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A method and apparatus for forming an electrical connector having a first hollow cylindrical portion of a first outside diameter and a second hollow cylindrical portion of a second outside diameter which is less than the first outside diameter, are provided in which two successive extrusion operatio

A method and apparatus for forming an electrical connector having a first hollow cylindrical portion of a first outside diameter and a second hollow cylindrical portion of a second outside diameter which is less than the first outside diameter, are provided in which two successive extrusion operations are performed. In the first extrusion operation, a billet of ductile metal is placed in a first die and an intermediate billet is formed by back extruding the first portion of the connector over a punch while forward extruding a part of the billet in the die to form a portion of reduced diameter approximately equal to the second outside diameter of the electrical connector. In the second extrusion operation, the intermediate billet is placed in a movable die section and the intermediate billet and the movable die section are moved downward from an initial position by means of a finish punch. The finish punch contacts the intermediate billet and is received within a first cylindrical recess defined by the billet. Downward movement of the movable die section forces the portion of reduced diameter of the intermediate billet over a stationary punch, thus forward extruding the second cylindrical portion of the connector. The finish punch is then retracted from the connector, and the connector is ejected from the movable die section by raising the stationary punch with respect to the movable die section.

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A method of forming an electrical connector having a first cylindrical portion with a first outside diameter, said first cylindrical portion defining a first cylindrical recess therein, and a second cylindrical portion with a second outside diameter, said second cylindrical portion defining a second

A method of forming an electrical connector having a first cylindrical portion with a first outside diameter, said first cylindrical portion defining a first cylindrical recess therein, and a second cylindrical portion with a second outside diameter, said second cylindrical portion defining a second cylindrical recess therein, said second outside diameter being less than said first outside diameter, comprising the steps of: (a) forming a cylindrical billet of ductile metal, said cylindrical billet having an outer diameter substantially equal to said first diameter, (b) placing said billet in a first die and forming an intermediate billet by back extruding said first portion of said connector over a punch cooperating with said die, while forward extruding said billet in said die to form a portion of reduced diameter, said portion of reduced diameter having an outside diameter approximately equal to said second outside diameter, (c) placing said intermediate billet in a movable die section, said movable die section have an upper portion of an inside diameter substantially equal to said first diameter and a lower portion of an inside diameter substantially equal to said second diameter, said first cylindrical portion of said connector being positioned in said upper portion of said die and said portion of reduced diameter being positioned in said lower portion of said die, (d) moving said intermediate billet and said movable die section downward from an initial position by means of a finish punch, said finish punch contacting said intermediate billet and being received within said first cylindrical recess, downward movement of said movable die section forcing said portion of reduced diameter over a stationary punch within said die such that said portion of reduced diameter is forward extruded, thereby forming said second cylindrical portion and said second cylindrical recess therein and producing said connector, (e) retracting said finish punch from said connector, and (f) ejecting said connector from said movable die section by raising said stationary punch with respect to said movable die section.