FIELD OF THE INVENTION 0001 This invention relates to forming tools and more particularly to a tool for forming an armature guide eyelet disposed in a solenoid actuated fuel injector with a feature that limits rotation of the closure assembly of the fuel injector.

BACKGROUND OF THE INVENTION 0002 It is believed that tools exist for forming the inside diameter of an armature guide eyelet. The armature guide eyelet that is disposed in a fuel injector, is such an eyelet. These tools form a uniform inner diameter of the armature guide eyelet. The uniform inner diameter fails to limit rotation of the closure assembly within the fuel injector. 0003 It would be beneficial to provide a tool to form a non-uniform armature guide eyelet for use in a fuel injector to limit rotation of a closure assembly of the fuel injector.

BRIEF SUMMARY OF THE INVENTION 0004 The present invention provides a tool for forming an armature guide eyelet. The armature guide eyelet that is formed by the tool is disposed in a solenoid actuated fuel injector to limit relative rotation between the closure member and its support member. The tool preferably includes a body having a working end, a support end and at least one sizing rib disposed along a longitudinal axis. The at least one sizing rib has a perimeter with a first portion and a second portion. The first portion has a substantially constant distance Dc from the longitudinal axis. The second portion has a varying distance Dv from the longitudinal axis. 0005 Further, the present invention also provides a method of forming an armature guide eyelet to be used in a solenoid actuated fuel injector. The method can be achieved by aligning at least one non-uniform sizing rib and an armature guide eyelet having a constant inner diameter along a longitudinal axis, and forming the constant inner diameter of the armature guide eyelet into a non-uniform inner diameter with the at least one non-uniform sizing rib.

BRIEF DESCRIPTION OF THE DRAWINGS 0006 The accompanying drawings, which are incorporated herein, and constitute part of this specification, illustrate the presently preferred embodiments of the invention, and, together with the general description given above and the detailed description given below, serve to explain the features of the invention. In the drawings: 0007 FIG. 1 is a perspective view of the forming tool of a preformed embodiment. 0008 FIG. 2 is a cross-sectional view of the forming tool of FIG. 1. 0009 FIG. 3 is a perspective view of the tool of FIG. 1 & FIG. 2 performing an operation on an armature guide eyelet.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 0010 FIG. 1 illustrates a tool 10 according to a preferred embodiment. The tool 10 is used to form an armature guide eyelet with non-uniform surfaces of contact. The preferred embodiment of the tool 10 provides a method of forming the armature guide eyelet with the tool 10. Multiple embodiments of the tool 10 can be employed to achieve different embodiments of the armature guide eyelet. The different embodiments of the armature guide eyelet may be used in a fuel injector with a rotation limiting feature, as disclosed in commonly owned U.S. patent application Ser. No. 09/770,980, filed Jan. 26, 2001, which is incorporated herein by reference in its entirety. 0011 A fuel injector (not shown) with the rotation limiting feature preferably has an armature guide eyelet and a closure member, which is preferably, a needle/armature assembly. The armature guide eyelet and needle/armature assembly are disposed along a longitudinal axis. The armature guide eyelet and the needle/armature assembly have mating non-uniform surfaces of contact. The mating of non-uniform surfaces of contact limits rotation of the needle/armature assembly within the fuel injector. 0012 The tool 10 has a base 14 and a body 16. The body 14 has a working end 20, a support end 22 and at least one sizing rib 18 which are disposed along a longitudinal axis 200. The shape of the base 14 and body 16 are preferably cylindrical. However, the base 14 and the body 16 may both or independently be configured as a square, rectangular, hexagonal, triangular, or any other geometric shape. The base 14 is coupled to the support end 22 of the body 16. The base 14 and body 16 are coupled by puddle brazing 24. Other methods for coupling the base 14 and the body 16 can be employed for example, welding, the use of adhesives and friction fitting so long as the base 14 is second to the body 16 such that movement of the base 14 results on relative movement of the body 16. The base 14 is preferably fabricated from AISI A-2 60-62 Rc steel. The body 16 is preferably fabricated from CD 35F carbide. Other materials, such as for example tool steel, may be used to fabricate both or one of the base 14 and body 16. 0013 The at least one sizing rib 18 has a perimeter 26 that is disposed about the longitudinal axis 200. The perimeter 26 has a first portion 28 and a second portion 30. The first portion 28 of the perimeter 26 is disposed on an imaginary circle 29 that surrounds the longitudinal axis 200. The first portion 28 of the perimeter 26 has a substantially constant distance Dc that extends from the longitudinal axis 200. The second portion 30 of the perimeter 26 has a varying distance Dv that extends from the longitudinal axis 200. In the embodiment of FIG. 1, the varying distance Dv is less than the constant distance Dc. 0014 The second portion 30 of the perimeter 26 has a sector 31. The sector 31 cuts through the imaginary circle 29 at two points P1 and P2. The sector 31 is tangent to the imaginary circle 29 and parallel to the longitudinal axis 200. The sector 31 creates a flat portion 32 that extends through the at least one sizing rib 18. The at least one sizing rib 18 may provide as a plurality of sizing ribs 18a, 18b, 18c, 18d and 18e. The flat portion 32 may be formed in a variety of ways. In one embodiment, the flat portion 32 is ground into the plurality of sizing ribs 18a-18e. In a further embodiment, the flat portion 32 is machined into the plurality of sizing ribs 18a-18e. It should be recognized by those skilled in the art other techniques may be employed to form that the flat portion 32, such as for example, forged, molded and cast. 0015 The varying distance Dv of the second portion 30 may be varied to create other embodiments of tool 10 as well. For example, in one embodiment, the varying distance Dv may be configured such that the second portion 30 bows outward away from the longitudinal axis 200. In this embodiment, the varying distance Dv from the longitudinal axis 200 to the second portion 30 of the at least one sizing rib 18 is greater than the constant distance Dc from the longitudinal axis 200 to the first portion 28 of the at least one sizing rib 18. 0016 In a further embodiment, the varying distance Dv may be configured so that the second portion 30 bows inward, toward the longitudinal axis 200. As was the case with the embodiment of FIG. 1, the varying distance Dv from the longitudinal axis 200 to the second portion 30 of the at least one sizing rib 18 is less than the constant distance Dc from the longitudinal axis 200 to the first portion 30 of the at least one sizing rib 18. 0017 In other embodiments, the constant distance Dc of the first portion 28 may include multiple areas of constant distance. Examples of such multiple areas of constant distance Dc of the first portion 28 may include triangular, star and hexagonal configurations. When the multiple areas of constant distance is mated with a similarly shaped needle/armature, the multiple mated areas of constant distance Dc act to limit rotation. 0018 A cross-section of the body 16 of the tool 10 is shown in FIG. 2. Each of the plurality of sizing ribs 18a-18e has a corresponding one of a plurality of outer surfaces 36a-36e. Each of the plurality of outer surfaces 36a-36e are configured to be convex with respect to the longitudinal axis 200. Sizing rib 18a with corresponding outer surface 36a may provide an entry sizing rib. Sizing ribs 18b-18e with corresponding outer surfaces 36b-36e may provide a plurality of finishing sizing ribs. The entry sizing rib 18a has a first diameter D1 and the plurality of finishing sizing ribs 18b-18e have a second diameter D2. The first diameter D1 of the entry sizing rib 118a is preferably smaller than second diameter D2 of the plurality of finishing sizing ribs 18b-18e. The entry sizing rib 18a is disposed at an outer end 40 of the working end 20 of the body 16. 0019 A method of forming an armature guide eyelet 12 with the tool 10 of the preferred embodiment will now be described. The method may be achieved by aligning the tool 10 with the armature guide eyelet 12 along the longitudinal axis 200. The eyelet 12 configured for operation by the tool 10 of the preferred embodiment has a constant inner diameter 42. The plurality of sizing ribs 18a-18e of the tool 10 are driven through the constant inner diameter 42 of the armature guide eyelet 12. The entry sizing rib 18a makes first contact with the constant inner diameter 42 of the armature guide eyelet 12. The plurality of finishing sizing ribs 18b-18e make second and final contact. Since the entry sizing rib 18a is slightly smaller in diameter D1 than the diameter D2 of the plurality of finishing ribs 18b-18e the sizing of the armature guide eyelet 12 made by the initial penetration of the entry sizing rib 18a is not complete. The plurality of finishing sizing ribs 18b-18e form and establish the final size of the inner diameter of the armature guide eyelet 12. Since the forming tool 10 is non-uniform in shape, for example, the flat 32 cuts through the plurality of sizing ribs 18a-18e, the result of driving the sizing ribs 18a-18e through the armature guide eyelet 12 forms an armature guide eyelet 12 with a non-uniform inner diameter 44. 0020 FIG. 3 shows the preferred embodiment of non-uniform tool 10 and the resultant shape of the armature guide eyelet 12 with the non-uniform diameter 44. An alternate embodiment of an armature guide eyelet 12 may be formed with the previously described embodiment of the forming tool 10 wherein the varying distance Dv of the second portion 30 of the perimeter 26 bows outward away from the longitudinal axis 200. 0021 It will be appreciated by those skilled in the art that changes could be made to the embodiments of the tool 10 described above without departing from the broad inventive concept thereof. It is understood, therefore, that this invention is not limited to the particular embodiments disclosed, but is intended to cover modifications within the spirit and scope of the present invention as defined in the appended claims.