Method of forming a trailer hitch receiver tube

A method of forming an elongated receiver tube for a motor vehicle trailer hitch assembly of the type wherein said receiver tube has a hollow interior passage which receives a hitch bar having a rectangular cross section, comprising the steps of:

• providing an elongated rectangular cross-section hollow tube having a substantially uniform wall thickness,
• providing die means having a forming surface for defining an enlarged bead end for said receiver tube, said forming surface including a stop separating the enlarged bead end from a tube receiving portion of the die means,
• providing a single punch having a post fitting with a rectangular cross section for engagement within said rectangular tube hollow interior passage and said punch having a radial forming surface engageable with an end of said tube, said rectangular post defined by small radius corners adjacent said radial forming surface and more rounded corners at a leading end of the post,
• loading said tube into said die means with said end positioned within said bead forming surface and extending a desired distance from said stop,
• placing said punch with said post in said tube interior passage with said radial forming surface engaging said end of said tube,
• forcibly displacing said punch against said tube end causing said end to be deformed to conform to said die and post forming surfaces thereby providing a bead around said tube end having an increased wall thickness thereby strengthening said tube end and forming sharper corners in the interior of the bead and more round corners in the tube interior contacting the post;
• and
• forming an elongated receiver tube for a motor vehicle trailer hitch assembly.