Systems and methods for internal channel formation within a workpiece

A tool for forming an internal channel within a workpiece, the tool comprising:

• a tool body including a central axis and a shoulder;
• a pin projected outward from the shoulder along the central axis, wherein the pin includes a flange that is axially spaced from the shoulder along the central axis;
• wherein the shoulder includes a plurality of spiral grooves,
• wherein the flange includes a first surface, a second surface, and a radially outer surface extending between the first surface and the second surface,
• wherein the first surface is positioned axially between the second surface and the shoulder along the central axis, and
• wherein second surface comprises a plurality of spiral grooves.

A method of forming an internal channel within a workpiece, wherein the workpiece includes a first surface, a second surface opposite the first surface, and a groove extending into the first surface that extends across the workpiece, the method comprising:

• (a) rotating a tool about a central axis, wherein the tool comprises:
• a tool body including a central axis and a shoulder;
• a pin extending axially from the shoulder along the central axis;
• and
• a flange mounted to the pin that is spaced from the shoulder along the central axis,
• wherein the shoulder comprises a plurality of spiral grooves,
• wherein the flange includes a first surface, a second surface, and a radially outer surface extending between the first surface and the second surface,
• wherein the first surface is positioned axially between the second surface and the shoulder along the central axis, and
• wherein second surface comprises a plurality of spiral grooves thereon;
• (b) inserting the tool into the workpiece from the first surface such that the flange is positioned between the first surface and the second surface;
• (c) moving the tool across the workpiece along the groove in a radial direction with respect to the central axis;
• (d) engaging the shoulder of the tool with the first surface of the workpiece during (c);
• and
• (e) forming the internal channel with the flange during (c) and (d).

A tool for forming an internal channel within a workpiece, the tool comprising:

• a tool body including a central axis and a shoulder;
• a pin projected outward from the shoulder along the central axis, wherein the pin includes a flange that is axially spaced from the shoulder along the central axis;
• wherein the shoulder includes a plurality of spiral grooves, and
• wherein the flange includes a first surface, a second surface, and a radially outer surface extending between the first surface and the second surface, wherein the first surface is positioned axially between the second surface and the shoulder along the central axis, wherein the first surface is frustoconical in shape, and wherein the radially outer surface comprises a plurality of radially extending notches.