Flaring and swaging bits, and methods using same

A system, comprising:

• a rotary insert comprising:
• a shank portion;
• a stopper portion coupled to the shank portion such that a T-shape is formed thereby;
• and
• a tip opposite the shank portion, the tip having a base coupled to the stopper portion, the tip extending away from the stopper portion along an axis of symmetry, the tip having a tip end spaced apart from the stopper portion, the tip comprising a first face disposed opposite a second face, the first face and the second face defining a continuous outer edge, the continuous outer edge extending from the tip end to the base;
• the continuous outer edge intersecting the axis of symmetry at the tip end;
• the outer edge having a maximum radius relative to the axis of symmetry at the base, the continuous outer edge from the tip end to the base tapering outward relative to the axis of symmetry;
• from the tip end to the base the tip having at least one stage portion, the continuous outer edge curved toward the tip end in the at least one stage portion;
• the stopper portion having a stopper radius greater than the maximum radius of the tip;
• and
• a drill or an electric screwdriver having a chuck engaging the shank portion to enable the tip to widen an open end portion of a metal tube when (1) the shank portion is inserted into the chuck of the drill or the electric screwdriver, (2) spun via the drill or the electric screwdriver, and (3) inserted into the open end portion of the metal tube while spinning so as to sufficiently heat the open end portion of the metal tube via friction generated between the tip that is spinning and the open end portion of the metal tube and thereby widen the open end portion of the metal tube using a hot process,
• wherein,
• the drill or the electric screwdriver is not a tailstock, and
• the tip is insertable into the open end portion of the metal tube up to the stopper portion.

A method for flaring a an open end portion of a metal tube, the method comprising:

• coupling a rotary insert to a chuck of a rotary power tool, wherein the rotary power tool is a drill or an electric screwdriver, wherein the rotary power tool is not a tailstock, wherein the rotary insert comprising:
• a shank portion;
• a stopper portion coupled to the shank portion such that a T-shape is formed thereby;
• a tip opposite the shank portion, the tip having a base coupled to the stopper portion, the tip extending away from the stopper portion along an axis of symmetry, the tip having a tip end spaced apart from the stopper portion, the tip comprising a first face disposed opposite a second face, the first face and the second face defining a continuous outer edge, the continuous outer edge extending from the tip end to the base;
• the continuous outer edge intersecting the axis of symmetry at the tip end;
• the outer edge having a maximum radius relative to the axis of symmetry at the base, the continuous outer edge from the tip end to the base tapering outward relative to the axis of symmetry;
• from the tip end to the base the tip having at least one stage portion, the continuous outer edge curved toward the tip end in the at least one stage portion;
• and the stopper portion having a stopper radius greater than the maximum radius of the tip;
• inserting the tip of the rotary insert into a cavity defined by an interior surface of a the open end portion of the metal tube while the rotary insert is coupled to the chuck of the rotary power tool;
• and
• rotating the rotary insert by spinning the shank portion via the chuck of the rotary power tool to cause friction between the tip and the interior surface of the open end portion of the metal tube, to increase the diameter of at least a portion of the metal tube including the open end portion, to create a flare of the open end portion of the metal tube, and to increase structural quality of the metal tube from heat provided to the metal tube via friction generated between the tip that is spinning and the open end portion of the metal tube using a hot process,
• wherein,
• rotating the rotary insert occurs as the tip of the rotary insert is inserted into the cavity defined by the interior surface of the open end portion of the metal tube, and
• the tip is insertable into the open end portion of the metal tube up to the stopper portion.

A method for swaging a an open end portion of a metal tube, the method comprising:

• coupling a rotary insert coupled to a chuck of a rotary power tool, wherein the rotary power tool is a drill or an electric screwdriver, wherein the rotary power tool is not a tailstock, wherein the rotary insert comprising:
• a shank portion;
• a stopper portion coupled to the shank portion such that a T-shape is formed thereby;
• a tip opposite the shank portion, the tip having a base coupled to the stopper portion, the tip extending away from the stopper portion along an axis of symmetry, the tip having a tip end spaced apart from the stopper portion, the tip comprising a first face disposed opposite a second face, the first face and the second face defining a continuous outer edge, the continuous outer edge extending from the tip end to the base;
• the continuous outer edge intersecting the axis of symmetry at the tip end;
• the outer edge having a maximum radius relative to the axis of symmetry at the base, the continuous outer edge from the tip end to the base tapering outward relative to the axis of symmetry;
• from the tip end to the base the tip having at least one stage portion, the continuous outer edge curved toward the tip end in the at least one stage portion;
• and the stopper portion having a stopper radius greater than the maximum radius of the tip;
• inserting the tip of the rotary insert into a cavity defined by an interior surface of a the open end portion of the metal tube while the rotary insert is coupled to the chuck of the rotary power tool;
• and
• rotating the rotary insert by spinning the shank portion via the chuck of the rotary power tool to cause friction between the tip and the interior surface of the open end portion of the metal tube, to increase the diameter of at least a portion of the metal tube including the open end portion, to create a swage of the open end portion of the metal tube, and to increase structural quality of the metal tube from heat provided to the metal tube via friction generated between the tip that is spinning and the open end portion of the metal tube using a hot process,
• wherein,
• rotating the rotary insert occurs as the tip of the rotary insert is inserted into the cavity defined by the interior surface of the open end portion of the metal tube, and
• the tip is insertable into the open end portion of the metal tube up to the stopper portion.

A rotary insert, comprising:

• a shank portion;
• a stopper portion coupled to the shank portion such that a T-shape is formed thereby;
• and
• a tip opposite the shank portion, the tip having a base coupled to the stopper portion, the tip extending away from the stopper portion along an axis of symmetry, the tip having a tip end spaced apart from the stopper portion, the tip comprising a first face disposed opposite a second face, the first face and the second face defining a continuous outer edge, the continuous outer edge extending from the tip end to the base;
• the continuous outer edge intersecting the axis of symmetry at the tip end;
• the outer edge having a maximum radius relative to the axis of symmetry at the base, the continuous outer edge from the tip end to the base tapering outward relative to the axis of symmetry;
• from the tip end to the base the tip having at least one stage portion, the continuous outer edge curved toward the tip end in the at least one stage portion;
• and the stopper portion having a stopper radius greater than the maximum radius of the tip,
• wherein,
• the tip widens an open end portion of a metal tube when (1) the shank portion is inserted into a chuck of a drill or an electric screwdriver, (2) spun via the drill or the electric screwdriver, and (3) inserted into the open end portion of the metal tube while spinning so as to sufficiently heat the open end portion of the metal tube via friction generated between the tip that is spinning and the open end portion of the metal tube and thereby widen the open end portion of the metal tube using a hot process,
• the drill or the electric screwdriver is not a tailstock,
• the tip is insertable into the open end portion of the metal tube up to the stopper portion,
• the rotary insert is a single element,
• the rotary insert comprises metal, and
• the at least one stage portion comprises only one stage portion.