Joining sheet metal

Claim 1

A method of joining sheet metal in a single operation comprising: (a) assembling at least two pieces of sheet metal in an overlapping relationship; (b) positioning a die against one outside face of the sheet metal assembly, said die including a cavity defined by an anvil forming the bottom surface of said cavity and by opposed laterally expansible side wall members mounted by pivot means for lateral pivotal movement relative to said cavity; (c) moving a punch against the opposite outside face of the sheet metal assembly in a longitudinal direction toward the die cavity in a manner to draw both pieces of sheet metal into the die cavity toward said anvil to form a cup-shaped portion with at least one side wall and a bottom wall without shearing any portion of the sheet metal, said drawing of said pieces of sheet metal tending initially to bias said side wall members toward one another; (d) continuing movement of the punch in said longitudinal direction toward said anvil to compress said bottom wall of said cup-shaped portion of the sheet metal pieces therebetween and thereby extrude said bottom wall in a lateral direction while at the same time permitting said side wall members to move apart without restricting such lateral extrusion, whereby there is formed a laterally enlarged shape which mechanically interlocks the two pieces of sheet metal, (i) said lateral extrusion occurring without fracture of any portion of the sheet metal, and (ii) said side wall members moving apart sufficiently easily to prevent any extrusion in said longitudinal direction; (e) longitudinally supporting said side wall members independently of said pivot means on a lateral portion of said side wall members remote from said cavity during longitudinal movement of said punch; and (f) withdrawing the punch from the joined sheet metal assembly.

Claim 2

A method of joining sheet metal in a single operation comprising: (a) assembling at least two pieces of sheet metal in an overlapping relationship; (b) positioning a die against one outside face of the sheet metal assembly, said die including a cavity defined by an anvil forming the bottom surface of said cavity and by opposed laterally expansible side wall members mounted by pivot means for lateral pivotal movement relative to said cavity; (c) moving a punch against the opposite outside face of the sheet metal assembly in a longitudinal direction toward the die cavity in a manner to draw both pieces of sheet metal into the die cavity toward said anvil to form a cup-shaped portion with at least one side wall and a bottom wall without shearing any portion of the sheet metal, said drawing of said pieces of sheet metal tending initially to bias said side wall members toward one another; (d) continuing movement of the punch in said longitudinal direction toward said anvil to compress said bottom wall of said cup-shaped portion of the sheet metal pieces therebetween and thereby extrude said bottom wall in a lateral direction while at the same time permitting said side wall members to move apart without restricting such lateral extrusion, whereby there is formed a laterally enlarged shape which mechanically interlocks the two pieces of sheet metal, (i) said lateral extrusion occurring without fracture of any portion of the sheet metal, and (ii) said side wall members moving apart sufficiently easily to prevent any extrusion in said longitudinal direction; (e) longitudinally supporting said side wall members independently of said pivot means on a lateral portion of said side wall members remote from said cavity during longitudinal movement of said punch; and (f) withdrawing the punch from the joined sheet metal assembly.