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Abstract

A geometrically optimized expansion cone for radially expanding a tubular member. In some embodiments, the expansion cone includes an annular body having an outer surface. The outer surface includes a linear surface having a constant diameter, a curvilinear surface extending from the linear surface, a recessed surface having a diameter less than the diameter of the curvilinear surface, and a chamfer between the recessed surface and the curvilinear surface. The diameter of the linear surface is substantially equal to an inner diameter of the tubular member after expansion, while the chamfer has a maximum diameter less than an inner diameter of the tubular member prior to expansion. The curvilinear surface has a diameter defined by a radius of curvature which is tangent to the chamfer at the maximum diameter and tangent to the linear surface.

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First Claim