2  via insertion of actuating rod  146  into insertion end  150  of swaging device  134 .  
         [0043]    For example, in a preferred embodiment, the length of slits  144  from end  150  to fulcrum  152  is 0.25 inches (6.35 millimeters), and the swaging ridge  140  is positioned approximately 0.055 inches (1.4 millimeters) from end  150  for sufficient expansion for providing sufficient swaging force. Preferably, as shown in FIG. 8, slits  144  are equally spaced about a circumference of expandable extent  138 . Also, in a preferred embodiment, at least six (6) slits  144  are included. It is noted that not all slits  144  are shown in FIG. 7 for clarity. Preferably, insertion end  150  is tapered to facilitate insertion of device  132  through stakes  112 . Shaft  136  is preferably a hollow member integrally formed with extent  138  and has a similar dimension to the expandable extent  138 .  
         [0044]    FIGS.  9 - 11  illustrate use of the swaging assembly  130  for swaging stakes  112  to actuator arms  78 ,  80 ,  82  and  84 , illustrated for a single actuator arm. As shown, first and second stakes  112 - 1  and  112 - 2  are inserted through hole  98 . As shown in FIG. 9, the length of the swaging ridge  140  is sufficient so that swaging ridge  140  may be simultaneously aligned within channels  114  of both first and second stakes  112 - 1  and  112 - 2  coupled to a single actuator arm  78 ,  80 ,  82 ,  84  so that swaging ridge  140  supplies an expansion force to both first and second stakes  112 - 1  and  112 - 2  simultaneously in a single position. In an example embodiment, the length of the swaging ridge is 0.028 inches (0.71 millimeters). Preferably, as shown, swaging ridge  140  is a “V”-shaped notch extension. The tip of the “V”-shaped notch essentially aligns between a gap between first and second stakes  112 - 1  and  112 - 2  inserted into actuator arm  78 ,  80 ,  82 ,  84 , and the sloped sides of the “V”-shaped notch are aligned to supply a generally radially-directed swaging force to stakes  112 - 1  and  112 - 2 .  
         [0045]    Prior to a swaging operation, spacers  116 - 1 ,  116 - 2  are positioned between adjacent actuator arms. End  150  of the swaging device  132  is inserted in a first direction through opening  120  of spacers  116 - 1  and  116 - 2  and into channels  114  of stakes  112  to align swaging ridge  140  with stakes  112 - 1 ,  112 - 2 . As the swaging device  132  is inserted, swaging ridge  140  provides a slight compressive force to the stakes  112  toward wall of hole  98 . Since the remainder of the swaging device  132  is profiled smaller than stake channels  114 , no other significant forces are supplied to the stakes during insertion of the swaging device  132 .  
         [0046]    As illustrated in FIGS.  10 - 11 , after device  132  is positioned, the actuating device  134  is inserted into channels  114  in a second direction, opposite of the first insertion direction. To operate swaging device  132  as shown in FIG. 11, actuating rod  146  is inserted through insertion end  150  for expanding extent  138  and swaging ridge  140 . As previously explained, insertion of devices  132  and  134  does not supply a significant force to stakes  112 - 1  and  112 - 2 . Force is not applied during insertion, but after the swaging ridge  140  is aligned and actuating device  134  (i.e., rod  146 ) is inserted into channel  142  so that a generally radially-directed uniform force is supplied to both stakes  112 - 1  and  112 - 2  via symmetric ridge  140 , as illustrated by arrows  152  in FIG. 11. The uniform radially-directed force to stakes  112 - 1  and  112 - 2  reduces differences in preload characteristics for the first and second stakes  112 - 1 ,  112 - 2 .  
         [0047]    Although use of an embodiment of the swaging assembly is illustrated for swaging suspension assemblies to a single actuator arm, the swaging assembly  130  may be used to swage suspension assemblies to sequential actuator arms on an E-block having any number of actuator arms, for multi-disc drives. FIG. 12 is a schematic illustration of use of a fixture for swaging suspension assemblies to multiple actuator arms of an E-block. As shown in FIG. 12, swaging device  132  and actuating device  134  are supported by spaced posts  160  supported by base  162 . Positioning devices  164 ,  166  are coupled to swaging device  132  and actuating device  134  to move the devices supported in spaced relation via posts  160  toward and away from one another, as illustrated by arrows  170 ,  172 . An E-block (shown diagrammatically) may be supported by a platform (shown diagrammatically) supported by base  162 . The E-block is supported so that holes  98  of actuator arms (having stakes  112 - 1 ,  112 - 2  inserted therein) align with the supported swaging device  132  and actuating device  134  for insertion therethrough. Positioning devices  164 ,  166  may be a mechanical screw or, alternatively, may be a pneumatic system or any other known system.  
         [0048]    For operation, spacers  116 - 1 ,  116 - 2  (not shown for clarity) are positioned between adjacent actuator arms of an E-block. The swaging device  132  and actuating device  134  are operating via positioning devices  164 ,  166 . As previously explained, to swage stakes to actuator arm  78 , positioning device  164  first aligns swaging ridge  140  (within channel  114  of stakes), and then positioning device  166  aligns actuating device  134  for insertion through channel  142  of swaging device  132  for swaging stakes to actuator arm. Thereafter, positioning device  166  is operated to withdraw actuating device  134  from channel  142  so that swaging device  132  may be advanced and aligned with stakes inserted through actuator arm  80  for similarly actuating stakes to arm  80 . This process is repeated until the desired stakes are swaged to each actuator arm. Thereafter, devices  132 ,  134  are completely retracted so that the E-block can be removed.  
         [0049]    [0049]FIG. 13 is a flow chart illustrating steps of use of an embodiment of a swaging device for connecting suspension assemblies to actuator arms of an E-block. The swaging operation starts as illustrated by block  174 ; and the swaging device  132  is inserted into hole  98  of actuator arm  78 , as illustrated by block  176 . Thereafter, the swaging device  132  is aligned relative to stakes  112  of a first actuator arm  78 , as illustrated by block  178 . Actuating rod  146  is inserted through holes  98  of actuator arms (i.e., opposite to swaging device  132 ), as illustrated by block  180 . The rod  146  is advanced for insertion through channel  142  of swaging device  132  to expand swaging device  132 , as illustrated by block  182 . The swaging device  132  is expanded to deform stakes to the first actuator arm  78 . After stakes are swaged to the first actuator arm  78 , actuator rod  146  is withdrawn from channel  142  of the swaging device  132 , as illustrated by block  184 . The swaging process continues for each actuator arm  80 ,  82 ,  84  such that the swaging device  132  is sequentially positioned relative to stakes  112 - 1 ,  112 - 2  of multiple actuator arms  80 ,  82 ,  84  to secure each actuator arm  78 ,  80 ,  82 ,  84  to the E-block, as illustrated by block  186 . After each actuator arm  78 ,  80 ,  82 ,  84  is staked, the swaging device  132  and rod  146  are withdrawn, as illustrated by block  188 , to complete the swaging process for an E-block, as illustrated by block  190 .  
         [0050]    [0050]FIG. 14 illustrates an alternate embodiment of an expandable swaging device  192 , and like numbers are used to refer to like parts. As shown, swaging device  192  includes a dome-shaped swaging portion  194 , instead of a “V” shaped swaging ridge  140 . The length of the dome-shaped swaging portion  194  may be sized to extend along a greater extent of stakes  112 - 1 ,  112 - 2 . It should be understood that the swaging portion may be formed of a variety of shapes or configurations and that the invention is not limited to the particular embodiments shown.  
         [0051]    [0051]FIG. 15 illustrates another alternate embodiment of an expandable swaging device  196 , and like numbers are used to refer to like parts illustrated in previous embodiments. As shown, swaging device  196  includes multiple swaging ridges  140 - 1  through  140 - 4  at spaced locations to align with stakes  112  inserted into holes  98  of multiple actuator arms  78 ,  80 ,  82 ,  84 . The ridges  140 - 1  through  140 - 4  are spaced a predefined distance  198  corresponding to the extent between stakes  112  of multiple actuator arms  78 ,  80 ,  82 ,  84  so that ridges  140 - 1  through  140 - 4  are simultaneously positioned relative to stakes  112  of multiple actuators arms  78 ,  80 ,  82 ,  84  to swage stakes  112  to multiple actuator arms  78 ,  80 ,  82 ,  84  via insertion of actuator rod  134 .  
         [0052]    Accordingly, various embodiments of an expandable swaging device and actuating device may be used without departing from the spirit and scope of the present invention.  
         [0053]    Thus, as described, the swaging assembly  130  includes an expandable swaging device  132  which is expandable between an insertion dimension and a swaging dimension. In the insertion dimension, the swaging device  132  may be inserted into stake channels without supplying significant biasing forces tending to affect the flying characteristics of the data heads. Once inserted and aligned in stake channels, the swaging device is expanded to the swaging dimension to impart a swaging force to the tubular stake for connecting suspension assemblies  102 ,  104  to actuator arms. Preferably, the swaging device  132  is actuated by a rod-type actuating device  146  which is insertable into channel  142  of the expandable member to expand the swaging device  132  to the swaging dimension. Also, preferably, the expandable member is formed of a tubular member having at least one slit  144  extending therealong.  
         [0054]    It is to be understood that even though numerous characteristics and advantages of the various embodiments of the present invention have been set forth in the foregoing description, together with details of the structure and function of various embodiments of the invention, this disclosure is illustrative only, and changes may be made in detail, especially in matters of structure and arrangement of parts within the principles of the present invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed. For example, the particular elements may vary depending on the particular application while maintaining substantially the same functionality without departing from the scope and spirit of the present invention.