When applying a rounded chamfer to the tips of both legs of the headrest stay, the tips are thinned by boring without generating any chips. [Solution] The open end of the leg portion of the headrest stay is thinned without
cutting its inner wall surface, and the thinned end is plastically processed into a hemispherical shape. A punch is pressed into the opening at the end of a round
metal pipe to remove material from the inner wall surface of the end, thus
thinning the inner wall of the end. In a round
metal pipe headrest stay, the open end portion of the leg portion is thinned, and the open end portion is rounded. The end portion is thinner than the base portion of the stay leg portion, and at the boundary between the thinned portion and the thick base portion, the material that has flowed out due to the pressing process protrudes inward. In the
thinning process, a punch that is larger than the inner
diameter of the opening and smaller than the outer
diameter of the opening is pressed into the open end portion from the opening end to thin the inner wall of the open end portion. First, a star-shaped or gear-shaped punch is pressed in to remove some of the material, and the remaining material is removed by rotating the punch in the circumferential direction and pressing it in. After this, a round punch is pressed in.