Patent Publication Number: US-8113030-B2

Title: Methods for manufacturing flanged article

Description:
TECHNICAL FIELD 
     The present invention relates to methods for manufacturing a flanged work or flanged article. More particularly, the present invention relates to methods for manufacturing a flanged article that includes a central depressed body coupled to a peripheral flange. 
     BACKGROUND ART 
     A known method for manufacturing a flanged article is taught, for example, by Japanese Laid-open Patent Publication Number 10-202329, in which a toothed recessed plate or ratchet plate for a seat reclining device of a vehicle is exemplified as a flanged article that can be prepared utilizing the known method. In this known art, a disk-like sheet material or sheet blank is placed and clamped between upper and lower dies of a press forming machine. Thereafter, a punch associated with the upper die is lowered by a predetermined distance toward a corresponding die opening defined within the lower die. As a result, the sheet material is press formed or half die cut, to thereby form the ratchet plate that comprises a central depressed body and a peripheral flange. The peripheral flange of the ratchet plate is integrally connected to the central body via an annular shear deformed connecting portion. As a result, the peripheral flange and the central body define a circular open cavity or recess. Further, two tooth forming edges are circumferentially defined on the punch. Therefore, a pair of toothed portions can be formed on the inner circular circumferential surface of the peripheral flange when the sheet blank is press formed. 
     Typically, the ratchet plate thus produced may be post-treated by utilizing a punching machine in order to trim or die cut the outer circumferential surface of the peripheral flange. However, when the ratchet plate is die cut by the punching machine, the peripheral flange may be subjected to a substantial shearing force. As a result, the peripheral flange may be partly deformed due to plastic flow. Such deformation of the peripheral flange may deform the toothed portions formed on the inner circumferential surface of the peripheral flange. This may lead to decreased accuracy or partial damage of the toothed portions. 
     DISCLOSURE OF INVENTION 
     It is, accordingly, one object of the present teachings to provide improved methods and apparatus for manufacturing flanged articles. 
     In one embodiment of the present teachings, methods are taught for manufacturing a work having a peripheral flange by pressing a sheet material. The method includes the step of half die cutting the material so as to simultaneously form inner and outer circumferential surface of the peripheral flange while the peripheral flange is simultaneously subjected to isostatic pressures that are directed from the flange inner surface to the flange outer surface or from the flange outer surface to the flange inner surface. The half die cutting step is performed so as to form an inner connecting portion that interconnect the flange and a base portion of the work and an outer connecting portion that interconnect the flange and a sheet material positioned outside the flange. Also, the half die cutting step is performed such that the outer connecting portion has a thickness thinner than the thickness of the inner connecting portion. 
     According to the present teachings, the peripheral flange may be press formed while isostatic pressures are oppositely applied thereto. The peripheral flange thus formed may have a smooth outer circumferential surface that is free from deformation and fracture. Therefore, the flanged article thus produced is not necessary to be post-treated in order to trim the outer circumferential surface of the peripheral flange. As a result, it is possible to produce the flanged article in which the peripheral flange may have highly accurate toothed portions. 
     Other objects, features and advantages of the present teachings will be readily understood after reading the following detailed description together with the accompanying drawings and the claims. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         FIG. 1  is a vertical, cross-sectional view of a first pressing machine according to one representative embodiment of the present teachings, illustrating a condition in which a sheet material is disposed on a lower die assembly; 
         FIG. 2(A)  is a vertical, cross-sectional view of the first pressing machine, illustrating a condition in which an upper die assembly is lowered in order to clamp the sheet material between the upper and lower die assemblies; 
         FIG. 2(B)  is an enlarged view of an encircled portion in  FIG. 2(A) ; 
         FIG. 3  is a vertical, cross-sectional view of the first pressing machine, illustrating a condition in which the sheet material is preformed in order to form a preformed sheet material; 
         FIG. 4(A)  is a vertical, cross-sectional view of the first pressing machine, illustrating a condition in which the preformed sheet material is half die cut in order to form an intermediate recessed plate; 
         FIG. 4(B)  is an enlarged view of an encircled portion in  FIG. 4(A) ; 
         FIG. 5  is a vertical, cross-sectional view of the first pressing machine, illustrating a condition in which the upper die assembly is returned in order to remove the intermediate recessed plate from the first pressing machine; 
         FIG. 6  is a vertical, cross-sectional view of a second pressing machine according to one representative embodiment of the present teachings, illustrating a condition in which the intermediate recessed plate is disposed on a lower die assembly; 
         FIG. 7  is a vertical, cross-sectional view of the second pressing machine, illustrating a condition in which an upper die assembly is lowered in order to clamp the intermediate recessed plate between the upper and lower die assemblies; 
         FIG. 8  is a vertical, cross-sectional view of the second pressing machine, illustrating a condition in which the intermediate recessed plate is die cut in order to form a recessed plate; 
         FIG. 9(A)  is a plan view of the recessed plate; and 
         FIG. 9(B)  is a cross-sectional view taken along line IX(B)-IX(B) in  FIG. 9(A) . 
     
    
    
     BEST MODE FOR CARRYING OUT THE INVENTION 
     A detailed representative embodiment of the present teachings is shown in  FIGS. 1 to 9(B) , in which a circular dish-like toothed recessed plate W is exemplified in  FIGS. 8 ,  9 (A) and  9 (B) as a flanged article that can be prepared utilizing the present teachings. Such a recessed plate W may be utilized, e.g., with a housing that defines a locking mechanism for a vehicle seat reclining device. The recessed plate (i.e., flanged article or work) W is preferably formed by processing a previously formed, intermediate toothed recessed plate (i.e., intermediate flanged article) W′ ( FIGS. 6-8 ). Further, the intermediate recessed plate W′ is preferably formed by processing a sheet blank or sheet material M ( FIGS. 1-5 ). 
     As shown in, for example,  FIG. 4(A) , the intermediate recessed plate W′ as a primary product may preferably comprise a peripheral flange m 1 , a base portion or central circular depressed (offset) body m 2  and a flange outer periphery m 3  (i.e., a material portion positioned outside the flange or a material portion positioned outside the work). As best shown in  FIG. 4(B) , the peripheral flange m 1  is integrally and continuously connected to the central body m 2  via an annular shear deformed (inner) connecting portion n 2 . Consequently, the inner circular surface of the peripheral flange m 1  and the lower surface of the central body m 2  define a circular open cavity or recess R 1  as shown in, for example,  FIG. 5 . In addition, two opposing toothed portions m 11  are defined on the inner circular surface of the peripheral flange m 1  as shown in, for example,  FIG. 5 . In addition, as best shown in  FIG. 4(B) , the peripheral flange m 1  is integrally and continuously connected to the flange outer periphery m 3  via an annular shear deformed (outer) connecting portion n 1 . Further, the connecting portion n 1  may have a thickness of from 0.1 to 0.3 mm, and preferably 0.2 mm. 
     As shown in  FIGS. 8 ,  9 (A) and  9 (B), the recessed plate W as a secondary product (or final product) may preferably be formed by simply removing or die cutting the flange outer periphery m 3  from the intermediate recessed plate W′. Therefore, the recessed plate W may preferably comprise the central circular depressed (offset) body m 2  and the peripheral flange m 1 . Similar to the intermediate recessed plate W′, the peripheral flange m 1  is integrally and continuously connected to the central body m 2  via the annular shear deformed connecting portion n 2 , so that the inner circular surface of the peripheral flange m 1  and the lower surface of the central body m 2  define the circular open cavity or recess. R 1 . In addition, the two opposing toothed portions m 11  are defined on the inner circular surface of the peripheral flange m 1 . 
     The intermediate recessed plate W′ may be formed from the sheet material M by utilizing a first pressing machine  1  as shown in  FIGS. 1-5 . Thereafter, the intermediate recessed plate W′ is preferably processed by utilizing a second pressing machine  2 , to thereby form the recessed plate W as shown in  FIGS. 6-8 . 
     As shown in, for example,  FIG. 1 , the first pressing machine  1  may include a first upper die assembly that can move with respect to a first lower die assembly. The first upper die assembly may include a first upper die base U 1 . The first upper die assembly may further include an annular half die cutting die or punch  23  (i.e., a half die cutter) which constitutes a second set of pressing members, a disk-shaped ejector plate  21  (i.e., a first biasing member) which constitutes a first set of pressing members, and an annular stripper plate  22  (i.e., a second biasing member) which constitutes a third set of pressing members. The annular punch  23  is fixedly connected to the lower surface of the first upper die base U 1 , so as to move together with the first upper die assembly (the first upper die base U 1 ). The ejector plate  21  is closely positioned within the annular punch  23 . The ejector plate  21  is movably attached to the lower surface of the first upper die base U 1  via an elastic member  21   a  (e.g., a gas spring and a compression spring), so as to vertically move along the annular punch  23 . The elastic member  21   a  is arranged and constructed such that the ejector plate  21  is normally biased or forced downwardly. The stripper plate  22  is positioned around the annular punch  23 , so as to closely surround the same. Similar to the ejector plate  21 , the stripper plate  22  is movably attached to the lower surface of the first upper die base U 1  via an elastic member  22   a  (e.g., a gas spring and a compression spring), so as to vertically move along the annular punch  23 . Similar to the elastic member  21   a , the elastic member  22   a  is arranged and constructed such that the ejector plate  21  is normally biased or forced downwardly. As will be appreciated, the annular punch  23 , the ejector plate  21  and the stripper plate  22  may preferably be arranged and constructed such that their lower surfaces are normally coplanar with each other. 
     The first lower die assembly may include a first lower die base D 1 . The first lower die assembly may further include an annular die  12  (i.e., a second die element) which constitutes a third set of pressing members, an annular ejector member  13  (i.e., a counter biasing member) which constitutes a second set of pressing members and a cylindrical die  11  (i.e., a first die element) which constitutes a first set of pressing members. The annular die  12  is fixedly connected to the upper surface of the first lower die base D 1 , so as to align with the annular stripper plate  22  of the first upper die assembly. The annular die  12  may preferably define a cylindrical die opening F 1  therewithin, the die opening being concentric with the annular punch  23  of the first upper die assembly. The annular die  12  may preferably be constructed such that the die opening F 1  has a diameter that is slightly greater than the outer diameter of the annular punch  23 , so as to receive the annular punch  23 . The cylindrical die  11  is positioned within the die opening F 1  so as to be coaxially aligned with the annular punch  23 . That is, the cylindrical die  11  is positioned so as to be vertically opposite to the ejector plate  21  of the first upper die assembly, so that a cylindrical annular space is formed between the dies  11  and  12 . The cylindrical die  11  is fixedly connected to the upper surface of the first lower die base D 1 . The annular ejector member  13  is positioned within the annular space between the dies  11  and  12 , so as to contact both of the cylindrical surfaces of the dies  11  and  12 . The ejector member  13  thus positioned is coaxially aligned with the annular punch  23 . That is, the ejector member  13  is vertically opposite to the annular punch  23 . Further, the ejector member  13  is movably attached to the upper surface of the first lower die base D 1  via an elastic member  13   a  (e.g., a gas spring and a compression spring), so as to vertically move along the annular die  12  and the cylindrical die  11 . The elastic member  13   a  is arranged and constructed such that the ejector member  13  is normally biased or forced upwardly. As will be appreciated, the annular die  12  and the ejector member  13  may preferably be arranged and constructed such that their upper surfaces are normally coplanar with each other. 
     The cylindrical die  11  is preferably structured so as to have substantially the same shape as the recess R 1  that will be formed within the intermediate recessed plate W′ (the recessed plate W). In addition, the cylindrical die  11  may preferably be arranged and constructed such that its upper surface (i.e., a die surface) is slightly lower than the upper surfaces (i.e., die surfaces) of the annular die  12  and the ejector member  13 , so that difference in level is formed therebetween. Also, tooth forming edges  11   a  may be disposed around the circumference of the cylindrical die  11 . The tooth forming edges  11   a  preferably correspond to the two opposing toothed portions m 11  that will be formed along the inner circular surface of the peripheral flange m 1 . Further, as best shown in  FIG. 4(B) , the ejector member  13  may preferably have a thickness smaller than the thickness of the annular punch  23 . The ejector member  13  can be designed such that the difference between the thickness of the ejector member  13  and the thickness of the annular punch  23  substantially corresponds to the depth of the tooth forming edges  11   a  of the cylindrical die  11 . 
     As shown in, for example,  FIG. 6 , the second pressing machine  2  may include a second upper die assembly that can move with respect to a second lower die assembly. The upper die assembly may include a second upper die base U 2 . The second upper die assembly may further include a cylindrical cutting die or punch  124  (i.e., a die cutter) and an annular stripper plate  122  (i.e., a third biasing member). The cylindrical punch  124  is fixedly connected to the lower surface of the second upper die base U 2 , so as to move together with the second upper die assembly (the second upper die base U 2 ). As will be appreciated, the cylindrical punch  124  may preferably have the same outer diameter as the outer diameter of the annular punch  23  of the first pressing machine  1 . Further, the cylindrical punch  124  may preferably have an open cavity or recess C formed in the lower surface thereof. The recess C is arranged and constructed to fit over the central circular depressed body m 2  of the intermediate recessed plate W′. The stripper plate  122  is positioned around the cylindrical punch  124 , so as to closely surround the same. Similar to the stripper plate  22  of the first pressing machine  1 , the stripper plate  122  is movably attached to the lower surface of the second upper die base U 2  via an elastic member  122   a  (e.g., a gas spring and a compression spring), so as to vertically move along the cylindrical punch  124 . The elastic member  122   a  is arranged and constructed such that the stripper plate  122  is normally biased or forced downwardly. 
     The second lower die assembly may include a second lower die base D 2 . The second lower die assembly may further include an annular die  112  (i.e., a third die element). The annular die  112  is fixedly connected to the upper surface of the second lower die base D 2 , so as to align with the annular stripper plate  122  of the second upper die assembly. The annular die  112  may preferably define a cylindrical die opening F 2  therewithin, the die opening being axially aligned with the cylindrical punch  124  of the second upper die assembly. The annular die  112  may preferably have an inner diameter substantially equal to the outer diameter of the cylindrical punch  124 , so that the die opening F 2  defined therewithin can closely receive the cylindrical punch  124  when the second upper die assembly is lowered ( FIG. 8 ). 
     A representative method for manufacturing the recessed plate W using the first and second pressing machines  1  and  2  will now be described. As shown in  FIG. 1 , the sheet material M is first disposed on the first lower die assembly of the first pressing machine  1 . That is, the sheet material M is disposed on the annular die  12  and the ejector member  13  of the first pressing machine  1 . Subsequently, as shown in  FIG. 2(A) , the upper base U 1  of the first upper die assembly of the first pressing machine  1  is moved (lowered) until the annular punch  23 , the annular stripper plate  22  and the ejector plate  21  contact the upper surface of the sheet material M. As a result, the sheet material M is clamped between the annular stripper plate  22  and the annular die  12  and between the annular punch  23  and the ejector member  13 . At this time, as shown in  FIG. 2(B) , a space S is formed between the sheet material M and the upper surface of the cylindrical die  11 , because the upper surface of the cylindrical die  11  is slightly lower than the upper surfaces of the annular die  12  and the ejector member  13  as described above (i.e., the difference in level is formed therebetween). 
     Thereafter, as shown in  FIG. 3 , the first upper die assembly (the upper base U 1 ) is further moved toward the first lower die assembly. As a result, the annular punch  23  will be moved downwardly against the elastic force of the elastic member  13   a , so that the sheet material M is preformed (shear press formed) by cooperation of the annular punch  23  and the annular die  12 , to thereby form a preformed sheet material M′ as a preformed material (a first half die cutting step). At this time, the ejector plate  21  is lowered together with the annular punch  23 . Conversely, the stripper plate  22  may be upwardly moved along the annular punch  23  so as to elastically deform the elastic member  22   a . As a result, the stripper plate  22  may be downwardly biased due to the elastic force of the deformed elastic member  22   a , so as to provide compression forces to the preformed sheet material M′. As will be recognized, this preforming operation may preferably be continued until the sheet material M contacts the upper surface of the cylindrical die  11 . That is, the first upper die assembly is moved downwardly until the space S disappears (or decreases to zero). Therefore, the preformed sheet material M′ may have a depressed (offset) portion Ma having offsets that correspond to the space S. 
     After completing the preforming operation, as shown in  FIG. 4(A) , the first upper die assembly is further moved toward the first lower die assembly. As a result, the annular punch  23  will be further moved downwardly against the elastic force of the elastic member  13   a , so that the preformed sheet material M′ is shear press formed or half die cut by cooperation of the annular punch  23  and the annular die  12  and the cylindrical die  11 , to thereby form the intermediate recessed plate W′ as the primary product (a second half die cutting step). As previously described, the intermediate recessed plate W′ thus produced includes the peripheral flange m 1 , the central circular depressed body m 2  and the flange outer periphery m 3  that are interconnected via the connecting portions n 1  and n 2  ( FIG. 4(B) ). At this time, both of the ejector plate  21  and the stripper plate  22  may be upwardly moved along the annular punch  23  so as to elastically deform the elastic members  21   a  and  22   a . As a result, the ejector plate  21  and the stripper plate  22  may be downwardly biased due to the elastic force of the deformed elastic members  21   a  and  22   a , so as to provide compression forces to the intermediate recessed plate W′. Further, when the preformed sheet material M′ is press formed, the toothed portions m 11  are simultaneously formed along the inner circular surface of the peripheral flange m 1 , because the tooth forming edges  11   a  are defined around the circumference of the cylindrical die  11 . 
     This shear press forming operation may preferably be continued until the connecting portions n 1  and n 2  may respectively have a desired or predetermined thickness. As best shown in  FIG. 4(B) , the connecting portions n 1  and n 2  may respectively have a different thickness, because the preformed sheet material M′ has the depressed portion Ma having the offsets that correspond to the space S. In other words, the connecting portion n 1  has a thickness thinner than the thickness of the connecting portion n 2 . As will be appreciated, the difference between the thicknesses of these connecting portions n 1  and n 2  is substantially equal to the height of the space S. 
     Further, in the first and second half die cutting steps, the half die cutting operation that is performed by the annular punch  23  and the annular die  12  will be referred to as an outer half die cutting step. Conversely, the half die cutting operation that is performed by the annular punch  23  and the cylindrical die  11  will be referred to as an inner half die cutting step. As will be appreciated, the inner and outer half die cutting steps may respectively form the inner and outer circular surfaces of the peripheral flange m 1 . 
     As described above, the shear press forming operation can be performed by lowering the first upper die assembly toward the first lower die assembly and not by lifting the first lower die assembly toward the first upper die assembly. In other words, the annular punch  23  can be moved utilizing the weight of the first upper die assembly in order to half die cut the preformed sheet material M′. Therefore, additional forces that are required to move the annular punch  23  can be effectively reduced. 
     In addition, according to the present shear press forming operation, the peripheral flange m 1  of the intermediate recessed plate W′ can be formed while it is transversely restrained between the cylindrical die  11  and the annular die  12 . Therefore, the peripheral flange m 1  may be prevented from bending or deforming that is caused by plastic deformation. In addition, the peripheral flange m 1  may preferably be subjected to isostatic pressures that are directed radially inward and outward (i.e., in the directions shown by arrow in  FIG. 4(B) ). Therefore, the peripheral flange m 1  may have a smooth outer surface that is free from deformation and fracture. 
     After completing the shear press forming operation, as shown in  FIG. 5 , the first upper die assembly is moved upwardly so as to be away from the first lower die assembly. As a result, the ejector plate  21  and the stripper plate  22  will be downwardly returned to their resting positions due to the elastic forces of the elastic members  21   a  and  22   a , so that the intermediate recessed plate W′ will be disengaged from the annular punch  23 . At the same time, the ejector member  13  of the first lower die assembly will be upwardly returned to its resting position due to the elastic force of the elastic member  13   a , so as to upwardly eject the intermediate recessed plate W′ from the die opening F 1  of the first lower die assembly. Thus, the intermediate recessed plate W′ will be removably positioned on the first lower die assembly while the peripheral flange m 1  is supported via the ejector member  13 . 
     The intermediate recessed plate W′ thus produced is then processed by utilizing the second pressing machine  2 . That is, as shown in  FIG. 6 , the intermediate recessed plate W′ is placed on the second lower die assembly (the annular die  112 ) of the second pressing machine  2  while the peripheral flange m 1  is positioned within the cylindrical die opening F 2  of the annular die  112 . At this time, the flange outer periphery m 3  is seated on the annular die  112 . Subsequently, as shown in  FIG. 7 , the upper base U 2  of the second upper die assembly of the second pressing machine  2  is moved (lowered) until the annular stripper plate  122  contacts the upper surface of the flange outer periphery m 3 . Thus, the flange outer periphery m 3  is clamped between the annular stripper plate  122  and the annular die  112 , so that the intermediate recessed plate W′ is immovably positioned on the second lower die assembly. 
     Thereafter, the second upper die assembly is further moved toward the second lower die assembly. As a result, the cylindrical punch  124  will be moved downwardly, so that the recess C formed in the lower surface of the cylindrical punch  124  fits over the central circular depressed body m 2  of the intermediate recessed plate W′. At this time, the stripper plate  122  may provide compression forces to the flange outer periphery m 3  due to the elastic force of the elastic member  122   a , so that the flange outer periphery m 3  can be rigidly clamped between the annular stripper plate  122  and the annular die  112 . 
     Subsequently, as shown in  FIG. 8 , the second upper die assembly is further moved toward the second lower die assembly. As a result, the cylindrical punch  124  will be projected into the die opening F 2  so as to engage the annular punch  112 . Upon engagement of the cylindrical punch  124  and the annular punch  112 , the connecting portion n 1  connecting the peripheral flange m 1  and the flange outer periphery m 3  is die cut along the outer circular surface of the peripheral flange m 1 , so that the recessed plate W is formed as the final product. 
     At this time, the stripper plate  122  may further provide compression forces to the flange outer periphery m 3  due to the elastic forces of the elastic members  122   a , because the elastic member  122   a  is further elastically deformed. Therefore, the flange outer periphery m 3  can be further rigidly clamped between the annular stripper plate  122  and the annular die  112 , so as to be effectively prevented from deforming (plastically deforming) when the connecting portion n 1  is die cut. As a result, the peripheral flange m 1  may have a smooth die cut surface that is free from deformation and fracture. 
     Further, because the connecting portion n 1  has a reduced thickness as described above, the connecting portion n 1  can be easily die cut by exerting limited forces thereon. Also, upon completion of the die cutting operation, the produced recessed plate W may fall into the cylindrical die opening F 2  of the annular die  112  as a result of gravity. Therefore, the recessed plate W can be easily removed from the second pressing machine  2  by simply returning the second upper die assembly to its resting position (an uppermost position). 
     According to the present method, the sheet material M is half die cut in the first pressing machine  1 , to thereby form the intermediate recessed plate W′ having the peripheral flange m 1 . Also, when the intermediate recessed plate W′ is formed, the toothed portions m 11  are simultaneously formed along the inner circular surface of the peripheral flange m 1 . 
     In addition, the connecting portion n 1  of the intermediate recessed plate W′ is die cut in the second pressing machine  2  in order to separate the flange outer periphery m 3  from the peripheral flange m 1 , to thereby form the recessed plate W. As previously described above, because the connecting portion n 1  can be easily die cut without exerting large forces thereon, such die cutting operation does not lead to decreased accuracy or partial damage of the toothed portions m 11  that are formed in the inner circumferential surface of the peripheral flange m 1 . 
     Further, according to the present invention, the half die cutting operation and the die cutting operation can respectively be completed using the first and second pressing machines  1  and  2 . Therefore, it is not necessary to use additional machines such as a special cutting machine. As a result, it is possible to reduce manufacturing steps and manufacturing costs for the recessed plate W. 
     Naturally, various changes and modifications may be made to the present teachings without departing from the scope of the invention. For example, in the above described embodiment, the half die cutting operation and the die cutting operation are performed using the first and second (two) pressing machines  1  and  2 . However, the half die cutting operation and the die cutting operation can be performed using a single common pressing machine. For example, both of the half die cutting and the die cutting operations can be performed using only the first pressing machine  1 . In such a case, the first pressing machine  1  is designed such that the first upper and lower die assemblies (the first upper and lower die bases U 1  and D 1 ) can be optionally replaced with the second upper and lower die assemblies (the second upper and lower die bases U 2  and D 2 ) after the half die cutting operation is completed. Alternatively, the first pressing machine  1  is designed so as to include the second upper and lower die assemblies (the second upper and lower die bases U 2  and D 2 ). In addition, the second upper and lower die assemblies can respectively be combined with the first upper and lower die assemblies. For example, it is possible to use the first upper and lower die bases U 1  and D 1  as common upper and lower die bases and to omit the second upper and lower die bases U 2  and D 2 . 
     A representative example of the present invention has been described in detail with reference to the attached drawings. This detailed description is merely intended to teach a person of skill in the art further details for practicing preferred aspects of the present teachings and is not intended to limit the scope of the invention. Only the claims define the scope of the claimed invention. Therefore, combinations of features and steps disclosed in the foregoing detail description may not be necessary to practice the invention in the broadest sense, and are instead taught merely to particularly describe detailed representative examples of the invention. Moreover, the various features taught in this specification may be combined in ways that are not specifically enumerated in order to obtain additional useful embodiments of the present teachings. 
     Additional examples of methods for manufacturing a flanged article are found in U.S. Pat. No. 6,907,764, the contents of which are hereby incorporated by reference.