WO2001003866A1

WO2001003866A1 - Drive socket and method of forming same

Info

Publication number: WO2001003866A1
Application number: PCT/US2000/016303
Authority: WO
Inventors: Jackie L. Hyatt
Original assignee: Hand Tool Design Corp
Current assignee: Hand Tool Design Corp
Priority date: 1999-07-07
Filing date: 2000-06-29
Publication date: 2001-01-18
Anticipated expiration: 2002-01-07
Also published as: EP1192017B1; US6390929B2; DE60005010T2; AU5737200A; US6240813B1; DE60005010D1; CN1108890C; EP1192017A1; US20010007213A1; CN1360527A; TW424034B; ATE248666T1

Abstract

A method of making a recess (58) in a drive socket (100) and the like includes forming a groove (72) to extend along a face of an elongated drive opening (66) in a metal workpiece (38) from one end of its drive opening (66), moving material from the surface of the groove (72) to increase its depth from its outer end along only a portion of its length and gathering the material so moved from the groove surface to form a ledge (90) between ends of the groove (72), whereby a recess (58) is defined by the groove extending beyond the ledge (90). In addition, a female drive device for socket wrenches and the like is disclosed having an elongated drive opening (66), a groove (72) longitudinally extending from one end of the drive opening (66) along a face of the drive opening, and a ledge (90) between ends of the groove (72a). The ledge (90) protrudes radially inwardly such that a recess (58) is defined by the groove extending beyond the ledge (90) for retaining a male drive member.

Description

DRIVE SOCKET AND METHOD OF FORMING SAME

FIELD OF THE INVENTION

This invention generally relates to drive sockets and drive socket

forming processes and particularly concerns female drives having

retention recesses for hand, power and impact wrenches and the like and

an improved method of forming such drives.

l o BACKGROUND OF THE INVENTION

Various processes have been used in the past in forming socket

wrenches, extension bars, adapters and the like. These devices such as the

socket wrench itself are standard devices, well known in the art. A

15 conventional square drive socket is provided at one end of the socket

wrench and is releasably attachable to a drive tang of a handle unit for a

ratchet, for example. A fastener socket is coaxialiy formed at an opposite

end of the wrench. The fastener socket is commonly serrated or of

hexagonal cross-section. A through-hole may extend between the

20 coaxialiy aligned sockets. The through-hole serves to provide clearance, for example, for a shank of a bolt on which a hex nut is threadably

engaged with the nut received within the hex fastener socket. For a quality

product, such socket wrenches are formed of alloy steel. Standard screw

machines conventionally have been used in the manufacture of such

wrenches which normally require several sequential machining operations.

Drive socket openings for such wrenches commonly have a recess

for receiving a spring-operated ball, for example, in a tang of a drive

handle for retaining the socket wrench and handle attachment in driving

engagement. However, problems are frequently encountered in forming

such recesses in socket wrenches and the like because of long standing

difficulties in achieving consistency and accuracy in the size, shape and

location of a recess in a face of the drive socket opening while also

insuring that the depth of the recess is consistently accurate, particularly

when each face of the drive opening has a recess. Specifications for

female ends of such square drives for hand, power and impact wrenches

are set forth in Table 7, The American Society of Mechanical Engineers

publication ASME B107.4M-1995. When such parts are being produced by machining operations such

as turning or index milling operations, for example, how one sets a cutter

and how one sets the travel of the cutter are variable but important

functions. If the drive opening is not precisely dead center relative to a

major longitudinal axis of the workpiece or if the cutting tool itself is

somewhat off center, any resulting product will be nonconforming because

the recesses are of different depth, or the recesses are misaligned from a

symmetrical centered position in the faces of their respective drive

opening, or the recesses are not axially aligned relative to the major

longitudinal axis of the part. Moreover, such machining processes require

specialized equipment, are expensive if not fully automated, suffer from

limited tool life and resultant defects such as burrs.

OBJECTS OF THE INVENTION

One object of this invention is to provide an improved drive socket

having a unique recess of predetermined depth in a face of a drive socket

opening with the recess precisely located in desired symmetrical relation

to a face of the drive socket opening. Included in this object is the aim of

providing an improved method of making such a drive socket. Another object is to provide an improved drive socket having a

plurality of drive faces within a drive opening wherein every face has a

recess formed at an identical depth and location relative to the recesses in

the other faces and a method of making such a drive socket.

Still another object is to provide an improved method of making a

recess in a face of a drive opening of a drive socket of high quality in a

simplified manufacturing process of reduced cost and which eliminates

commonly required secondary machining operations.

Other objects will be in part obvious and in part pointed out more in detail hereinafter.

SUMMARY OF THE INVENTION

This invention is directed to a method of making a drive socket with

a recess in its drive opening for use in retaining the drive socket on a

complementary handle attachment and includes a series of steps. A metal

workpiece is first provided having a drive opening with a face extending

inwardly from one end of the drive opening. A metal forming step forms a groove along at least a portion of the length of the face of the drive

opening, followed by moving material from the groove surface along only

a portion of the length of the groove and gathering the moved material to

form a ledge between ends of the groove such that a recess is defined by

the groove extending beyond the ledge.

This invention also is directed to a drive device having a metal

socket with a drive opening having a face extending inwardly from

adjacent one end of the drive opening. A groove extends along at least a

portion of the face of the opening. A ledge protrudes radially inwardly

from the groove between ends of the groove such that a recess is defined

by that portion of the groove extending beyond the ledge.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional view, partly broken away, showing a

female drive end of a prior art square drive device;

FIG. 2 is an end view of the device of FIG. 1: FIGS. 3-8 are cross-sectional views, partly broken away, showing

other embodiments of female drive ends of prior art square drive devices;

FIGS. 9 and 10 are schematic representations showing one

embodiment of a method of this invention;

FIGS. 9A and 10A are cross-sectional views of a workpiece

corresponding to the steps illustrated in FIGS. 9 and 10, respectively;

FIGS. 9B and 10B are side views, partly broken away, of a punch

used in the steps shown in FIGS. 9 and 10, respectively;

FIG. 11 is an isometric view, partly broken away, of a punch of the

type shown in FIG 10B;

FIG. 12 is a cross-sectional view, partly broken away, showing a

drive socket of this invention similar to that shown in FIG. 10 A;

FIG. 13 is an end view of the drive socket of FIG. 12; FIG. 14 is an assembly view, partly broken away and partly in cross-

section, schematically showing a drive socket of this invention drivingly

engaged with a tang of a drive attachment;

FIG. 15 is a cross-sectional view, partly broken away, showing a

portion of another embodiment of a drive socket of this invention;

FIG. 16 is an end view of the drive socket of FIG. 15;

l o FIG. 17 shows a portion of yet another embodiment of a drive

socket, partly broken away and partly in section, of this invention;

FIG. 18 is an end view of the drive socket of FIG. 17;

15 FIGS. 19-22 are isometric views of different types of workpieces

suitable to be sequentially formed by a method of this invention to make

drive sockets of this invention;

FIG. 23 is a cross-sectional view of another drive socket made in

20 accordance with this invention; FIGS. 24 A and 24B are end views of opposite ends of the drive

socket of FIG. 23;

FIGS. 25 and 26 are schematic representations showing a

further embodiment of a method of this invention;

FIGS. 25 A and 26 A are cross-sectional views of a workpiece

corresponding to the steps illustrated in FIGS. 25 and 26, respectively;

FIGS. 25B and 26B are side views, partly broken away, of a punch

used in the steps shown in FIGS. 25 and 26, respectively;

FIGS. 27, 28 and 29 are schematic representations showing yet

another embodiment of a method of this invention;

FIGS. 27A, 28 A and 29 A are side views, partly broken away and

partly in section, of a workpiece corresponding to the steps illustrated in

FIGS. 27, 28 and 29; and FIGS. 28B and 29B are side views, partly broken away, of punches

used in the steps illustrated in FIGS. 28 and 29, respectively.

A better understanding of the objects, advantages, features,

5 properties and relations of the invention will be obtained from the

following detailed description and accompanying drawings which set forth

certain illustrative embodiments and are indicative of the various ways in

which the principles of the invention are employed.

l o DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to the representations of prior art illustrated in FIGS. 1-8,

drive ends and spindle ends for portable hand, power, impact, air and

electric tools are depicted having square female ends. As is well known in

15 the art, a retention feature is commonly provided in the drive end, say, of a

socket wrench in the form of a recess for receiving a spring-operated ball,

for example, in a drive tang of a handle attachment such as that of a ratchet

for positioning and holding the socket wrench in relation to the tang of the

handle so that the device can be released by force applied to one of the

20 parts. A cross-hole type retention feature is shown in devices 2, 4 and 6 of

FIGS. 1-3 and FIG. 5 providing a recess in a drive opening 10, 12 and 14,

respectively, wherein the recess is formed in a face 10A, 12A and 14A of

the opening by cross holes 16, 18 and 20. These holes are usually drilled,

but in some cases, can be pierced. In the design shown in FIG. 1, it is up

to the user to orient the device 2 to a ball (not shown) on the attachment,

such as a ratchet handle. It may be made more user friendly by having a

hole in each of the four flats of the opening, but this adds more costs.

FIGS. 4 and 8 show a design wherein recesses such as at 22 (FIG. 4)

and 24 (FIG. 8) will be understood to be formed on each of the four faces

of a square opening 26 and 28 to provide the retention feature. The drive

device 30 (FIG. 4) and 32 (FIG. 8) may be a socket wrench, e.g., that is

clamped on its outside diameter and is then machined or cut by spinning

the socket and inserting a cutting tool or burr bit (not shown) into its

square opening 26, 28. Manufacturing by such machining is slow and

expensive because it is critical to meet dimensional criteria. The device 34 shown in FIG. 6 does not have any retention feature

within its square opening 35 nor is it required for one quarter inch female

openings in accordance with the standards prescribed in ASME

B107.4M1995.

The prior art device 36 of FIG. 7 is also formed in a series of

machining operations, and this retention design is limited to sizes that are

large enough to pass a drill or reamer through an end opposite the square

drive end of the tool, i.e., through the end on the left hand side of the

device 36 as viewed in the drawing.

It will be appreciated by those skilled in the art that if the square

drive opening is not precisely formed to extend longitudinally within the

workpiece in coaxial alignment with a major longitudinal axis of that

workpiece, the depth of the recesses 22 and 24 shown, for example, in

FIGS. 4 and 8 will be different. If the axes of the drive end opening and

the workpiece are not contained in the same plane, those same recesses

will be misaligned axially along the length of the device just as the cross

holes 18 (FIG. 3) would be if they were not coaxialiy formed in

perpendicular relation to the major axis of the device 4. In each of the prior art devices illustrated in FIGS. 1-5, 7 and 8, the forming of the square

drive opening and the ball receiving recess are separate independent steps

subject to critical dimensional tolerances, whether by punching or

broaching the drive square, or by piercing, cross-hole drilling, or by

turning or milling operations in forming the recesses. Any error in

aligning and/or centering of the workpiece or the machine tool results in

recesses of undesired different depth, undesired misaligned recesses or

recesses that are not symmetrically located on the drive face of the square

drive opening.

Referring now in detail to steps of the present invention shown in

FIGS. 9 and 10 and corresponding FIGS. 9A, 10A and FIGS. 9B, 10B, it

will be understood that a finished quality product is formed from metal

which can be of different compositions including carbon steels and steel

alloys to provide quality female drive ends for a wide variety of tools

including hand tools, power tools, impact tools such as socket wrenches,

extension bars, adapters and the like. For convenience, the finished

product is hereinafter called a drive socket. In the specifically illustrated

embodiment of FIGS. 9 and 10, a workpiece 38 is shown having a fastener socket 40 of hexagonal cross-section for use in driving a correspondingly

shaped fastener (not shown).

To provide workpiece 38 with a retention feature, a recess of a

precisely controlled, predetermined depth is desired to be formed in an

economical manner suited to be readily repeated and to provide

consistently uniform part dimensions particularly adapted for an

automated metal forming operation.

An extrusion punch 44 (FIGS. 9, 9B) preferably is provided that has

a square cross-section corresponding to a desired size of a square drive

opening, for example, of the drive socket to be formed from workpiece 38.

Punch 44 has a raised protuberance or hump 46 extending longitudinally

along each flat (such as shown at 48) of the square punch 44 with each

hump 46 located precisely midway between opposite longitudinal edges of

its respective flat 48. The limit of travel of the leading end 62 of each

hump 46 of the extrusion punch 44 within workpiece 38 establishes a

desired location of an inner groove end such as at 56 for a recess 58 (FIG.

10 A) to be formed within workpiece 38. Although a drive socket may be

formed, say, with only one recess 58 in its drive end, in this specifically illustrated embodiment, it is intended that a recess 58 be formed in each

face such as at 64 of the square drive opening 66, and extrusion punch 44

(FIGS. 9, 9B) is provided accordingly with a series of identical humps 46

symmetrically located respectively on each of the four flats such as at 48

of the square punch 44. As will be seen, there then will be no need for an

end user to orient the drive opening 66 to a ball in a drive attachment.

While there are a number of different ways to make a recess in a

drive socket, a multi-station forming process is described below in

reference to FIGS. 9 and 10.

Once workpiece 38 is transferred by suitable transfer fingers, not

shown, in a well known manner to carry the metal workpiece into

longitudinally aligned position with die station 68 (FIG. 9) which has a die

cavity 70 of a volume substantially equal to that of the workpiece 38, a

ram, not shown, preferably moves punch 44 to force workpiece 38 into

cavity 70 against stop pin 69 (FIG. 9). Punch 44 forms square drive

opening 66 in workpiece 38 with a precisely centered groove 72 (FIG. 9 A)

extending longitudinally from outer drive end 74 of each face 64 of the

drive opening 66 by exerting sufficient pressure on workpiece 38 to cause flow of metal between the die 68 and the external surface of the square

punch 44 centrally located within die cavity 70 (FIG. 9). Upon retraction

of the square punch 44 (FIGS. 9 A, 9B), the workpiece 38 is ejected from

die 68 by knock-out sleeve 71 and moved into aligned registration with a

cavity 76 of a second die station 78 (FIG. 10) by suitable transfer fingers,

not shown.

In accordance with this invention, a second punch, namely, a square

finishing punch 80 (FIGS. 10, 10B and 11) is provided with humps, such

as at 82, symmetrically located on each flat 84 of the square punch 80 and

of increased height relative to humps 46 of extrusion punch 44 (FIG. 9B).

At this second die station 78, partially formed workpiece 38 is inserted

into cavity 76 under the force of ram operated square punch 80 that is

aligned with square opening 66 and drives into the cavity 76 to seat

workpiece 38 against a knock-out pin 83. Humps 82 increase the depth of

the grooves at their lead-in portions 72A in accordance with this invention.

That is, humps 82 move metal material from a surface or face of each

previously formed groove 72 to increase its depth at a lead-in portion 72A

along only that portion 72A of each groove 72 and gather the material so

moved from the face of groove portion 72A to form a ledge 90 intermediate opposite inner and outer ends 56 and 92 of groove 72. By

virtue of this method, a recess 58 is accordingly defined in each face 64 of

opening 66 by that portion of groove 72 that extends beyond ledge 90. As

seen in FIG. 10, a square slug 93 is pierced out by punch 80 between

socket 40 and opening 66. Upon retraction of square finishing punch 80, a

finished drive socket 100 (FIG. 10A) is then ejected by knock-out pin 83.

Drive socket 100 now has a completely formed drive end with recesses 58

in each face 64 of drive opening 66 of square cross-section.

In accord with the above described steps, an elongated drive

opening 66 of square cross-section and a groove 72 longitudinally

extending along at least one face of opening 66 may be preformed in a

single operation. While it is contemplated that the drive opening 66 and

the groove 72 along at least one of its faces 64 may be formed by other

manufacturing operations, the above described use of the disclosed

extrusion punch 44 is preferred. Thereafter, in accordance with this

invention, the steps of moving material from the face of the previously

formed groove to increase its depth along only a portion of its length and

gathering the material so moved from the groove portion 72A to form a

ledge 90 are performed in a single separate metal forming operation, if desired, simultaneously on each of the four faces 64 of the square opening

66 of workpiece 38. As best seen in FIGS. 12 and 13, the metal material

moved from the faces of the lead-in portions 72A of the first formed

grooves 72 to increase their depth from the outer ends 92 of the grooves 72

at outer drive end 74 of socket 100 is illustrated in broken lines at 98. The

gathered material moved from the lead-in portions 72A of each groove 72

creates the ledges 90 intermediate opposite inner and outer ends 56 and 92

of the grooves 72 to define the recesses 58 of identical size and shape

between the inner ends 56 of grooves 72 and the ledges 90.

A drive socket 100A (similar to drive socket 100 of FIG. 10A)

is schematically illustrated in FIG. 14 wherein drive socket 100A is in

assembly with a handle unit 102 shown having a drive tang 104 and ball

106, resiliently biased radially outwardly by a spring 108 housed in drive

tang 104. Ball 106 is captured within a recess 58 for maintaining the

socket wrench 100 A and drive handle 102 in driving engagement. Lead-in

portions 72 A of grooves 72 adjoining the drive socket end 74 of the

wrench 100A are of greater depth than the depth of the recesses 58

because of the increased height of the identical humps 82 on finishing

punch 80 relative to the height of the identical humps 46 on extrusion punch 44. While the width of the humps 82 of finishing punch 80 are each

identical to one another, that width dimension may vary from one finishing

punch to another. Thus, a lead-in groove portion 72A of somewhat greater

width than the recess 58 may be formed on each face 64 of the opening 66

as in FIG. 10A. Alternatively, that lead-in groove portion 72A may be

formed by the finishing punch hump 82 so as to be of equal width to that

of the recess 58 as seen in FIG. 12. The height dimension of each hump

82 on finishing punch 80, however, is identical and is always greater than

that of the corresponding humps 46 on extrusion punch 44 to ensure

proper formation in a given drive socket of identical ledges 90 over which

the ball 106 of the handle 102 rides during attachment, before being

captured within a recess such as at 58 (FIG. 14). The ball 106 captured

within recess 58 significantly reduces any end play due to the bi¬

directional retention effected by the illustrated assembly.

The cross-sectional shape of the groove 72 itself is optional. The

groove may be of a variety of cross-sectional shapes, and thus the

projecting humps on the punches may be of varying cross-section to form

grooves of different shapes. For example, the grooves may be of

triangular cross-section as shown at 73 (FIGS. 15 and 16) or rectangular cross-section as shown at 75 (FIGS. 17 and 18). The disclosed fluted or

arcuate groove such as at 72A (FIG. 13), however, requires less

movement of material and is preferred.

This invention is not limited to a drive socket having a square drive

opening such as at 66. Rather, this invention is equally useful with other

types of openings within which the above described recesses 58 may be

formed such as exemplified by a hexagonal opening 61 ( FIG. 19), a seven

sided opening 63 (FIG. 20), a triangular opening 65 (FIG. 21) and a

pentagonal opening 67 ( FIG. 22).

This invention may also be used with a drive opening 166 located

between serrated fastener sockets 140, 140A of different sizes on opposite

ends of a double ended drive socket 100B (FIG. 23). As in the above

described embodiment, at least one face such as at 164 of drive opening

166 is shown formed with a groove 172 extending longitudinally inwardly

from outer end 174 of the drive opening 166. It will be understood that a

finishing punch, not shown, then moves material from a surface of groove

172 to increase its depth at its lead-in portion 172A and gathers the

material so moved to form a ledge such as at 190 which cooperates with groove 172 to form a recess such as at 158. Thus, a central recess is

provided for cooperating with a ball on a drive attachment which can be

inserted into drive opening 166 from either end. While it is not shown, if

it is desired, the groove 172 may be extended the full length of opening

166 with a ledge being formed at each lead-in groove portion at opposite

ends of drive opening 166.

FIGS. 25 and 26 depict steps used in a method (similar to those

described above in FIGS. 9 and 10) in forming a recess 258 (FIG. 26 A) in

groove 272, sequentially formed first by square extrusion punch 244

(FIGS. 25 and 25B) and then by square finishing punch 280 (FIGS. 26 and

26B). Square finishing punch 280 has an identical protrusion such as at

282 on each of its four flats (only three of which are shown) uniformly

formed in symmetrical relation to its respective flat 284 and of increased

height relative to the height of the four identical protrusions such as at 246

on extrusion punch 244. As shown, the latter extend rearwardly from

leading end 262 of extrusion punch 244. Accordingly, upon aligning

punch 280 with opening 266, the depth of grooves 272 at their lead-in

portions 272A is increased by protrusions 282 as square finishing punch

280 drives workpiece 238 against knock-out pin 283 within die cavity 276 to move material from the faces of the lead-in groove portions 272A,

increasing their depth, and then gathering the material so moved to form

ledges 290 respectively on the four faces 264 (only three faces being

shown in FIG. 26A) of the square drive opening 266 with each of the

recesses 258 being precisely uniformly formed with a preselected common

depth. In this illustrated embodiment, punch 280 has a reduced leading

end 281 of circular cross-section serving to pierce a round slug 293 (FIG.

26) from the center of the workpiece 238 to form an opening 242 between

the bottom of the drive opening 266 and fastener socket 240. The drive

socket 100C of FIG. 26 A shows the first formed groove 272 extending to

the bottom of the drive opening 266.

FIGS. 27-29 schematically depict the use of a method of this

invention (similar to those described above in FIGS. 9 and 10) that may be

used in forming a blind depth socket drive opening 366 with recesses 358

in a reducing adapter (not shown) or extension bar as illustrated at 100D

(FIG. 29 A). In the method depicted in FIGS. 27-29, it will be understood

that workpiece 338 (FIG. 28 A) is moved among stations in a multi-station

metal forming machine wherein a hump 346 on each flat 348 of square

extrusion punch 344 (FIG. 28B) serves to form a groove 372 in precisely centered relation to a longitudinally extending flat 364 of the square

opening 366 formed under the driving force of ram operated punch 344

which forms the square opening 366 in workpiece 338 upon flow of metal

between die cavity 370 and the external surface of punch 344. Upon

retraction of the square extrusion punch 344, workpiece 338 (FIG. 28 A) is

moved by transfer fingers, not shown, into axial alignment with die station

378. Ram operated finishing punch 380 (FIG. 29B) that is in aligned

registration with workpiece 338 (FIG. 28 A) drives that partially formed

workpiece 338 into die cavity 376 of die 378, whereby the driving force of

the ram operated square finishing punch 380 increases the depth of the

lead-in portions 372 A of grooves 372 and moves the material therefrom

and gathers it to form ledges 390 between opposite inner and outer ends

356 and 392 of grooves 372. Accordingly, recesses 358 are defined by

grooves 372 extending beyond ledges 390 for retaining a male drive

member.

The disclosed invention is suited not only for use in cold forming

and so-called warm forming processes but also in hot forming of alloys of

higher strength qualities so as to be used with a wide variety of metals

including carbon steels and high quality steel alloys. Except for possible removal of crusty scale after cooling a part made by a hot forming process,

secondary machining operations commonly encountered in conventional

metal forming are eliminated, together with the additional time consuming

manufacturing steps and costs inevitably associated with such secondary

machining operations. In addition, burrs common to such machining

processes are also eliminated. By virtue of the closely controlled

dimensioning of each groove and recess formed in accordance with this

invention, the grooves and recesses on each face of the drive opening of a

given drive socket are identically formed in precisely uniform shapes and

sizes for improved fit-up of the drive unit within its drive socket and to

provide improved consistency in pull-off forces required because of the

identical ball recess depth on all sides of the socket drive opening.

Although this invention has been illustrated and described with

respect to exemplary embodiments thereof, it should be understood by

those skilled in the art that various changes, omissions and additions may

be made without departing from the spirit and scope of the invention.

Claims

I claim:

1. A method of making a recess in a drive socket and the like and

comprising the steps of

providing a metal workpiece having a drive opening with a face

extending inwardly from one end of the drive opening,

forming a groove having a surface extending from an outer groove

end along at least a portion of the face of the opening,

moving material from the groove surface to increase the depth of the

groove from its outer end along a portion of its length, and

gathering the material moved from the groove surface to form a

ledge between ends of the groove, whereby a recess is defined by the

groove extending beyond the ledge.

2. The method of claim 1 wherein the providing step includes

providing a generally cylindrical metal workpiece with the face of the drive opening extending in axially aligned relation to a major

longitudinal axis of the workpiece.

3. The method of claim 1 wherein the providing step includes

providing a metal workpiece having an elongated drive opening with a flat

face, and wherein the forming step includes forming the groove to extend

from an outer groove end adjacent the one end of the drive opening in

symmetrically aligned relation to the flat face of the opening.

4. The method of claim 1 wherein the forming step includes

simultaneously forming both the drive opening of the providing step and

the groove of the forming step in a single metal forming operation.

5. The method of claim 1 wherein the steps of moving and

gathering are simultaneously performed in a single metal forming

operation.

6. The method of claim 5 wherein the moving and gathering

steps are effected by providing a punch having a longitudinally extending

flat thereon and a protrusion longitudinally extending along the flat of the punch for registration with the groove with the protrusion being of greater

height than the depth of the groove, and driving the punch into the

workpiece to move material and increase the depth of the groove from its

outer end along only a portion of its length and to simultaneously gather

the material being moved to form the ledge between ends of the groove.

7. The method of claim 1 wherein the forming step includes

forming the drive opening of the providing step with a square cross section

having four flat faces longitudinally extending inwardly from adjacent the

one end of the drive opening while simultaneously forming a groove

symmetrically aligned and longitudinally extending along at least a portion

of each of the four faces of the square opening of the workpiece in a single

metal forming operation.

8. The method of claim 7 wherein the moving and gathering

steps are simultaneously performed in a single metal forming operation on

each of the four faces of the square opening of the workpiece to form a

ledge in each face in axially aligned relation to the other ledges, whereby

recesses of identical size, shape and axial location are formed in each face

of the drive opening.

9. The method of claim 1 wherein the forming step is effected by

providing a power operated punch of square cross section having four side

flats thereon and a groove-forming protrusion longitudinally extending

along at least one flat of the punch, driving the workpiece into a cavity of a

die with the power operated punch and simultaneously forming the square

opening and groove along at least a portion of the length of the face of the

opening of the workpiece by flowing its metal material between the punch

and die, and

wherein the moving and gathering steps are effected by providing a

second power operated punch of square cross section having four side flats

thereon and a protrusion longitudinally extending along one flat of the

second punch corresponding to the protrusion of the first punch with the

protrusion of the second punch being of greater height than the protrusion

of the first punch, and driving the second punch into the workpiece with

the protrusion of the second punch aligned with the previously formed

groove in the workpiece to increase the depth of the groove from its outer

end along a portion of its length and simultaneously to form the ledge

between the ends of the groove.

10. The method of claim 1 wherein the moving and gathering

steps are performed in a cold forming process.

1 1. The method of claim 1 wherein the moving and gathering

steps are performed in a hot forming process.

12. The method of claim 1 wherein the moving and gathering

steps are performed in a warm forming process.

13. A method of making a recess in a drive socket and the like and

comprising the steps of

providing a generally cylindrical metal workpiece,

forming an elongated drive opening coaxialiy within the workpiece

with a square cross sectional opening and four flat faces extending

inwardly from adjacent one end of the drive opening, forming a groove having a surface symmetrically aligned and

longitudinally extending along at least a portion of the length of each face

of the opening,

moving material from the surface of each groove from an outer

groove end adjacent the one end of the drive opening to increase the depth

of each groove along only a portion of its length, and

gathering the material moved from each groove surface to form a

ledge between ends of each groove, whereby a recess is defined in each

face of the drive opening by its respective groove extending beyond the

ledge.

14. The method of claim 13 wherein the first and second forming

steps are effected by providing a power operated punch of square cross

section having four identically formed side flats thereon with a groove-

forming protrusion longitudinally extending in symmetrically aligned

relation along each flat of the punch, and driving the workpiece into a

cavity of a die with the power operated punch and simultaneously forming the square opening and groove along each face of the opening of the

workpiece by flowing its metal material between the punch and die, and

0 wherein the moving and gathering steps are effected by providing a

second power operated punch of square cross section having four

identically formed side flats thereon with a protrusion longitudinally

extending along each flat of the second punch corresponding to that of the

first punch with the protrusions of the second punch being identical to one

5 another and of greater height than the protrusions of the first punch, and

driving the second punch into the workpiece with the protrusions of the

second punch aligned with the grooves in the workpiece to simultaneously

perform the moving and gathering steps, whereby the faces of the drive

opening have recesses defined by the grooves extending beyond the ledges

o with the recesses being of identical size and shape and symmetrically

located within the drive opening.

15. A female drive device for hand, power and impact wrenches

and the like and comprising a metal socket having a drive opening with a face extending

inwardly from adjacent one end of the drive opening,

a groove extending along at least a portion of the length of the face

of the opening, and

a ledge between ends of the groove, the ledge protruding radially

inwardly from the groove, whereby a recess is defined by the groove

extending beyond the ledge for retaining a male drive member.

16. The drive device of claim 15 wherein the groove is of arcuate

cross section.

17. The drive device of claim 15 wherein the groove is

symmetrically aligned in the face of the opening.

18. The drive device of claim 15 wherein the socket is of generally

cylindrical shape, wherein the drive opening is coaxialiy aligned within the socket and

is of square cross section,

wherein said first face of the drive opening is one of four identical

flat faces extending longitudinally inwardly from adjacent the one end of

the drive opening,

wherein said first groove extending along at least a portion of the

length of said first face of the opening is one of four identical grooves

respectively formed in the four identical flat faces extending longitudinally

inwardly from adjacent the one end of the drive opening, and

wherein a ledge protrudes radially inwardly between ends of each

groove in axially aligned relation with said first ledge of said first groove.

19. The drive device of claim 18 wherein the grooves extend from

the one end of the drive opening, and wherein the grooves are of identical

depth and length and are symmetrically located in their respective face of

the drive opening.

20. The drive device of claim 18 wherein the recesses are of

identical size, shape and axial location in their respective face of the drive

opening.

21. A female drive device for hand, power and impact wrenches and

the like and comprising

a cylindrical metal socket having an elongated drive opening of square

cross section coaxialiy aligned within the socket, the drive opening having

four identical flat faces extending longitudinally inwardly from one end of

the drive opening,

each face of the drive opening having a groove longitudinally

extending from the one end of the drive opening along at least a portion of

the length of the face, the grooves of the drive opening being of identical

depth and length and symmetrically aligned in their respective face of the

drive opening, and

a ledge protruding radially inwardly between ends of each groove in

each face in axially aligned relation with the ledges of the other grooves, whereby recesses defined by grooves extending beyond the ledges are of

identical size, shape and axial location and are symmetrically aligned in their

respective faces of the drive opening.