Wheel cylinder piston having a flared boss end and a method of flaring a boss end

A method of forming a flared end on a boss having an end surface substantially perpendicular to the boss center line, said method comprising the steps of:

• (a) making a sintered powdered metal part with a boss to be flared;
• (b) providing an axially movable mandrel with an annular flat end surface lying in a plane perpendicular to the axis of mandrel movement;
• (c) and striking a peripherally extending surface section of the boss end surface with the mandrel annular flat end surface throughout the area of the peripherally extending surface section in a direction parallel to the boss center line while providing no lateral support to the boss which would tend to prevent flaring of the boss end;
• the striking action axially compressing a cylindrical portion of the boss under the peripherally extending surface section to create an annular shear fracture extending substantially parallel to the boss center line at the inner edge of the struck peripherally extending surface section to a depth less than the length of the boss as controlled by the striking force and stroke of the mandrel annular surface and the compaction characteristic of the powdered metal part while flaring the sheared cylindrical portion outwardly to form a flared end on the boss.