M O D ERN SHO P PRACT I CE PROCESSES MET HO D S . . .

MACHI N ES T OO LS AN D D ET AI LS
.

A Pra ct i cal Treat i se on

T he Hot and Cold M a c hin e-Formin g of Steel and I ron in t o Fin ishe d
w it h T ools Dies an d
, v olv ed i n t he

plica te For m
g gs a n
Pressed Parts i rom Bar

Cmn prisi n g

m en t Ior T w
'

, Red Fo an d orki ng inW m

X
,

Hot Pres sed a n d I ron ar t s : eir M an u fac t u re an 11s

em l1lin g .

in to Finished Produ ct s rop Ha m m ers : T heir Dev elop

.
D Forging M ac hm e, St eam Ha m m er
Foundations an d D ies . .

Bu lldozer a n d Swagin M ac hi n e Met hods a n d Processes Ma chin e. .

wit h Exa mp es of M odern Practi ce a n d T ools I n v olved .

J OSE PH V .
W OO D WO RT H
'

Au thor of Di es : Thei r C on struct ion a n d Use, etc.

CONT AI N I N G 800 I LLUS TRATI O N S

 PRE FAC E

IN th is wo rk I hav e en deavo red to p roduce a p ract ical

mechan ical book t reat in g subj ects comp reh en siv ely an d t ho r
,

o ughly ,
wh ich u n t il n ow have been stran gely ig n o red by
w riters an d comp il ers of p ract ica l wo rks on t he mechan ical
arts. Although I search ed carefully I was u n abl e to locate
,

an y wo rk of v a lu e publ ish ed in an y l an gu ag e wh ich t reated

, ,

pra ct ically an d u n derstan d in gly t he arts of D ie Sinking an d -

Dr op an d Hydra u lic Forgi ng .O n ly i n t he m ech an ica l pub

l icat ion s America n M a chinist an d M a chin ery did I find art icl es
an d i l lu st rat ion s on t he subj ects wh ich app ear ed to m e to be

of su fli cien t v alu e to l ive; an d I h ere acknowl edge my g reat

obl igat io n to both these jou rna l s for t he v alu abl e m atter
wh ich I secu red f rom th eir column s an d have n ow embod ied
in t he contents of th is volum e .

I bel iev e that t he exten s iv e d ev elopm ent of t he Die Sink -

ing art an d t he w id e ad ap tat ion of M a cbinc Forging p rocesses

-

by all m etal parts manufactu rers togeth er w ith t he m eager

,

n ess of publ ish ed in fo rm at ion on t he p ract ise involv ed m ake ,

a wo r k of th is k ind n ec essary t im ely an d va lu abl e

, , .

T he text of t he t reat ise is co n c ise ; techn ica l an d a mb igu

ou s ter m s h ave been repl ac ed by p ract ica l an d fam i l iar shop

wo rds ; an d all t he i l lu st rat ion s an d desc ript ion s are pl ain an d

simpl e to u n d erstan d .Thu s a tho rough comp rehen sio n of
,

the info rm at ion an d data co n tain ed in th is t reat ise by t he

greatest number is assu red .

The desc ript ion of ev ery subj ect an d m ethod in volv ed has
been bo i l ed down to t he simpl est an d fewest possibl e wo rd s ;
“
so that t he m eat of all m ay be arriv ed at an d d igested in
the sho rtest t im e by t he bu sy m en of m eta l s who w i l l con su lt

the pages fol low in g .

 PREFACE

T he hot an d cold shap ing squ eez in g fo rm ing an d bend

, , ,

i n g of dupl icat e m etal part s an d h igh speed steel cutt i ng -

tool s by fo rg ing in d rop d ies d rop h amm ers steam ham

-
,
-
,
-

mers hyd rau l ic p resses an d fo rg ing m ach in es are becom ing

, ,
-
,

more app rec iated by t he most advanced m anufactu rers an d

m ech an ics ; bu t unt i l t he publ icat ion of th is wo rk to t he
, ,

av erage m ech an ic fam i l iar it y w ith t he adv anc ed shop p rae

t ise tool s an d p rocesses has been den ied b ecau se of t he al

, , ,

most total l ack of d esc ript iv e p ract ica l l iteratu re an d al so t he ,

co n se rv at ism of m anufactu rers an d experts in publ ish ing their

shop p ract ise a n d knowl edg e evolut ion
- T h erefo re to m ak e
.
,

poss ible among m echan ics a b road an d comp reh en sive

knowl edge of th ese arts I p resent th is book hop ing it w il l ,

find a val u abl e an d perm an en t pl ace in it s fi eld .

J
O S E PH V . Wooow o n m '
.

B ROO KLYN , N . Y .
,

J an uary , 1 91 1 .
 C O N T EN T S
Pages 7 to 10

C HAPT ER 1

DI E-SI N KI NG AN D D R OP- F O RGI N G RACT I SE AN D D ESIGN FO R M OD ERN

P

‘
FO RGI N G PR ESSI N G
, ,
A ND ST AM PI N G O F D U PLI CAT E M ET AL PART S

D rop- F orge W or k
— M l Li
at er ia s for , a n d fe o f,
D ro p
- F or i
g gn D i es
— Au t om obi le Sho D ro - F or i n Prac t ise— Mak in a D i e
p p g g g
T oo l s Em p l oyed i n M ak in g D ies T he Lead Cast in g or Proof
—
— St akin T ool s U sed for Re a ir i n D ies — Exam l es of D ro
g p g p p
F orgin g D ies T r im m in g D ies Heat in g F u rn ac es Harden
— — —

in g D rop F org in g D ies D ie Prac t ise for Ac c u ra t e F orgi n g

- —

Met hod O f Si n k in g a Drop F orge D ie M ic rom et r ica l F orgin gs

- —
-
Drop F orgin g a Rat c het D r i ll Han dl e V an a diu m F orgi n g
- —

g an d ShO p Prac t ise in t he Mak in g O f C u t

— D i - in k i n
.D ies e S
t in g T ool H ol de s f r M ac hi n e T o l s
- r o o
— D p F orgin gs on t he
r o -

Pac i fi c Coast M ac hin in g a D eep F orm in g D ie D ies for

— —
—
F in ishin g B ossed Lev ers Sec t ion a l D ies Mat erial s Used for
—
—
D ies Pr i n c ip l es of D rop - F orgi n g a n d St amp i n g Large Par ts
—
Rem ova l of Fin Produ c ed in D rop F orgin g D iff erenc e Be
-

t ween T reat m en t of St eel a n d Wrou ght I ron Work w it h

—

Hol es Fl an ged T hrou gh I t M et hods of App l y in g I m p act or

—
—
Pressu re on D ies Met hods U sed for Mak i n g D ies Mark in g —
an d Work in g O u t D ier
— T yp in g or Hu bbin g Proc ess .

Pages 1 1 to 61

C HAPT ER I I
I KI N G
D I E-S N I
AN D EM BOSS NG PRACT I SE M ET HODS, Pnocnss ns,
M ACH I N ES ,
AN D T OO LS

Makin g Forc es for Em bossed W —

Prop erl y Made F orc es D if
ork
—

feren t Shaped F orces St eel F orces for Fl at Work Cop p er an d

— —
—
B rass F orc es C u t t in g t he I m pression in D ie Sink in g Riffles
- —
an d T heir U se
— D r i ll in g O u t t he St oc k U sin g t he B reak in g
—
—
O u t Chisel T he Cham p n ey D ie Sin k in g Proc ess H ist ory
- —
an d Ev ol u t ion of t he Proc ess
— M odel in g, Cast in g, an d Drop
— —
D r iv in g M odel I n t o t he D ie Heat in g an d Harden in g
p in g
Of t he D ies
— —
Exac t n ess of Siz e of D ies F in a l D evel op m en t
of Cham p n ey Proc ee ie Sin k in g Mac hin es
- —
C l osed an d
O pen D ies for F orgin gs V al u e of Modern Mac hin ery
—
—
Prev ision an d Su p erv ision Hob for M ak in g F orgi n g D ies .

Pages 6 2 t o 93
4 C O N T EN TS

C HAPT ER I I I

D RO P FO RG I N G D I ES T H EIR D ESIG N CON ST RUCT I ON AN D

-
, , ,
US E IN
D RO P H AM M ER D RO P PR E S AN
- S ,
D FO RGI N G M ACH I N E
- — ,

C om bi n a t i o n D rop D ies U n i o n B e t w een M et a l Pa

- — rt s
—D ie- B l ocks
a n d I m p ressi on B l oc k s
- — M ak i n g D ie t o Resist VVear Key i n g —
—
Wi de Seat D ies F irst Pr in c ip l es i n Hol din g- D ier Bol t
-

He a d i n g D i e s
—
F o r i
g g n -P r e ss D ie s f o r M a k i n g H a m m e rs

Sa v i n g U n n e c e s sa ry M o v e m e n t s
—
M a k i n g a D o u b l e- F ac ed
Ham m er T he F i n ishi n g O f t he D ier Few D ies N eeded for
—

Forgin g Press Set“ of T ool s f”or F orgin g a Fu lc ru m B rac ket

- —

Forgin g D ies for Pin - En ds F orgin g D ies for Rou n d an d -

—
Sq ua re U p se t t i n g D rop F org i n g D ies for G u n \V ork U n usu a l
- - —

J o b o f D r o p
- F o rg i n g
— T r i m m i n g W re n c h B l a n ks i n D i es

T r im m in g C heap Hard are A Sl ab T ru c k f r F rge Shop

w — - o o -

T he P ss bi ies
o i l i t o f P l a n i n g- T o o l s fo r F i n i sh i n g F o r i
g n gs
Work on Han d V ise Forgin gs Forgin g U n der St eam - Ham m er
- —
— F or i n L e P i ec s
— D o - H m m e r F o i — D r o -For
g g ar g e r p a r g g n p
i n o r S ee i — S t t i n t h D i e s
— A cc rat e F orgi n gs
g g q u z n g e g e u
—
Forgin g H igh G rade St eel s Efi ec t s of All oy in g Mat er ia l s
-

—
Hy drau l ic Press G iv es Best Resu l t s Heat in g T O O Su dden l y .

Pages 94 t o 1 3 8

C HAPT ER IV

D RO P- FO RGI N G AN D R
H A D EN N I G PLAN T S GNS
D ESI ,
FU N D AM ENT AL
I I
CON D T O N S, A N D EQ U I PM EN T I N V OLV ED IN T H EI R I
ATT A N M EN T

T he D rop - Forg
e an d H P l
arden i n g
a n t D r o p F orge an d Harden in g
-—
—
D epart m e s n t U n d e r O n e R oo f L o c a t i o n o f D ie -
Si n k in g D e
p a r t m e n t
— B oard St ea m
, ,
H e l v e ,
T r i p a n d D r
,
o p H a m m e rs

Pl an of M odern D rop F orge a n d Harden i n g Pl an t Lay ou t of

- —

Harden i n g D ep art m en t Adv an t ages of O il F u el Refi t t ed

— —

Coal F orges an d Fu rn ac es for F u el O i l Arran gem en t O f Pi

- - —

i
p g n
-
F i n i s hi n g D e p art m en t
—
O i l - B u rn in
g F or g es a n d H e a t ers
— Si n le an d D ou bl e O en i n F o r e F r nac es
—
T o -Sl ot a d
g p g g u p n
—
En d- Hea t in g F orges I n st all at ion of F orges B u rn ers B raz in g — —
—
Fu rn ac es Heat ers Pages 1 3 9 t o 1 6 2

C H APT E R V

D R O P H AM M ERS :
- THE IR D EV ELO PM EN T , W EIG HTS, I
FOUN D AT ONS, AN D
I
D ES

—
T he D ev el op m en t of t he l an c ed T readl e
D rop Ha m m er Cou n t erba
-

Com p ou n d Lev er D ev ic e for O p era t i n g t he L i ft i n g O r Head

—
Mec han ism Joi n t ed Sw i n ghead Con st ru c t ion Pap er Pu ll eys
—
 CO N T EN T S
— Met hod of Fast en in g BoardHa m m er F in — ou n dat i on s

Rat io of Base as C om p ared w it h We ight of Ham m er Fou n da

—

t ion s for D rop Ham m err

- — - —
D rop Ham m er Effec t s T he Am bl er
D rop - Ham m er Sec u r in g Ham m er- Heads Ham m er-D ies
- - - —
I m p rov ed an d U p t o D at e D rop Ham m er Cap ac i t y of St eam
Ham m ers an d Siz e of Work Ru l es for F i n din g t he Capac it y
—

O f St eam -Ham m ers, an d t he H orse- Pow er Req u ired for O p era

— l
t i on D ev e op m en t o f S t eam D rop Ham m ers
- .

Pages 1 6 3 t o 1 85

C HAPT E R V I

ST EEL AN D IRO N : I I G R ED U CI N G AN D FO RGI G

T W ST N N
— "
I R EAT M EN T
‘

, ,

FO R W O RKI N G I N M ACH I N E F O RGI N G -

Ma —
Ac t ion of St eel an d I ron U n der D i fferen t D egrees of Heat
F u el U sed i n T est s Pract ica l
,

— —
t er ia ls U sed i n Ex p er i m en t s
Resu lt s of Exp er i m en t s VVorkin g St oc k in D rop D ies Fac i l
— - —
- —
i t ies for Rep rodu c t ion O f D rop D ies Sp o i l in g D ies T he D ies
—

an d t he D rop
—
Ec on om y of D ies Prac t ica l Eff ec t of Work i n g
—
I ron Efi ec t of D rop s on St oc k Work in g i n D rop an d B en d
— —
—
in g Mac hin e I m p rov ed An v i l B l oc k Pages 1 86 t o 2 02

C HAPT E R V I I

PR ESS AN D H AM M E R FO RM I N G OF H EAV Y H OT AN D CO LD BA R AN D
SH EET ST O C K IN I
D ES, T OG ET H E R WIT H M AN U FACT U E R AN D
ASSEM BL N I G OF F I N I SH ED R
P OD U CT S F RO M SU CH
M ak in g a Wheel barrow \V heel O p erat ion s on —
Mak in g t he VVheel—

Flan ges Pressed St eel G ears How M et al Wheel s are Made

— - —

Wheel T i re Mak in g St eel Wheel s Earl y H ist ory of Cha in

— —

Mak in g A N ew Met hod of M ak i n g Wel dl ess Cha in s D ies

— —

for Wel dl ess C ha i n s M odern Met hods of Man u fac t u r i n g

—

Wel ded Cha in Form er M et hod of Mak i n g Cha in Presen t

— —

Met hod of Mak i n g Wel ded C ha in T he L in k W in der T he

— - —

L in k Cu t t er T he Wel din g M ac hi n e T he D ie T he Proc ess

- — — —

of Wel din g Pages 2 03 t o 2 40

C H APT ER V I I I

FO RGI NG - I
M AC H N E, ST EAM -H AM M E R ,
B U LLD OZ ER ,
AN D WAGI NG
S
I
M AC H N E M ET H O DS A N D PRO CESSES

Han dy Bu ll dozer Ap p u rt en an ce —
T ac k a n d T ac k
s T ac k - D ies—

Mak in g T ool s a d h i
n T e r A c t i on
—
A R a p id- Ac t i o n Hy dra u l ic
F orgi n g - Press— T rem en dou s Pressu re O f t he Hydrau l ic Press
O pera t i on of Proc ess
—
Pressu re for Sm all Work Hot - Pressed
—
6 O
C N T EN TS

N Mau t- hi n e—
A Large Hydrau i
c O rgi n g Mac hin e
— Mak in glcF -

l c —
E ev at or B u ket s w i t h t he St eam Ham m er Lo om ot iv e For
- c
gin gs m ade in Hydrau i Ma hi n e
— lc
A Job for t he Heav y Swa c
M — c F -M achi n e F
i
g gn - a hi n e D rop - or in
g g for t he A j ax or i
g gn
— —
A Ro k D r i U sed as a St eam Ham m er Shear for Cu t t in g
- c ll -

O ff I ron Pages 2 41 t o 2 7 4

C HAPTER I X

M AC H I NE-
FO RG I N G ,
WIT H EX AM PLES OF M O D ERN P RACT ISE AN D
T O O LS I N VOLV ED
Mac hin e - F orgin g M an u fac t u r in g C on n ec t i n g-Rods
for St eam
— —
En gi n es D ie for T u rn i n g Eye B o l t s F orgi n g w it h D ies i n 3
-

Ra i l road Shop T he Adv an t age of Sp ec ia l T ool s i n F orgin g

—
—
Forgi n g Wit hou t Sp ec ial T ool s T en T hou san d T on Press at
t he D ussel dorf Ex hibi t ion Pages 2 7 5 t o 2 92

C HAPT ER X

H YD RAU LI C F O RGI N G M ET H O D S, AUT O EN O U S G W ELD I N G AN D

G EN ERAL RACT I SE
SH O P P

Hy drau l ic F orgin g D scrip t ion of Hy dra l ic Pr sr Exam p l es

—
e u e
—

of
—
Prod c t ion Prop r Prac t ise for Hy dra l ic F orgin gs
u e u

Som e Ap p l icat ion s of A t ogen o s Wel di n g Heat in g M eta l

u u
-

B efore W l din g F el for Preheat in g Wel din g Con c l sion s

— e
— u u
—
B u i l t U p r Wel d d U p D ie \V ork G e er l Prac t ise for
- O
— e -
n a

Har den in g D rop D ies of V ar ious St eel s

- Pages 293 t o 3 08 . .

C HAPT ER X I

H IG H -SPEED ST EEL, D RO P AN D H YD RAU LI C F O RG ED CUTT I NG

, TOO LS,
D R O P- P RESS PRACT I SE AN D H AR D EN I N G D R O P D I ES
,
-

What is G ood Ju dgm en t H igh Sp eed St eel an d T ool Hol ders

— - -

Com bin at ion T oo l Hol ders an d T he i r Use Ec on om y in Use

- —

of T ool Hol ders Forgin g t he H igh-Sp eed St eel -C u t t in g Poin t s

- —
—
T he D rop Press in Fl at Ware O p era t i on s F ou n dat ion s for
- - —

Fl at “fare D rop Presses Hol din g D ies in D rop Presses D ies

- - — - —
-W
for Mak i n g Fl at are
—
T rea t m en t an d U se of D ies for Fl at
Ware Co rrec t an d Rel iabl e Met hod for Harden in g Drop
'
—

Ham m er D ies Wi t hou t Loss M ore L osses i n Win t er-T i m e

— '

t ha n i n Su m m er
— T em p erat u re o f C ool i n g Wa t er Hav e Pl en t y
—

O f Su p p l y Pi pes for w
—
- a t er Harden i n g t he D ie D raw in g t he
—

—
T em per Cool t he D ie T horou ghl y Pages 3 09 t o 3 2 9
 I N T RO D U CT O RY

V ERY l ittl e of valu e has b een w ritten on d rop fo rg ings -

,

die sink ing t he m ach in e fo rm i ng of st eel an d t he shop p rac

-
,
-
,

t ise involv ed as it actu ally ex ists in t he mod ern d rop forg ing
,
-

S hop .H ere an d th ere a sol itary die or d ev ic e has been p ic

,

t u red an d desc rib ed or a few sk etch es m ad e of d ies th at m ay

,

have been ent irely im ag in ary so far as can be l earn ed f rom

,

an
y ev id ence ofl ered an d wh ich are of such si mpl e an d ele
,

men t ary n at u re as to conv ey no adequ ate id ea wh atever of t he

magn it ude an d d iffi culty O f t he wo rk to an y on e not f am il iar
w ith it Th is cl ass of cont ribut ion s covers the greater part O f
.

what has b een publ ished on a subj ect th at has grown an d

developed f ro m t he hand fo rg ing p rocess Of t he h ammer an d
-

anv i l to on e of t he most impo rtant b ranch es of modern

,

mach in e indu st ry .

H und red s of parts th at were fo r me rly cast f ro m m al l eabl e

iron or h and fo rged f rom bar stock are now d rop fo rg ed
,
-
,
-
,

t he ext ra cost b eing mo re th an m ad e up by t he u n ifo rm ity ,

st rength an d rel iab i l ity of t he p roduct ; an d no one has b een

,

qu icker to real iz e th is than t he really l iv e u p to date au t om o ,

- -

b i l e m anufactu rer to whom t he m ech an ical wo rld is indebted

,

for so m any oth er v alu able m ech an ical d ev elopm ents .

T he h isto ry of die sink ing an d d rop fo rg ing go es back

- -

fifty y ears or mo re in N ew Engl and I n t he bl acksm ith shops .

-

“ ”
of t he o rig in al Yankee Toolm akers a l i m ited am ount O f ,

wo rk had b een p rev iou sly don e in d ies for as long a per iod ,
“ ”
but on ly or ch iefly in o rder to i mpart a fi n ish to wo rk
wh ich had been al ready h and fo rged an d nearly compl eted at
-

the anv il Th is p ract ise was n ec essaril y adopted in o rd er to

.

attain u n ifo r m ity in a numb er of s i m i l ar fo rg ing s econ om

, ,

ically Su ch un ifo rm ity could only be p roduc ed on t he an v i l

.

7
8 I N T RO D U CT ORY

w ith t he common tool s of t he sm ith at the sac rifice of m uch ,

t im e an d l abo r H ence long befo re the p ract ise of pr odu cing

.
,

fo rg ings by d rop d ies or m ach ine fo rg ing comparat ive inter

-
,

ch angeab i l ity was eventu al ly attain ed in anv il m ade fo rg ings -

by m ean s of d ies u sed in t he power hamm er T he d ies ev en - .

,

th en w ere Ofte n in sect ion al fo rm as th ey rem ain to day when

, ,
-

h eavy fo rg ings are requ ired .

T he m ak ing of d rop fo rg ing d ies tog eth er w ith the h ard

-
,

en in g p roc ess th rough wh ich th ey are put an d t he m ethod s of

u sing th em is a t rade by itself tho u gh closely all ied to tool

, ,

an d d ie m ak ing as und erstood in t he big shop s of to da -

y .

Each b ranc h of shop wo rk p resents it s i nd iv idu al p robl em s

-
,

an d a tool an d die m ak er though sk i l led i n oth er l in es can

, ,

n ot go i nto a fo rg ing shop a n d m ake d ies w ithout spec ial

-

i n st ru ct ion s t rain ing an d a k nowl edge of t he p ract ise in

, ,

volv ed .

I n d rop fo rg ing die wo rk as in oth er k ind s of tool wo rk

- -
,
-
,

th ere are v ariou s g rad es of accu racy an d fin ish req u ired .

Som e fo rg ing s m u st com e f rom the h amm er p ract ica lly fi n

ished to S iz e wh i le oth ers are m ad e l arge enough to al lo w
,

con sid erabl e m ach in ing Wh ere on ly a few p ieces of rough

.

n atu re are requ ired l ittl e sk il l is n eed ed in m ak ing or m ain

,

t en an ce of the d ies but wh ere s m al l accu rate p arts are to be

, ,

m ad e in l arge qu ant it ies spec ial tool s for both h and an d

,

m ach in e u se are necessary an d t rain ed sk ilfu l d iem akers are

, ,

n eed ed as w el l as a carefu l sel ect ion of t he steel u sed

,
.

T he employm ent of d rop forg ing an d t he p roduct ion of -

hot an d cold p ressed parts of t he n atu re referred to i n t he fo re

go ing are increasing con stantly an d ra p idly A l arge number
,
.

of fi rm s are now equ ipp ed w ith m ach in ery u sed exclu siv ely
for th is cl ass O f wo rk an d th ey supply eno rm ou s n umb ers of
,

forg in gs to m anufact u rers of m etal wo rk ing m ach in ery au -

,

t om obi les ra i l road cars car parts an d in n u m era bl e u sers of

,
-
,
-
,

m eta l parts .

D rop fo rg ings an d p ressed m etal p art s b ear t he sam e rel a

-

t ion to t he wo rk of t he bl acksm ith shop th at m ac hin e molded - -

cast in gs bear to th at of t he found ry I n both cases t he sk illed .

,
 I N T RO D I CTO RY
'

m ech an ic an d his l abo r are d ispen sed w ith I n each in stan c e .

t he fin ish ed p roduct has t he adv antag e of much g reat er accu

racy an d un ifo rm ity in sh ap e an d d im en sion s T he numb ers .

t u rn ed f rom t he d ies as f rom t he mold in g m ach in es are Often

, ,

th irty to fo rty t im es as great as tho se wh ich are produced by

hand by sk i l l ed m en I n both c ases too t he quest ion of
.
, ,

m ach in ing is often in separabl e f rom that of the m ethods O f

p rodu ct ion adopted becau se accu racy of sh ape an d un ifo rm ity
,

of d im en sio n s in fo rg ings an d cast ings al ike are favo rabl e to

the most econom ical m ach in ing since allowanc es wh ich are ,

either i n su ffi c ient or excessiv e for t he m ach ine s are equ a lly

undesirabl e an d troubl esom e T he bl acksm ith wo rk ing at .

.

the anv il ev en w ith the help o ff ered by templets an d gag es

, ,

—
is u n abl e to p roduc e two p iec es to say noth ing of tw enty
—
int ricate an d el abo rate p ieces absolut ely al ike u nl ess at an ,

eno rmou s expend itu re of t im e I t is Ch eaper th erefo re an d.

, ,

is t he p ract ise to l eav e pl enty of su rplu s su rface stock to i n su re

th at t he wor k sh al l fin ish up all over wh en mach ined ; oth er
wise the fin al fin ish ing wou ld occupy much t ime even mo re ,

th an th at req u ired for t he fo rm at ive wo rk of fo rg ing Bu t .

o i —
fo rg ings wh ich are d ropped r m ach n e fi n ished th at is d rop
—
fo rged a ll com e exactly al ike f rom t he d ies ; an d interch an ge
ab i l ity to t he desired degr ee is attain ed i n the i n it ial p roc ess ,

without extra care or t i m e spen t on t he part of the wo rkm an .

Mo reover since the al lo wance or su rplu s stock left is sm al l

, , ,

in amo unt an d regu l ar p ickl ing can be m ore u sefu lly p rae
,

t ised th an wh en a llowanc es are exc essive .

—
T he acc u racy of fo rg ings m ach ine an d die p rod u c ed
however is f u rth er advantageou s in t he fact th at a con sid er
,

abl e amount O f m ach in ing is often avo ided altogeth er T he .

smooth glossy
, pol ish ed an d accu rate su rfaces l eft f rom t he
, ,

d ies are often good enough for han dl es l evers an d num erou s , ,

oth er parts O r if th ey are req u ired to be pol ish ed bright for

.

good app earance th en a pol ish ed su rfac e imparted by em ery

,

wh eel bu fl or tumbl ing barrel is su ffi c ient w ithout an y

, , ,

mo re m ach in in g i n t he l ath e sh ap er or m i ll ing m ach in e

, , .

Pu n ch ed hol es m ay be simply l app ed in st ead of b ein g ,

IO I N T RO D U CTO RY

d ri ll ed and ream ed t he lom t ion s of t he hol es b eing fix ed w ith

,

accu racy by t he d ies .

T he p rocess of die sink ing rel ates t o t he eng rav in g or

-

sink in g of the f em ale or lower d ies su ch as are u sed for d rop

,

fo rg ings hot an d cold m ach in e fo rg ing swedgin g an d the

, , ,

p ress wo rk ing of m etal s T he p roc ess of fo rce m ak ing rel ates

.
-

to the eng rav ing or raisin g of t he m al e or upper d ies u sed in

p oduc ing t he lower d ies for t he p ress form in g and mach ine
r -

fo rg ing of dupl icate parts of m etal .

 CH APT ER I

I
D E S N KI N G
I - AN D D R O O RGI N G
P F
-
PRACT SE I AN D DES IG N FO R
M DERN O FO RGI N G PR ESS I N G
, ,
AN D STAM P N I G OF D U PLI CAT E
M ETAL PARTS

D RO P-FO RG E WO RK
M ateria ls fi r , an d l i fe f
o, D r o
p For i
g g
n D-
ies

cast in to blocks is n ot su itabl e for d rop fo rgin g

ST EEL, ,
-

d ies as flaws or blo w hol es are l ikely to d ev elop wh ere l east

,
-

expect ed or d es ired ; so as a g en eral rul e fo rg ed blocks

, ,

of open h eart h c ruc ible steel are u sed

- Th ese bloc ks are .

either pu rc h ased ready fo rg ed i n v ar io u s siz es f ro m the st eel

, ,

manufact u rers or are fo rged in the shop where they are u sed
,

the fo r m er pl an b eing t he u su al on e .

A rough est im ate as to t he av era g e l if e of a d rop fo rg ing -

die u sed for m ed iu m S iz ed wo rk on Bessem er st eel is g iv en

,
-
,

by a fo rem an of lo n g experience as about fou r thou sand ,

p ieces Som e d ies might be b roken imm ed iately whe n pu t in

.

operat ion wh il e oth ers m ight st and for a hun dred thou san d
,

p ieces or m o re .

Aut omobile Shop D r op Forging Pra ctise

-

The F igs 1 to 2 2 an d t he d ata rel at in g to th em were O b

.

t ain ed in t he facto ry of T hom as B Jefi ery 8: CO , Kenosh a, . .

Wis T h is compan y s d rop fo rg in g p l ant is far ah ead of

.
-
’

anyth i ng outs id e of t he big conc ern s th at m ake a sp ec ialty of

d rop fo rg ng
- i s a n d co n s is
,t of a wel l l ghted fin ely equ ipped
s - i
,

tool room u sed only for d rop fo rge die wo rk , a tho ro u gh ly

-
,
- -

u p to d at e h ard en in g pl an t , an d a big b u i ld in g f u l l O f st ea m
- -

hamm ers p u n ch p resses, h eat in g f u r n ac es, an d every app li

-
,

a nc e n ecessary for fi rst cl ass w o rk

-
.

11
12 D RU -
P FO RC I N G , DI E S N
-
I KI N G , ET C
.

T heg reat er part of t he d rop fo rg in gs m ad e h ere are of -

Bessem er steel bar tho u gh som e of t he mo re p art icul ar au to

,

FI G . 1 ,
— Pl an in g a die-b l oc k o n a shap er .

m ob i l e fitt ings m ad e of sp ec ia l g rad es O f tool t eel All

are -s
.

o f t he d rop forg in g d ies are o f t he h igh est cl ass cal l in g for

-
,

FI G . 2 — A p a ir o f t yp ica l drop-forgin g dies an d t heir w ork .

 O
DR P- FO RG E W O RK 13

t he b est die m ak in g sk ill an d n ec essi tat in g a g reat d eal

-
,
of

ha n d w ork in add it io n t o t he mo st accu rat e m ac hi n in g

-
.

M ( t hing (I D ie

In o rig in al
t he ou tl in in g o f a set o fd rop forgin g d ies t he
-
,

m easu rem en ts for t he fo r k in g c av it ies m ay be tak en f rom a

FIG . 3 . Profi l i n g m ac hin e

-
u se d i n die-s i n k i n g
.

b lu print
e- suppl ied
by t he d raft in g room o r t hey m ay be -
,

—
ta k en f rom a p iece al ready m ad e possibl y a forgin g or l ead
cast in g obtain ed f ro m som e fo rm er set O f d ies or p erh ap s a ,
i . l ) R0 | ’
ET C .

p iec e m ad e u p fo r a m odel S o m et im es a s heet m eta l t empl et

.
-

is m ad e to ass ist in obtain i n g t he d es ired sh ap e of t he die

cav it ies wh il e in oth er cases o n ly t he outl in e sc ribed on t he
,

FI G . 4 .
—
Fi n ishin g die, F ig 2 , . on t
h
e l
p rofi in g m ac hi n e , Fig 3
. .

copp ered su rfac e togeth er w ith t he n ec essary m easu rem ents

, ,

is n eed ed T he siz e an d o u tl in e O f t he fo rg ing to be m ad e

.
,

as w el l as t he acc u racy req u i red gov ern t he m et hod of p ro

,

c ed u t e .

T he die bl ocks wh ich as al ready stat ed are fo rg ed of

-
, , ,

op en h eart h c ru c ibl e st eel

-
are fi rs t pl ac ed in a sh ap er an d
,
lo I) RO P FO RC I N G ,
DI E SI N KI NO ,
-
ET C .

“
d ow n part o f t his die t he rest ,
o f t he work co n s ist i n g of

sc rap i n g g o u gi n g a n d c hisel i n g
, , .

Too/s Employ ed in M a king D ies

Fo r t he h d work t he die is h eld in a sp ec ia l bal l v ise
an -
,

w hic h is sh own i n F ig 5 A v ise O f t his typ e is t he han d iest

. .

d ev ic e im ag in abl e for h eavy die wo rk T h is il l u strat ion al so -

.

S how s t he b reak in g d own p art a l ittl e mo re cl ear ly th an t he

-

p rev iou s exampl es .

F ig 6 sh ow s a few o f t he to o l s sc rap ers an d r ifii ers u sed

.
, ,

in t he fin ish in g wo rk T h ese are mo stly m ad e of old fil es

.
,

FI G . 6 .
— Sc rap ers, fi l es ,
r ifli ers, et c .
,
d by di
u se -
e s i n k ers
.

an d are g ro u n d or b en t to su it t he n eeds o f t he part ic u l ar

cases .

I n F ig 7 are som e of t he m i ll ing tool s th at h av e been

.

m ad e esp ec ially for t his wo rk O n ly twen ty fou r of th em are .

-

show n tho u gh sev era l h u n d red of all sh ap es an d s iz es are in

,

st ock A n.o th er set of sp ec ia l c u tt ers is s hown i n Fig 8 . .

“ ”
T wo O f th ese h av e a s in gl e i n sert ed bl ad e or fl y c u tt er h eld -

in pl ac e by a set sc rew an d are v ery u seful t oo l s for som e ,

k ind s of wo rk .
 D RO P-FO RG E WO RK 17

FI G . 7 .
— A e m i ll in g t ool s
f w - d i n die-s in k i n g
u se .

T he tool s shown in F ig 9 are known as types an d are

.
,

u sed in sc rap ing out cyl in d rical cav it ies to size T h ese types .

a re tu rn ed t o t he p rop er s ize an d wh en u sed are sm eared w ith

,

FI G 8
. .
— l\I i ll in g- t ool s u se d i n d ie si n k i n g w i t h
-
, exa m p e l
of fl y -c u t t ers
.
18 DRO P- FO R G I N G , D I E-S N I KI N G , ET C.

red l ead ocked back an d fo rth in t he partly fi n ish ed cav

an d r

it y T he m etal is t h en sc raped away wh erev er t he lead shows

.
’
.

For cyl ind r ica l wo rk th ese types are ind isp en sabl e tool s
, .

T he tool s show n in F ig 1 0 w ere m ad e by on e of t he .

expe rt die si n k ers i n t he J effery shop ; T he to o

- l show n at t he
r ight is u sed to sc r ib e an outl in e f ro m a fo rg i n g I t con sists .

of a ha rd en ed steel bl ad e w ith a po in t on on e en d set in to a

, ,

flat steel block in such a way th at it is f ree to mov e u p an d

FI G 9. . T y p in g l
t oo s u sed by di -
e s i n k ers to form C irc u ar l
cav i t ies .

do wn to a l im ited ext en t T he riv et show n on t he s id e is passed

.

t hrough a sh ort slot in t he bl ad e Wh en in u se a fl at sp ri n g .

,

on t he top edg e of t he tool p resses t he po i nt dow n ward onto

t he copp ered su rfac e cau sing a m ark wh erev er m ov ed

,
TO .

u se th is tool it is h eld on edg e w ith t he po int d ow n an d t he

,

edg e of t he h ard en ed bl ad e in co n t act w ith t he fo rg in g T he .

steel block keep s t he bl ad e p erp en d ic u l ar an d by k eep i n g t he ,

edg e of t he bl ad e i n co n t act w ith t he fo rg ing wh i l e sc ra p in g ,

a co rrect outl i n e is O btai n ed wh ich cou ld not be do n e w ith an

,

o rd in ary sc riber on acc ou n t of t he wo rk ing outl i n e bein g con

s id erably abov e t he die f ac e .
 D RO P PO RG E WORK

FI G . 10.
— V ern ier ca l ip dep t h gage , i n side m ic rom et er
er-

an d sc r ibi n g- bl oc k
.

T he m iddle
tool shown in F ig 1 0 is a on e i n ch in sid e
.
-

m ic rom eter wh ich was m ad e by t he die sinker b ecau se he

,
-

could not buy on e sm al l enough for t he pu rpose T he oth er .

FI G . 11 — Sam p l es O f
. l d c ast in gs o r p roo fs from drop - forg i n g
ea -

dies for t est i n g acc u racy o f ou t l i n e

.
20 D RO P-
FO RGI N G , Dl E S N-
I KI N G , ETC .

tool is a regu l ar stock cal iper sq u are to wh ic h has b een added ,

a d epth gag e T he gage is m ad e so th at t he rod p roj ect s t he

.

sam e d ist an c e th at t he ca l ip er j aws are ap art T he u sefuln ess .

an d co n v en ience of th is tool are at o n c e apparen t to a tool

m aker .

The [ f a d Ca sting or P7 00]

Aft er t hem ech an ical wo rk on a set of d ies is do n e a l ead ,

cast in g of t he ca v ity is m ad e an d sent to t he superintend en t

FI G . 12 .
—
St a k n - l
i g t oo s u sed for rep a ir i n g dies
.

to bepassed upon I f it is co rrect t he d ies are h arden ed an d

.
,

sen t to t he fo rg in g sho bu t if it is O H s iz e or sh ap e or for

-
p , ,

an y reaso n n ot sat isfacto ry su it abl e ch anges are m ad e

, an d ,

an oth er l ead imp ression t ak en an d passed upon as b efo re .

Fig 1 1 shows a n u mber of th ese l ead cast in g s wh ich are kept

.
,

in t he too l room for referen c e an d t hey O ft en sav e con sid era

-
,

ble t ro u bl e wh en d u pl ic at i ng d ies .

St a king Too/s Used f or Repa i ring D ies

Aft er a set o f d ies has been in u se for som e t im e t he d ies ,

are l ik ely to d ev el op c racks or d raw i n g seam s w hich cau se

 D RO P F ORG E
- W O RK 21

r idg es ough spots on t he fo rg ings T h ese c racks are

an d r .

closed up by hamm erin g fi rst on on e s id e an d th en on t he

” “
oth er w ith a h amm er an d wh at are ca ll ed stak in g tool s
, ,

wh ich are simply sp ec ia l sh aped temp ered st eel pu n ch es m ad e

,

of ch isel steel stock Som e O f th ese stak in g tool s are shown

- .

in F ig 1 2 . .

f E xamples o D r op Forgi ng Dies

-

O n e h alf of a die set show i ng t he b reak ing down an d fi n

-
,
-

ishin g fo rm s is i l lu st rat ed in F ig 1 3
,
I n th is i llu st rat ion . .

FIG . l3 — An . l
exam p e o f dro p - forg in g die show i n g break in g
,

dow n die a t t he r ight .

t he m ethod of l eav ing a ridge aro u n d t he fi n ish in g fo rm an d

c u tt ing a ch an n el for t he fi n is v ery pl ain ly show n T his .

m ethod is follow ed in a ll of t he d rop d ies m ad e at t he Jefl ery -

shop s . F ig 1 4 show s a m ore compl icat ed die

. I n th is both .
,

edg ing an d fl att in g b reak in g d ow n die fo rm s are show n-

In .

u sin g th is die t he hot bar f rom wh ich t he fo rg ing is b ein g

,

mad e is altern ately swu n g f rom on e to t he oth er fo rm it

, ,

being h eld edgew ise in on e an d fl at in t he oth er an d g iv en a ,

blow or two u nt i l su ffi c ien tly red u ced for t he fi n ishin g fo rm ,

22 DR O PFO RGI N G
-
, DI E S N
-
I KI N G ,
ET C .

—
FI G . 14. D p forg i n g
r o - die, S how i n g bot h e dg in g an d fla t t i n g
break i n g- do w n dies .

aft er wh ich it is cut off f rom t he bar by a sh ear fasten ed to t he

h amm er at on e sid e O f t he die bl ock -
.

I n F ig 1 5 t he rough ing or b reak in g down die is shown

.
-
,

an d a l so a b en d ing f orm t he bar b eing rough ed in to sh ap e

, ,

FIG . 15 — D rop -forgi n g die,

. show i n g ben di f
n g orm
- in fron t .
24 DR P O -
FO RGI N G , D I E-
I KI N G
S N ,
ET C .

b ett er il lu st rate th is for t he ben efit O f those not fam il iar w ith
t he cl ass O f wo r k both h alv es of a set of d ies are show n in
,

Figs 1 6 an d 1 7
. T h ese show t he compl et e fo rg ing an d b end
.

in g part s for th is part icul ar p iec e T he en d of t he fin ish ing

.

fo rm al so shows a pl ac e wh ere on e of t he types ill u strated in

Fig 9 was u sed wh en fi rst wo rk ing ou t t he cav ity
. .

Some ofthe fo rg ings are of such sh ape th at the fin o r flash

p roduced is easi ly g round or m ach ined O ff wh il e oth ers are ,

FI G 1 8 . .
— D rop forgi n g die for wren c h a n d t r i m m i n g- die for sam e
-
.

put th oughr a t r i mm i ng d ie T h ese t r-

i mm ing d i
.es are about -

t he sa m e as t he t r imm i n g d ies u sed for oth er cl asses of wo rk

-
,

an d so n eed bu t l ittl e d esc r ipt ion Fig 1 8 shows a set of . .

fo rg in g an d t rimm in g d ies u sed for m ak ing au tomob ile

w ren ch es T he b reak in g down fo rm is v ery pl ainly shown
.
-
,

as is al so t he fi n ish i n g c av ity T he t r imm ing p u nch is at on e

.
-

s id e wh il e t he t r imm in g die in t he m iddl e is show n m ad e up

,
-

of fo u r separate part s T h is is don e b ecau se t he die parts

.

t hat sh ear ou t t he w rench sl ots w ear or b reak soon er th an

t he rest o f t he die an d wh en m ad e th is way th ey are easi ly
,
 D RO P FORG E
- W O RK 25

pl aced w itho u t n ecess itat ing

re a wholly n ew die, which would
be t he case if m ad e sol id .

FI G . 19 .
—A few exam
p es o f l drop - forgi n g dies in S t orag

Fig 1 9
. hows a n u mb er of d ies on t he sto rage sh elv es
s ,

only on e half O f each b ein g shown t he oth er half of each set

-
,

FI G 2 0
. .
—
O i l heat i n g
- c
fu rn a es an d drop - ham m er .
26 D RO P FO RGI N G
-
,
-
I KI N G
DI E S N ,
ET C .

bein g b ack of t he on e v isibl e T he t rimm in g d ies wh ich are

.
-

i n con stant u se are kept co n v en ien tly n ear t he p resses in t he

fo rge room Both t rimm ing an d fo rg in g d ies are sto red on
-
.

h eavy sh elv es close t o wh ere th ey are u sed th u s sav in g t he ,

“
u nn ec essary tot in g th at is p ract ised in so m an y shops .

H ea ting Fu rn a ces
T heh eat ing fu rnaces in a fo rg in g shop mu st be set n ear -

t he h amm ers an d Fig 20 shows how t he oil f u rn aces are

, .

FI G . 21 .
-
B row n 85 Sharp e hea t i n g an d a n n ea l in g f u rnac es

pl ac ed so th at l ittl e t im e is lost in gett in g t he h eat ed m etal to

,

t he h amm ers F ig 2 1 is an il l u st rat ion of t wo O f t he big

. .

Brown 8e Sh arp e f u r n ac es in t he h ard en in g room For sm al l -

.

work several sm all er f u r nac es are u sed bu t tho se show n are ,

u sed for l arg e wo rk an d are sa id t o be t he b est obt a in abl e

, .

H a rden ing D rop -Forgi ng D ies

Inh ard en ing d rop d ies on ly t he face is h ard en ed T he
- .

die is h eat ed an d pl ac ed fac e dow n in a tank O f wat er on a so rt

of a sp id er su ppo rt an d a st ream of wat er po u rs upward o n to
,

it
. F ig 2 2 show s how th is is don e
. I n t he i ll u st rat ion a .
 D R O P FORG E
- W O RK 27

r ou n d p ierc ing die is bein g h arden ed so th at t he water appears

,

t o be bo i l in g up th ro u gh t he c en t er wh ich wo u ld n ot be t he
,

case were it a so l id block l ike a fo rg in g die Large sp ec ial .

sh ap ed to n gs m ak e t he h andl i ng of t he h eavy st eel block s of

t he d rop fo rg e d ies comparat iv ely easy

- .

Die Pra ctise for Accu ra te Forgi ng

T he ten d ency of l ate y ears to tu rn out a b etter cl ass of
fo rg ings than fo rm er ly is b ecom ing gen era l I am gl ad to say , ,

FI G 22
. .
— Ha rden i n g t he fac e O f a o
dr p - forgi n g die .

an d t he a dopt ion of m ach in ery for th is cl ass of wo rk is I ,

k n ow acco u n tabl e mo re th an anyth in g el se for t he imp rov e

,

m ent ; t he d esire t o cut O E wo rk in the m ach in e shop being -

a l so a f acto r Be th at as it m ay t he d ies for such n ic e an d

.
,

acc u rat e wo rk mu st fi rst pass th ro u gh t he m ach in e shop It -

.

is a p rett y ro u gh an d scaly j ob th at com es f rom d ies th at h av e

not b een p rop er ly fitted up t o m atch acc u rately an d w ith a
s mooth fi n ish .

I n t he p rod u ct ion of good wo rk t he m eta l of wh ich t he,

d ies are m ad e is of t he fi rst impo rtan c e Wh il e g ray iron .

an sw ers t he p u rp ose for a t im e su ch d ies so o n b att er an d

,
28 DR O FO RGI
P- N G ,
-
D E S N
I I KI N G ,
ET C .

c ru sh an d t he scal e f rom hot iron wears into t he su rface an d

,

cau ses rough wo rk u nl ess th ey are overh au l ed f requ ently

, .

Basic steel wou ld be an i mp rov em ent if t he blow hol es could -

be el im in ated but it seem s th at few p erfect cast in gs are pro

,

du ced of th is m at erial Tool steel is v ery costly but f rom

.
-
,

my experien ce it fully pays for l ight d ies wh ere fo rg ings are

stand ard an d got out in l arg e n umb ers .

The pl an I h av e follow ed to sav e st eel an swers t he pu rpose

v ery n icely an d only takes about on e th ird stock as o rd inari ly
,
-

u sed F ig 2 3 shows t he . .

bl ank steel for t he die fac e -

,

sh ap ed for t he p u rpo se und er

a st eam h amm er F ig 2 4 is - . .

FI G 2 3
.
— St eel bl an k for di
.
c ast iron d ie hold er fitt ing
e .
- -
,

an d k ey ed into t he anv il
block as in o rd in ary p ract ise A inch steel p in is d riv en
.
-

into t he c ent er d eep enough to g iv e it a good b earing a bout —

—
1 % inch es d eep w ith t he top tap ered
an d p roj ect i n g about 1 in ch to let into

t he sg eel fac e Th is secu res t he steel fac e

.

to it s pl ace an d two keys d riv en on e f rom ,

t he b ack an d t he oth er f rom t he f ront ,

compl ete t he arrangem ent as shown in FI G 2 4 — Cast i ron . .

Fig 2 5
. T he cast die hold er an swers for
.
-
die ho]der - ,

all d ifferent sh apes u sed an d do es not ,

hav e to be remov ed unl ess it is wanted in m ach in ing t he d ies .

T he shap es should be m ad e 3 5 i nch 1 “

l arge an d t he recesses as smooth as pos

sibl e an d if sp ra y ed w ith wat er wh en in
,

u se th ey g iv e a n ic e fi n ish to t he for

g ings if t he fu el is cl ean an d f ree f rom

sulfu r .

FI G 2 5
.
—
D ie hol der
.
- O il is v ery l arg ely u sed n ow for
an d di e assem bl d h eat ing fo rg ings an d it certainly does
e
,

n ic e wo rk an d l eav es t he iron w ith a ,

su rfac e w i thout hol es or scarred pl ac es b es id es m ak ing t he ,

iron eas ier to wo rk an d h eat i n g t he p iec e un ifo r mly From .

 —
D RO P FORG E WO RK

my experience w ith O il for h eat ing an d w ith steel d ies for t he

hamm er I can say that there is no reason why fo rg ings cannot
,

be m ad e wh ich w ill requ ire p ract ica lly no m ach in e wo rk an d -

very l ttl g nd ng an d fi le work t o make t h em fit the ir re

i e r i i -

spect iv e p laces .

M ethod of Sin/t ing a D rop Forge Die

-

To sin k a pair of fo rg in g d ies for t he b reech or butt of a

g u n i nvolv es a g reat d ea l of h and wo rk a n d a con sid erabl e
-

amount of care if one is to do a good job

, Th ere w ere sev eral.

pairs of such d ies to Sink at on e t im e an d t he pu rpose h ere is

,

to show my readers how a sch eme was dev ised to make t he

mach in e h elp som e on t he job .

T he die m aker was too much of a Yan k ee to h ave a g reat

-

des ire for hard wo rk an d if th ere was an y ah ead of him he

,

was apt to wo rk his g ray m att er ov ert im e if n ec essary to get a

.

sch em e to avo id it T he on e shown by t he sk etches in Fig

. .

2 6 did not el im i n ate all t he h and wo rk but it did h elp a lot

-
,
.

A shows t he p iec e wh ich was to be fo rged t he w el l—

known butt pl ate of a m il itary rifl e T he d ies w ere wh at are
.

”
term ed m atch face an d are shown by h an d e b being t he
, ,

bottom an d c t he top die in t he d rop .

—
T he pl at e was to be redropp ed th at is fo rg ed p ickl ed , ,

to remov e scal e an d redropped at a h eat so low that it would

,

n ot sca le thu s g iv ing a su rf ac e wh ich cou ld be fin ish ed on t he

,

pol ish ing wh eel an d t he edges only were m ach in ed

, .

T he en t ire bottom of t he fi rst pair was ch ipped an d fil ed ,

an d wh en sampl es were secu red the m i l itary in sp ecto r put his

m ic rom eter on th em ju st as ch eerfu l ly as he did on a p iece of

mach in ed wo rk an d i nsisted that th ey com e w ith in two thou
,

san dt hs of t he d raw i n g at the two th ickest po ints they being ,

t he only pl ac es wh ere he cou ld apply his cal ip er All argu .

men t was in vain ; he mu st hav e som e sampl es l ike t he p rin t ,

an d to get th em out of th is pair of d ies involv ed a lot of sera

p ing an d g ri nd ing on t he tempered die accompan ied by lots ,

of uncharitabl e rem arks about t he in specto r .

V is ion s of t he pairs of d ies to follo w h au nted t he die

30 D RO P FORGI N G
-
, DI E-
S N I KI N G , ET C .

m aker in t he sm all ho u rs of t he n ight an d cau sed t he m ak in g ,

of t he fo rm er pl ate d an d c u tter e wh ich solved the p robl em,

n icely.

T he l in e ft on d was fil ed as n ear to sh ape as possibl e ,

secu red on t he d ie h by t he p in hol es shown an d a cut m ad e

-
,

FI G . 26 .
—
Di -
e s i n k in g for bu t t p l a t e of a l
m i it a ry ri fle .

w ith t he cutter e ct ing as a fo rm er p in a st ri p of l ead was

o
r a -
,

th en pl ac ed in t he cut an d t he d ies squ eez ed togeth er g iv ing ,

a fo r m wh ich co u ld be m easu red w ith a m ic rom et er an d by ,

fi l ing an d cutt in g in th is m an n er t he die m ak er was able t o

‘

g e t a t empl et o r fo rm er th at co rrespo n d ed ex actly w ith t he

d ra w ing With th is fo rm er an d t he cutter e t he d ies were

.

q u ickly m ach in ed as show n by t he dotted l in es on b an d an

, ,
32 DR O P-
FORGI N G , DI -
E S I N KI N G ,
ET C.

an d l lows t he u se O f a v ery del icate sh ank if care is u sed in

a

feed ing t he cut I n temperin g care is taken to get a good

.
,

temper t he whol e l en gth of t he shank for if l eft soft it is very ,

ap t to tw ist ofl As temp eri ng is v ery apt to sp ring it befo re

.
,

it is u sed it is pl ac ed in t he m ach in e after d raw ing t he t emper

an d p een ed w ith a punch u n t i l it run s t rue .

I n f is shown on e h alf of a pair of d ies wh ich Of cou rse in

-
, , ,

FI G 2 7
. .
— M ic rom et ric al forgi n gs an d t he ir m ak in g .

th is cl ass of wo rk are always dup l icates an d wh ich as a gen , ,

era l th ing h av e two imp ress ion s

, The fi rst operat ion is to ru n
.

a l ight cut w ith a ro u t i ng tool ac ro ss t he fac e at t he po i nt wh ere

t he imp ression is to be m ad e u sing c are to cut t he sam e d epth

,

in each die T h ey are th en cl amped sec u rely togeth er face to

.
,

face an d d rill ed an d ream ed m ak ing t he h alf hol e as show n

, , ,

t he l ight cuts p rev iou sly taken serv ing t o gu ide t he d ril l

st raight an d i n su r in g an eq u al d epth i n each h alf O n e h alf .

-

of t he die is now cl amped secu rely to t he sl id e of a die sink -

in g m ach in e an d t he b ack rest c is pl aced as shown the co rne r ,

 DR O P- FO RG E WO RK 33

x be in g pl aced flu sh w ith the side of t he h alf hol e An o rd i .

n ary C cl amp is generally u sed to fasten t he back rest

- .

“
The cherry is n ow pl aced in p roper position in the
m ach ine an d it simply requ ires carefu l m an ipul at ion of the
,

hand wheel Of the mach ine an d t he fol lower screw to sink to

half it s d iam eter in t he die T he sh ank of t he cu tt er se rves
.
'

as a stop an d the h alf hol e p rev ents cutt ing t oo d eep

, .

As th is is a rough ing ope rat ion the cutter is not fo rced

,

ent irely down at th is t im e Th is operat ion mu st of cou rse be

.

perform ed fou r t imes to m ake a pair of d ies w ith two imp res
sion s . All of the i mp ression s be ing rough ed out the d ies are ,

pl aced loosely on the pl aten of t he m ach ine an d b rought

“ ”
together on t he cherry and an o rd inary pattern maker s
,
-
’

cl amp is u sed to force them togeth er At th is t im e if the .

,

cutte r is v ery d el icate it is a good pl an to tu rn t he m ach ine

,

by hand as it is apt to catch on t he co m e rs an d it is an easy

, ,

matter to l ose the cutter at th is stage of t he wo rk I t is neces .

sary to open t he d ies sev era l t im es in th is op erat ion to f ree t he

cutter from t he ch ips as there is n o pl ace for them to wo rk

,

out Th ick soft card board is often u sed between t he d ies

.
,
-

to p revent closin g up too fast under the pressu re of the clamp .

We now have a die as shown in g the cuts y an d 2 be in g

,

made for stock cleara nce The cuts 2 shou ld be carried as

.

close to t he imp ress ion as the st rength of t he d ies w il l pe rm it ,

as the stock wh ich is drawn down at th is po int mu st ru n out

into a sp ru e an d th ickness h ere mean s waste of m at erial

, .

T he co rn ers of the sid es of t he imp ression s are n ow wel l

round ed O ff w ith ch isel an d fi le as shown by dotted l in es in
, g ,

t he end s of the i mp ression be ing l eft squ are .

Th is done the d ies are ready to temper and if badly

, ,

warped in tempe ring th ey are frequ ently ground on a su rface

grinde r though it is not necessary to tru e up t he ent ire su r
,

face The d ies are now cl amped togeth er an d a lead cas t is

.

taken of the imp ression I f it m easu res too l arge of cou rse a
.
,

l ittl e mo re m ay be g round 0 5 t he faces but if t oo sm all a lead

, ,

lap mu st be m ad e an d t he imp ression grou nd ou t We are .

now ready to pl ace t he d ies in the hamm er an d be gin fo rgin g .

 D RO P- FORGI N G , DI -
E S I N KI N G ,
ET C.

T he hamm er m an knows by experience how far to place

-

his red hot bar of tool steel in t he die to g iv e stock en ough to

-

fil l it Of cou rse if he takes too much t he su rplu s w i ll fo rce

.
,

out th rough t he hole in t he en d To get a fo rg ing th at ex .

act l
y co rre sp o nd s to t he d ies it is n ec essa r to hold the
,
bar y

in pl ac e unt i l t he d ies come togeth er fair it is of cou rse bein g ,

tu rn ed all t he t ime by the h amm er m an I t is impossibl e to - .

g et o n e o f th ese fo rg i ng s too sm a ll but i f t he wo rk is don e ,

by t he p iece it is somet im es taken f ro m t he hamm er befo re it

is down to siz e an d we h av e f requ ently seen a h amm er m an
,
-

ca ll ed to accou n t beca u se his work was over t he 002 l im it .

wh ich he was all owed Th is g ives an i l lu strat ion of a case

.

wh ere an in spect o r u ses a m icrom eter I n the bl acksm ith shop -

to good advantage .

D rop Forgi ng
- a Ra tchet Drill Ha ndle
of t he accompany in g d raw ing is a sh el l an d h andl e
F ig 2 8 .

for a ra tch et d ri l l an d Fig 2 9 shows t he p iece of stock f rom

, .

wh ich it was m ad e The w idth .

of the bar of stock to be u sed

was d eterm in ed by t he len gth
of the shell an d t he th ickn ess ,

was a t r ifl e mo re than t w ice

t he th ickn ess of on e side T he .

Fm 2 8
.
— D rop forged shell an d
.
-
l en gth w a s d et e r m i n ed b y ex

ha dl e for rat c h t dr i ll
n p er
e i m en t i n g.
unt i l the p rop er

l en gt h was fou n d .

Fig 3 0 shows t he fi rst opera t io n wh ich was done on a

.
,

cu sh ion h amm er w ith a pair of dies

shown i n F ig 31 T he operat io n
. .

requ ired con siderabl e sk i ll in t he

ope rato r but m ad e a n ice job if t he
,
—
FI G 2 9 St oc k for for
p iece was p roperly handl ed T he
. .

i F i 2 8
.

g g n g . .

stock for an ent ire o rd er was cut to

len gth an d each p iece put th rough t he fi rst operat ion T he .

s econd op era t ion shown by F ig 3 2 requ ires an oth er h and

,
.
,

ling .
 DR O P- FO RG E WO RK

The d ies for th is operation are shown in Fig 33 They . .

were of cast iron an d contained two spl itt in g Ch isel s an d an

expand in g m and rel as shown , X in F ig 3 3 .
,
.
,

is a steel st r ipp in g pl ate to d raw t he fo rg i ng

-

fro m t he m and rel after t he forg ing blow is

st ruck . Two blows w ith th is pair of d ies w ere
necessary T he fi rst on e w ith t he spl itt in g
.

Ch isel s fo r med t he p iece as shown i n F ig 3 2 .

,

an d the second on e expanded as show n in Fig , .

34 . The expand ing m and rel was sl ightly

larger th an t he fo rg ing was to fin ish so that ,

t he m and rel u sed for the fin ish ing op erat ion

would d rop freely into pl ace .

Pl G 3 0 — 1 “S t ;

I n t he second d rop was a pair of steel fi n 5 ‘

op era t i on on
rshrn
g d res th at w ere dupl i cates on e of Wll l Cll , Fig 2 3
’ ’

. .

is show n in Fig 3 5 . T he amount of stock

.

was ca lcu l ated so n icely th at v ery l ittl e fin was m ad e an d the

p iece was not trimm ed hot
at all T he flash is shown .

su rround i ng t he p i e c e of

wo rk .

Th is job was design ed by

Fm 3 1
.
— D ie
. s for Fi g 3 0 .
a bo ss.
bl ack s m i th who has

sinc e jo in ed t he m ajo rity .

H e was a fine O ld gentl em an an d a N O 1 mechan ic an d t he .

,

greatest crime he knew was to waste stock

in pe rfo rm ing a fo rg i ng op erat ion .

H e came to grief on e t im e howev er , ,

on th is part icu l ar job an d wasted m aterial

,

for an ent ire lot . I t was n ecessary th at t he

iron shou ld be fi rst cl ass to stand t he st rai n
-

PI G —

f i fi t fif g g
o
Know ing th is he alway s mad e
“

O f spl itt in g
'

'

.
,

a few sam pl es f rom each lot of iron to test Fig 2 3 . .

it ; but one t im e for som e un accou ntabl e

,

reason he fai l ed to tak e th is p recaut ion an d of cou rse th is

, ,

m u st be t he part icu l ar t i m e wh en t he stock was poo r .

H e cut ofl t he ent ire lot an d d rew dow n t he handles an d

’
,
36 DR O -
P EO RG I N G , DI -
E S I N KI N G , ETC.

wh en he st arted t he second operat ion near ly every on e of t hem

spl it at t he en d an d ,
there was noth ing to do bu t scrap t he
ent ire lot .

Th is confi rm s t he gen era lly understood fact that howev er ,

capabl e an d competent a m an m ay be he at some t im e or ,

oth er rel ax es his v ig i l ance a

l itt l e an d it seem s as thou gh ,

th is happen ed in most ca ses

wh en he shou ld hav e been
m o re al ert th an eve r .

Vanadiu m Forging Dies

The severity of the serv ice

on riveters an d fo rg ing d ies ,

bo i le r punches an d other t ools

in sim i l ar cases O ften m akes ,

the upkeep abno rm al ly CX pen

si ve even wh en the best car ,

bon steel is u sed I t is in such .

try ing situ at ion s that certain

FI G 3 3
. .
—
D ies for Fig 3 2 a lloy .
st eel.
s h ave s hown m ar k ed
superi o ri ty — a su peri orrt so
y .

great in fact as to be in som e in stances v ery notewo rt hy .

“
or ex ampl e in a sh ip bu i ld i ng yard on ce rt ai n seve re wo rk
,
-
,

pn eu m at ic hammer rivet ing d ies made of ,

t he best carbon steel obtai na bl e an d t reat ed

in app rov ed m ann er l ast ed on ly about t en

,

hou rs each The v ib ra t ion s c rystall ized

.

t he shanks of t he d ies t he result be ing ,

b reakage at t he ju nct ion O f t he shank an d

t he die p rope r Wh en th ese carbon steel
.

ri v et ing dies w ere repl aced by van ad ium

steel d ies the ir l i fe was g reatly extended —

,
FI G 3 4 Expan d ,
. .

fou rt een month s serv rce bern g repo rted in g t he shel l .

by on e concern u srn g th is al loy for it s

pn eu mat ic riveter d ies I n my op in ion V anad ium steel is t he
.

best al l arou n d die steel an d cutt ing tool st eel to day - -

.
 DR O P- FO RG E WO RK 37

D e Sinking
i - a nd Shop Practise in t he M aking of Cu tting Tool
Holders fi r M achine Tools
I n t he manufact u re of om e d rop fo rged cutt ing tool ho ld
s - -

ers for m ach in e tool s an d s im i l ar s h ap ed art icl es the parts are

, ,

case h ard ened by being packed in large boxes w ith raw bon e
-

an d Ch arcoal an d h eat ed i n fu rn aces in t he u su al way

, The .

method of handl ing t he i ron boxes is n ot however as com m on

as it m ight be These boxes arem ade w ith grooves or cor
.

ru gat ion s on each sid e extend i ng t he ent ire l engt h of the

,

box an d a l arge iron fo rk t he p rongs of wh ich ju st fit these

, ,

gr oove s, an d wh ich is swung f rom o n e t ra v el i ng tackle is u sed ,

FI G 3 S
. .
— T he st ee l fi n is in g dies
h - .

to put t he boxes into the fu rn ace an d to remove the m when

th ey are su ffi c iently heated Wh en t he boxes are rem oved.

t he conten ts are dumped into the cool i ng tank wh ich is fitted ,

w ith a sc reen to keep the parts O ff t he bottom an d insu re mo re

even an d tho rough cool ing all of wh ich is n ecessary to insu re
,

a un ifo rm cond it ion The sc reen j u st referred to can be

.

eas i ly removed to cl ean the bu rnt bone out of the bott o m Of

t he tank .

The tool holder set sc rews wh ich are m ade of tool steel
-
,
-
,

are h eated in spec ial fu rn ace s th at heats only the po i nts an d

d rops them into t he harden ing bath as fast as the operato r can
feed the m in T he bu rn er of th is type of fu rn ace is t he same
.

as that u sed on a b icycl e b raz er an d in fact t he fu rn ace is , , ,

p ri nc ipa l l y m ad e f ro m t he p arts of an O ld b raz i ng sta nd .

N atu ra l ly in a shop depe n d ing so m uch on d rop forgin gs

,
-
,

t he die m ak in g d epartment is on e of t he m ost i mport a nt in

-
38 D R OP-
F O RGI G N , D E S N
I -
I KI N G ,
ET C .

t he wo rks an d is well equ ipped Th is d epartm ent is in .

charge of a m an of long experien ce on th is cl ass of wo rk O n e of .

his rem arks h its t he d rop fo rg ing die p robl em squ arely on t he
-

head an d it is that t he g reat difli cu lt y in d rop fo rge wo rk is

,
-

not so much in m ak in g t he die but in m ak ing t he m etal go , .

in to it m ean in g of cou rse th at t he b reak ing dow n rough in g

, , , ,

or ben d in g op erat ion s are really t he mo st impo rtant an d t he

most difli cu lt to pl an out p roperly Almo st an y tool m aker .

-

can sink a fin ish ing die f rom a mod el but it takes b ra i n s an d ,

—
FI G . 36 . V iew of drop forg i n gs as t hey ap p ear
- w hen k
t a en
from di es .

ex perien ce to pl an an d wo rk out t he oth er part s of t he die so

that it w i l l wo r k sat isfacto rily w ithout unn ecessary waste of
t im e an d m aterial I n pl an n in g d ies or die parts of espec ially
.

difli cu lt sh apes pl aster of Paris mod el s are often u sed in o rd er

,
- -

to fi n d t he best sh ape or po sit io n for t he part to lie in ; th is is

espec ial ly i mpo rtant in so pl an n in g a die as to get th at g reat
—
desid era tu m of t he d rop fo rge shop t he fi n ish in g i n on e h eat
-
.

F ig 3 6 show s a n umb er of d rop fo rg in gs in clud ing tool

.
-
,

holders w ren ch es d rifts an d a C cl amp w ith t he flash st ill in

, , ,
-
,

pl ace T h ese fo rg in gs are ju st as th ey com e f rom t he steam

.

hamm er A t rimm ed off flash is shown on top of t he l arge C

.
-
40 DR O P- FORG I N G , DI E SI N
- KI N G , ETC .

sa l angl e pl ate or profi lin g block fam il iar to u sers of u n iv ersal

- -
,

m ill in g m ach in es is u sed T h ese blocks are m ad e so th at t he

, .

top m ay be swu n g aro u n d in a compl ete c ircl e Wh il e t he body ,

can be t ilt ed two way s about 4 5 d eg rees an d cl amp ed at an

, y ,

po in t on t he base Th ese adju stm ents g iv e almost an y an gl e

.

req u ired in die sin k in g th at c an n ot be O btain ed i n t he reg u l ar

-
,

p rofi ler v ise .

T he m ak i n g of d ies for t he Arm st rong bo rin g tool so ,

th at t he m etal wo u ld com e out of t he die was qu ite a d iffi cult ,

FI G . 38 .
—
Wooden p a t t ern s for a p a ir of heav y c ast - iron dies .

p robl em Th is was on e of t he few cases Wh ere gett ing the

.

m etal into t he die was n ot t he most impo rt ant th in g I t was .

easy en o u gh to m ake a die th at wou ld fo rge up t he sh ape

requ i red bu t ow in g to t he p ec u l iar sh ape of t he bo r ing tool

,

t he m eta l wo u ld be w edged i n too t ight to be easi ly remov ed .

T h is p robl em was wo rked out by u s in g pl aster of Paris i n t he

way p rev io u sly referred to a n d t he die as it was fi n al ly su c
, ,

cessfu lly m ad e is show n in F ig 3 9

,
O n e of t he bo ring tool
. .
-

hold ers is show n ly in g on top of t he die T he t ruck shown .

in th is il lu st rat io n is v ery u sef u l as it is j u st t he h eight of t he

,

wo rk ben ch es an d a h eavy d ie can be easily pu sh ed f rom one

to t he oth er .
 D RO P- FO RG E W O RK

D r op Forgings - on t he Pa cific Coast

T he Pac ific coast a good fi ld o ffers

a well qu ipped e for -e

die sin k ing an d d rop fo rg i ng establ ishm ent

- - At t he p resen t .

t im e ( 1 9 1 0) t he o n ly pl an t of it s k ind is in t he co n struct ion

departm ent at t he M are I sl and n avy yard I n th is depart .

FI G . 39 .
— D i es i n w hic h abor i n g- t oo l shan k is forged,
an d a c o n v e n ie n t for m of sh p t ru c k
o - .

m ent th ere is su ffic ient wo rk to keep fou r di inkers an d on e -

e s

d rop fo rger bu sy con stantly Th eir wo rk has g reatly reduced

- .

t he m an u factu r in g costs of fo rg i n g s T he die an d fo rge shops .

were put in o perat ion i n 1 905 T he die room is located in .

-

t he m ach i n e shop an d t he fo rge room in an an n ex to t he

-
,
-

bl acksm ith shop -

.

I n t he die shop th ere are two die sink in g m ach in es two

- -
,

l ath es two shapers a d rill p ress a die slott in g m ach in e a

, ,
-
,
-
,

su rface g ri nd er an d t he u su al sm al l tool s an d wo rk b en ch es
, .
42 DR O P- FO RGI N G ,
-
D E S N
I I KI N G , ET C .

In t he d rop fo rge room there are : O n e 1 2 00 pou n d hamm er

- -
,

on e 2 400 pound h amm er two t rimm in g p resses on e fo r ing

-
, g ,

fu rn ace an d on e fu rn ace for temperin g d ies .

By stand ard iz in g sh ip fi t t in gs an d m anufactu r ing th em in

-

qu an t it ies for stock to be u sed as n eed ed t he cost of th is class

,

of wo rk has been greatly red u ced Befo re t he establ ishm en t

.

of t he d rop fo rge pl an t all su ch fitt in gs were m ad e as n eeded

-
,

; - fo r ed s hi ifi
FI G . 40 D p
.ro g p t t i n gs .

a few at
a t im e by h an d in t he bl acksm ith shop
,
T he cost -
.

was n ec essarily h igh ; esp ec ially so as wages on t he Pac ific

coast were h igh . By stan d ard iz in g such fitt in gs an d m an u
fact u rin g i n q u an t it ies n ot o n ly is t he co st m aterially reduced ,

but al so t he d el ay of wait in g is el im in ated I n t he case of .

u rgen t repairs to sh ips del ay in an y part of t he wo rk is of

,

great impo rtan ce T he i llu st rat io n s in F igs 40 an d 41 s how

. .

t he gen era l cl ass of fitt in g s th at are d rop fo rg ed - .

H igh cl ass d ie steel is n ot u sed as it is fou n d th at for t he

-
,

k in d of fitt in gs m an ufactu red t he l ower p riced m aterial an -

sw ers equ a l ly well T h ere is n ot o n ly much l ess c ost of

.
 D R O P FO RG E - WO RK 43

material but also of l abo r ow in g to g reater ease of wo rk in g

, ,

t he softer m aterial T he die m ater ial is pu rch ased in open

.

hearth b ill ets 1 0 feet lo n g of t he p roper sizes an d is cut to

, , ,

req u ired l ength s for d ies For d ies th at w il l rec eiv e h ard
.

wear steel of
, pe r c e nt c a rbo n is u sed F or t he ge n e
.ra l .

ru n of d ies st eel c n t ca rbo n is u sed T h e cl asses

, p e r e es . .

of m aterial cost d el iv ered at t he M are I sl an d y ard about 3

, ,

cen ts per pound Th is is l ess than h alf t he cost of h igh g ra d e

.
-

die block steel

-
I t is of cou rse n ecessary to u se cy an id e in
.
, ,

tempering these d ies T he ch aracter of t he d ies u sed is show n

.

in t he il l u st ra t io n s F ig 4 1 , . .

D ies for v ery accu ra te wo rk are m ad e f rom h igh g rad e steel -

,

FI G . 41 .
—
Sp ec i m en drop - forge dies for S hip -fi t t in gs .

for t he reas n o
th at th is m aterial stands up better u n der t he
hamm er than does t he open h eart h steel of to per -

cen t carbon co n tent For o rd in ary fitt in gs as show n in t he

. .
,

il lu st ra t ion s F ig 40 sl ight s in k in g of t he imp ressio n m akes

'

.
,

t ic ll n o d ifferen c e ; t he fitt in g s are of such a typ e th at

p rac a
y _

absolutely accu ra te d im en s io n s — w ith in a few thou sandth s of

an inch — a re n ot req u ired .

Carefu l observ at io n s w ere m ad e of t he d ies after a thou

san d or mo re fo rg in gs had b een m ad e an d it was fou n d th at ,

som e of t he i mp ress io n s had su n k a m ax imum of of an

inch bu t t he m ajo rity S how ed n o d ep ression
, .

M a chin ing a D eep Forming D ie

p iece t o be p rod u ced is shown in two v iews in Fig

T he .

42 . T he on ly m aterial fit for it was a good steel cast in g or a -

d rop fo rg in g an d t he steel cast in g peopl e said N ot l ess th an

-
,
-
,
“
44 DR O P- FO RGI N G ,
D I E-S N I KI N G , ET C .

n in ety days or fou r months after we receive t he pattern s

, ,
“
an d t he d rop fo rge peopl e sa id
- A set of d rop d ies for th at
,
-

w il l cost an d we are now fou r w eeks beh ind in ou r die

departm ent .

Almost if not qu ite by acc ident a lot of d rop fo rg ings l ike

-

Fig 43 were located ; th ese were c ircu l ar if looked at the oth er

.

way O n e of these fo rg in gs was

.

bent or flattened to about t he re

qu ired shape by t he blacksm ith
an d compare d w ith what was
wanted an d as it nearly filled t he ,

b i ll it was dec id ed to m ake a die

an d fo rm th em to sh ape ra th er ,

FI G 42
.
— F org i g t o be m ade
. n th a n w a.
it fo r co rr e ct d rop fo r -

i
g gsn or ste el ca st i ng s ; an d th e n -

it was u p to t he shop to produce the good s .

At fi rst it looked as tho u gh it would be a Case of d igging

.

a cav ity out of the sol id steel but t he die m aker reb ell ed as
,
-
,

there was not much m ach in e shap in g of

t he die th at could be don e wh en mad e i n
t he sol id N eit her did he w ish to m ake
.

“ ”
a fo rce an d h eat up the die put t he ,

t wo und er t he d rop h amm er an d hub t he

-

cav it y t o t he p rop er sh ap e O n e reason .

being that their drop weighed only 1 90

pounds w ith a two foot d rop ; besid es -

that it would involve qu ite an expen se to

,
“ ”
hold an d apply t he fo rce I t final ly .

occu d to e t h d m an th at by tak ing

i -
r
r e e
FI G 43 Forgin g . .
-

t wo p reces an d putt i ng t he two top fac es c om m en ced w it h .

of them togeth er bo ring a cav ity in t he

,

face of the two p ieces to a d epth equ al to one half of the w idth -

of t he requ ired open ing th en pl ac ing t he t wo p ieces face to

,

face t he other way he would have a cav ity of p ra ctically t he

,

requ ired shap e .

Befo re do ing t he act in steel he took a p iece of p in e in ,

t he wood l ath e an d tu rn ed it out to a nom in al d iam eter d epth , ,

 D RO P- FO RG E WO RK 45

an d s ah pe sawed t he p iece in two along l in e A B Fig 44

, , .
,

placed t he t wo faces C an d D together an d so had an ocul ar ,

dem on stra tion that his m enta l p ict u re was co rrect .

H e then got out the steel for the die an d plunger al so a ,

patt e rn for t he holder an d had a cast ing made After the die
, .

FI G . 44 — . M et hod of di e- m ak i n g .

bored out it almost look ed l ike Fig 44 T he st eel . .

n ext sawed in h alf at A B Fig 44 an d in Fig 45 as , .

, .

in t he sect ion on e half only b ei ng shown

,
- The t wo h alves .

were n ext pl aced in the die hold er centered up on t he face

-
,

FIG . 45 .
— C s se t ion of
ro s- c Fig 44 . .

plate of t he l athe an d the hol e th rough t he bottom was bo red

, .

Th is hol e was t he same sh ape and size as the outside of the

forg ing
.

T he top f ace of t he die was al so con m v ed as shown at a , ,

Fig 46 so th at t he fo rg ing wou ld h ave a good seat w ith the

.
, ,

fo rg ing rest ing in t he die an d t he uppe r fo rmer ready to do

46 DR O PFO RGI
- N G , D E S N
I -
I KI N G , ET C.

t he fo rm ing Fig 46 is a c ro . ct ion .

-
ss se

on cen ter l in e C D F ig 47 F ig 49 , . . .

is a co rrespond ing sect ion of t he top

fo rm er T he fo rg ing cam e sol id l ike
.
,

F ig 43 an d was d ri ll ed as in F ig 42
.
, .

befo re being fo rm ed T he die hold er .

-

is st rength en ed by t he two l arge bolts

s how n at F ig 47 A po sit iv e knock
. .

out n ot shown was u sed to cl ear t he

, ,

die
As w i ll
n t he m ach in e wo rk
be see ,

h e , 46 .
—D ie show in g on t he d ie was l ath e an d sh ap er Wo rk ,

c o n c av ed fac e . an d th at of t he easiest k ind .

Dies f or Finishing Bossed L evers . Sect iona l Dies .

D ies of se ct ion al fo rm would includ e a boss only on a ,

l ever , F igs . 5 0 an d 5 1 ; t he l ev er end s stand i ng out beyond

FI G 47 . .
—
P an l of die-face .

t hed ies ; or a die wo u ld be u sed to punch a hole an d co rrect ,

a bo ss at t he sam e t im e ,
F ig 5 2 Lev er end s eith er fo rked
. .
,
48 DR O P- FO RGI N G
, DI -
E S I N KI N G , ET C .

hol es a type O f wh ich is the sp ri ng

,

sw edg e F ig 54 t he j aws of wh ich

, .
,

we re fash ioned ind ependently of

aid f rom t he m ach ine shop by a -
,

p rocess of typ ing or hubb ing f rom

a dummy or dupl ic a te fo rg ing .

V ery m any simpl e fo rm s ca n be

m ad e an d are m ade st il l in th is
,

way as a leg it im ate an d su it abl e

,

m ethod L ight swedges are u sed

.

on t he anv il j u st as t he h eav ier

,

ones are operated u nd er t he steam

or d rop h amm er .

T he sect ion al d ies are u sed

very exten sively n ow in t he bl ack
— sm ith shop for t he pu rpo se of fin al
-
Em . 52. C orre c t in g die .

FI G . 53 — Frn ishin g
. c on n ec t in g-rod en ds .

—
FI G . 54
. Sp r in g w edge for forgi n g .
 D RO P- FO RG E W O RK

o
C rrec t ion an d fin ish ing only Bu t along w ith t he u se of
.

t hese t h ere has grown t he p ra ct ise of d rop fo rg ing only eith er

,
-
,

FI G 5 5
. .
— Ex
a m p e of l forgin g- die, form in g c en t er

hol es in t he bosses o f t he w ork .

as a su b -departm ent of t he shop or carried on in a d istant

shop . Gen era l ly however t he m erely fi n ish in g d ies are u sed
, ,

for t he h eav ier fo rg in gs an d t he ,

regu l ar d ies for t he sm all er cl ass of

wo rk as shown in F igs 5 5 t o 5 9
, . .

To make t he l arger fo rg in gs en
t irely by fo rg ing opera t ion s wo u ld
often requ ire mo re h eav ier ham
m ers an d other appl iances than
most shops are equ ipped w ith an d ,

t he nu mbers w anted of t he l arge

fo rg ings m ight not be su fli cien t to

rend er h eav ier i n sta ll at ion p rofi t

ab e Bu t a l eaV Yfo rg in g m ay be
l
.

l
fi n i shed rn d res wh en I t would n ot
FI G 5 6 —
D ie s fo r a l e er. . v

w it h h bs a t bo t h en ds u .
 50 DR O P-EO RG I N G , DI -
E S I N KI N G ,
ET C.

be p ract icable to p roduce it en t irely f rom a rude lu mp .

Among wo rk of th is k ind m ay be in sta nced l arg e t ie rod ey es -

,

l arge bossed l evers Fig 50 , .

,

rings p i ll ars an d such l ike , , .

Som e of th ese are too long to be

emb raced i n a singl e die A .

lo n g t wo or th ree bossed l ev er ,

Fm 5 7 —
.D ies for forgi n g
.
f or i n s ta nc e is th en fi n is h e d o n ly ,

an y h | t eon e- it0s bo
,
s s e s an d fo r a n i nch or ,

two away f rom th em A p il l ar .

for h and rai l ing wo u ld h av e it s bossed po rt ion s fin ish ed sep

-

ara t ely an d t he body co rrected by

,

sw ag ing at t he anv i l or in oth er ,

d ies .

M ateria ls Used for Dies

T he mber Of s m i l ar ast
i c
nu —
FI G . 58 D ies for
. fi n ishin g
rngs requ rred rs O ften I n su ffi cren t t he

to j u st ify a l arge outl ay for cut

steel d ies Bu t d ies m ad e i n cast iron are n ot costly an d
.
,

th erefo re th ey are f requ ently m ad e wh en only half a dozen or a

dozen of sim il ar art icl es are requ ired .

Th ey m ay of co u rse be kept for fu , ,

tu re u se an d shou ld be wh en a job is , ,

l ikely to be repeated ; but apart f rom ,

that a v ery sm all n umbe r of fo rg ings

,

w il l pay t he cost of cast d ies .

T he g rowth of t he d rop fo rg ing -

an d stamp ing art has b een g radu al an d

n atu ra l T he m ere fact of h av ing cast

.

d ies ly ing by from p rev iou s jobs has

Fm S9 — D ies m
b e e n the ca u se
_
o f t h e ir u t il iza t io n f or
. .
p
p c wo k h ch m ght not oth
. .

vided w it h sp ace fo r re es O f r w i i er

rec e iv i n g t he fi w ise have been thought to ju st ify t he ex

n

pen se of n ew d ies Bu t bein g in stock .

,

sl ight an d u n impo rt ant ch an ges i n som e d imen sio n s in n ew

jobs wou ld O ften rend er t he d ies avai l abl e I n th is way t he be .

 D R O P-FO RG E WO RK 51

g inn ings of sta ndard izat ion arose For .

as t he d ies b egan to accumu l ate one ,

pair or set was m ade to do duty for

wo rk for wh ich it was n ot o rig in al ly in
tended Thu s t he d ifference of h alf a
.
,

ton or a ton of c ra n e power was not

al low ed to involv e t he m ak i n g of m i

nute d ifferences in t he fo rged wo rk for

t he c ran es but on e stand ard set was
,

u sed for both So in t he eng in e an d .

FI G 6 0 D ies w i t h -

pump wo rk t he sam e sta ndard sets ca m e . .

sp ac e for r c iv e e
rn to u se for pow ers an d i z es of m ech
s i g t he fi n n .

an rsm s that were not drssrm rlar an d ,

wh en t he d ifference O f yé inch or so in dim en , ,

sion s cou ld m ake no po ss ibl e d ifferenc e in t he

proper operat ion or strength of t he fo rged parts

or d eta i l s .

Princi p les f
o D rop Forgi ng -
a nd Sta mping
l a rge Pa r ts

Compara t ively few art icl es can be p rodu ced

in on e pair of d ies, an d those are ch iefly c ircu l ar
fo rm s t he d iam eters of wh ich at d ifferen t sect ion s
,

do not v ary greatly I f they do vary som e p re

.
,

l im i nary opera tion or b reak in g down is n ecessary .

FIG 6 1
. .

An d if a po rt ion of t he art icl e

Forgin g
m de a ta kes t he fo rm of an eye or a ,

in dies boss th ree or fou r successive ,

from a
bar
opera t ion s m ay be n ecessary to
.

p roduce t he fo rg ing as in t he ,

eye bolt
-
p rod u ced i n F
’

ig s 5 7 an d 5 8 T he . .

die maker has th en to settl e how t he wo rk

-

sh all be don e wh eth er in on e or mo re pairs

,

of d ies an d wh eth er u n d er on e h amm er or

,
—
FI G (i i D ie
t wo As a rul e to wh ich th ere are ex cep
,or form i n g
.
,

t ron s It I S desrra ble to do all wo rk at a

, t he en d of a
singl e h eat T h en if severa l opera t io n s are
.
,
ball c ran k .
52 DR O PF O RGI N G
-
, DI -
E S I N KI N G , ET C.

q
re u ire d they mu st be don e eith er i n on e set O f d ies or in ,

separate d ies . For sm all fo rg ings it is easy to get th ree or

fou r recesses in on e pair of d ies for rough in g down for for
, ,

m ation an d for cutt in g off or n ick ing for b reak ing off I n
, .

l arger p ieces it is n ecessary to h av e two hammers adj acent so ,

that t he stamper can u se th em both w ithout walk ing away f ro m

eit he r
. Bu t a few h amm ers are m ad e doubl e h eaded w it h two ,

— rem ov i n g
St r ipp i n g- die for fin an d i ts w ork .

a nv il s an d tubs to fac il itate such wo rk Wh en two h eats are

,
.

n ecessary th en it m ay be co n v en ient to perfo rm t he earl ier

,

opera t ion s on a l arge number of sim il ar p ieces an d th en change ,

t he d ies for t he sub seq u en t operat io n T h is perh aps is mo re

.
, ,

often done in t he regu l ar m ach in e shops than in t he d rop -

fo rg ing shops in wh ich t he wo rk is d iv ided between t wo ad

,

j acent hamm ers .

T hough t he sm ith wo rk i n g at t he anv i l en d eavo rs to gage

by a very rough met al est im at ion t he amount of m aterial wh ic h
is requ ired for a fo rg ing in o rd er to l essen t he l abo r t he
, ,
 D O
R P-F O RG E WORK 53

d rop hammer m an m ay be comparatively in difi eren t to that

-

considerat ion H e w il l not of cou rse have m u ch excess of

.
, ,

m etal if it can be avo ided yet he is much in t he sam e posit ion

,

as the anv i l s m ith who has a stea m or d rop h amm er av ai l able

adj acent to his anv i l The power hamm er is O ften resorted to

.
-

for rough in g down an Odd lump qu ickly in pl ace of tak i ng a ,

sm al l er sect ion wh ich would requ ire t he alter n at iv e of up set

,

t ing or of weld ing The sh apel ess lump is simply roughed

, .

do wn rap idly in far l ess t im e than wou ld be occu p ied in fu lle r

in g on the a n v i l or in pe rfo rm in g t he alte rn at iv e operat ion s
,

of upsett ing or weld ing I n th is way too v ery many Odds

.
, ,
‘

an d end s ,cropped f rom iron an d steel bars are u t il ized , ,

wh ich would oth erw ise go to swel l t he scrap h eap - .

FI G 6 4
. . FI G 6 5
. FI G 6 6 . .

Show i n g how fi n on rou n d work is forged in to bar by rot at i n g it .

The case of hot stamp ing an d d rop forg ing is analogou s - .

Though fo rg ings hav ing considera bl e difi eren ces in c ross sec -

t ion al areas are as a gen era l ru l e b rok en down in one or

, , ,

mo re opera t ions p rel im inary to fin ish ing yet a great deal of

, ,

wo rk is don e w ithout th is step by step process A cu bica l

- -
.

lump is taken an d pu t into t he d ies an d reduced A l arge .

amount of t he fin be ing sq u eez ed ou t in the p rocess th is is ,

remov ed i n an adj acent st r ipp ing d ie F ig 6 1 an d t he for

-
, .
,

g ing pu t back an d fin ish ed in t he fi rst or in another re , ,

cess fol lowed som et im es by a fin al t rimm ing Th is h eavy

, .

reduct ion is only po ss ibl e i n drop d ies fi rst beca u se the -

, ,

lump is raised to a h igh heat an d t he m ech an ica l wo rk done

on it m ain tain s t he h eat u n t il t he reduct ion is compl eted .

At t he anv i l t wo or th ree h eats wou ld O ften be requ ired to

acco m pl ish t he sam e amount of wo r k wh ich is don e in one

heat in d ies .
54 D RO P-F
O RC I N C , D I E-S N I KI N G , ET C .

Remov al
f o Fin Produ ced in Dr op Forgi ng -

The format ion of fin it w i l l be n oted is pecul iar to for

, ,

g i ng s ; i t do es not occu r i n anv i l wo rk So m et i m es d ies are - .

cut like F igs 5 9 an d 6 0 to receive fi n s I n F ig 6 0 a W ide

. . .

an d sh allow g roove is cu t al l around t he recess to receiv e t he

fin I n F ig 5 9 t he faces are sloped away w ith t he same

. .

obj ect Wo rk wh ich is O f cyl ind rica l form does not n eces
.

sari ly involv e t he fo r m at ion of pe rm an ent fin bem u se it can ,

be rotated as t he reduct ion is go ing on an d such ex cess of

, ,

m et al wh ich is squ eezed ou t l atera l ly is remov ed at once when

a par t ia l rotat ion is g iv en to the p iece as in F igs 6 4 an d 6 5 , . .

I n F ig 6 4 t he fin is shown squeez ed out ; in Fig 6 5 it is

. .

FI G . 67 .
—
I) ies for c ran e hook .

being d riv en in to
fo rg in g again Such be ing the case
t he .
,

F ig 6 6 is t he sh ape g iven to t he c ircu l ar d ies in cases where

.

t he c irc u l ar fo r m is not h amp ered by t he p rox i m it y of sh apes

wh ich wou ld interfere w ith rotat ion When t he work can be

‘

rotated t he resu lt is a fi n e smooth pol ish ed su rface wh ich in

, , ,

m any cl asses of wo rk renders an y subsequ ent m ach in ing u n

n ecessary or if fi n ish is essent ial a l ittl e grind ing m ay su ffi ce
, , , .

I n som e fo rg ings a p o rt ion onl y a stem or shank can be , ,

so t reated t he rem aind er con sist ing of an eye or a fl attened

‘

, ,

po rtion or a squ are shape

, .

s erence f
Between Treatment o Steel an d Wrought I r on

I n the bl acksm ith Shop w rought iron is st i l l u sed as ex

-
,

t en siv ely as steel for sm a l l fo rgings Bu t m any for m s whe n .

m ade of wrought iron m u st not be fo rged f ro m a sol id lump ,

56 D RO P- FO RGI N G , D I E-S N I KI N G , ET C .

hol e in t he pper die as

u ,
in F ig 7 0; in F ig 7 1 , a hol e W ith
. .

out it s p u nch is show n . Bu t p u n ch es are a l so often included

sol idly in t he die, as in F ig 7 4, . half in top an d half in

FI G . 70 .
—
Pu n c hi n g sm a ll hol e t hrou gh w ork i n dies .

bottom an d not qu ite m eet ing at t he center I n a shal low

, .

boss t he pu n ch m ay be in on e h alf of t he die on ly as for a ,

fo rg in g l ike F ig 7 2 T he m et al becom es squ eez ed into t he

. .

boss an d becom es imp rov ed th rough con sol id at ion O ften .

,

wh en hol es are l eft to be

d ril l ed t he c e n t e r s are ,

stamped by sm all con ica l o

p r

j ect ion s i n t he d ies wh i ch

serv e as accu ra te gu id es to t he

d ril l er Som et im es hol es are .

Fm 7 1
.
—
P n c hi n g hol s
. u
R u n c m d o n ly e
th r ough a P0 “
t o of h m l
,

t hro gh boss su
r n e t.
e et a F rg 7 3 , .
,

wh en t he centra l part has to

be bo red ou t sub sequ ently as in d ica ted by t he dotted l in es
, .

M et hods of Applying I mpa ct or Pressu re on Dies

Fo rm er ly all don e w ith h amm er blows As

die wo rk was .

t he d em and g rew for an exten sion of

t he sy stem to h eav ier fo rg ings an d ,

to art icl es in volv in g t he b en d in g of

FI G 7 2 —
Hol es p n c hed u
pl ates an d sh eets t he steam an d d rop
. .

,
by p n c hes i n t gral u e

hamm ers w ere n ot abl e to d eal wel l w i t h die .

 DR O P-FORG E WORK

w ith th ese T he dem and was m et by t he fo rg ing m aé hin es

. ,

wh ich are actu ated by hyd ra ul ic power or by gears c ranks , ,

an d toggl e lev ers Th ese w il l easily d eal w ith d ies an d art icl es
.

sev eral f eet in l ength m any of wh ich are too i nt ricat e t o be

,

FIG 73 — Sem i - hin g hol es

. .
pu nc .

dealt with by hamme rs ev en if their d iam eters did not set a

,

l im it to such treatm ent Th ey are p ra ct icabl e on t he hyd ra ul ic

.

p resses becau se two ra m s ca n be ut il ized on e act ing in t he

, ,

vert ical t he oth er in the ho rizonta l posit ion so wo rk ing at

, ,

ri ght an gl es w ith each oth er Th is is ut il iz ed for bend ing

. ,

FI G . 74 — C on stru c t ion
. Of die for forgin g a hol e t hrou gh a boss

weld ing, punch ing for Closing up jo ints for deal ing w ith
an d , ,

u nd ercut d es i gn s an d w ith hollow sp aces fo rm ed by bend i ng

,

an d weld i n g or by fo rg ing Typ ica l of much wo rk O f th is

.

cl ass is t he die an d punch u sed for fo rg ing t he rings for u p

t akes of v ert ica l bo i le rs F ig 7 5 f rom a pl ain p iec e of steel
, .
,

pl ate F ig 7 6 shows t he die for fo rg ing a c rank by p ressu re

. . .
58 D RO P FO RGI N G
-
,
I KI N G
D I E-S N ,
ETC.

A l arge amou n t of wo rk of th is k in d is don e in t he ra i lway -car

shops .

Stamp ed fo rg ings or d rop forg ings thu s d iv erge in to two

,
-
,

g reat g roups acco rd in g as they are p roduced by hamm er or

,

by g ra du al p ressu re Broadly t he fi rs t g roup i n clud es art icl es

.
,

of sm all an d m ed ium d im en sio n s t he l atter of a m assiv e ch ar ,

acter an d al l l arg e wo rk do n e in pl ates

, Th is is n ow a gen .

eral l
y acc ept ed d i v is io n a n d on e wh ich h ar mo n iz
, es w ith t he

FI G . 75 .
—
D ie for forgin g an d fla n gi n g m an -ho l e seat in gs
.

d ifi eren ce in hamm er blows d el iv ered on compara t ively sm al l

-

masses an d of p ressu re on th icker bod ies Wh en m ass is t he

, .

cond it ion p resen t slow p ressu re is mo re pen etra ting than

,

impact ju st as it is in l arge sh afts an d fo rg ings

, M o reover .
,

t he blows d el iv ered f rom a v ery h eavy h amm er are d es t ruct iv e

to d ies an d if th ey are made m assiv e enough to w ith stand

,

these blows th en th ey are t oo heav y for conv en ient han dl ing

, .

M assiv e d ies are of co u rse requ ired to resist p ressu re but th at

, , ,

is not n ear ly so d est ruct iv e as t he v iol en t j arri n g act ion of the

h amm er .
 D RO P- FO RG E W O RK 59

M ethods Used for M a king D ies

T he forces an d d ies u sed are as varied in th eir d etail s an d

cost as t he fo rg in gs them selv es are A g reat advantage of t he .

fo rg ing m ach in e d ies is that l ike m ach in e mold ing they are
, ,

as read i ly adaptabl e to t he

deman ds for a v ery few iden t i

ca l art icl es say t en or a doz en
, ,

as to hund red s or thou sa nd s .

Bu t the amount of wo rk put

into t he d ies an d t he p attern s
,

an d m ateria l s u sed for th em

h av e to bear a defi n ite rel at io n

to t he n u mb er O f p ieces t e
qu ired H ence we hav e at
.
,

ext rem es , d ies of cast iron

made ch eaply an d those of FI G 7 6 —D ie for forgin g c ran k
, . .
- .

m ild steel cut out w ith Care

an d h ard en ed Ex cept in n am e an d funct ion t he exampl es
.
,

at each ext rem e h av e l ittl e in common They are not mad e .

in t he sam e way an d t he p eriod s O f th eir serv ice are much

,

l ess in t he fi rst th an in t he second case .

T he cast d ies are mold ed f rom su itabl e pattern s Th ey .

m ay h av e to be cl ean ed up a l ittl e by t he m ach in ist bu t no ,

great amount of sk il l is requ ired for th is As th ey are l iabl e .

to f ractu re un l ess made m assive th ey are fre ,

qu ently enc ircl ed w ith bands of w rought iron ,

sh runk on as in F ig 52 Th ey are wh en
, . .
,

sm all l ifted w ith c ircul ar tongs F ig 7 8 or by

, , .
,

t he h and s but l arger d ies hav e handl es trust in

,

for li ft ing th em F ig 7 5 O r altern at ively

, . .
, ,

hol es are Cast for t he in sertion of rod s for t he

sam e pu rpo se Som e cast d ies w il l endu re
.

long serv ice oth ers f ract u re soo n D ies of

, .

FI G 7 7
. .
c ast steel are st ro n ger but are mo re l iabl e to ,

C t t ers
u for i n accu racy b ecau se f req u en tly
,
th ey a re n ot
"iCkin e st oc k u n ifo r m in st ructu re
.
.
60 D R OP- FO RGI N G ,
-
D I E SI N KI N G , ET C .

Working Ou t Dies
M a rking an d

D ies of fo rged stee l are m arked out on th eir faces an d ,

recessed by v ar io u s m ach i n e tool s an d by h and wo rk All , .

t he aid s ofi ered by m ach i n e an d tool s are ut i l ized as bo r ing , ,

slott i ng m i ll ing an d sh ap i ng
, , Bu t often v ery m u ch O f t he .

wo rk is l eft for t he Ch isel an d fi le to compl ete Th ere are .

sev era l spec ial m ach in es d es ig n ed wholly or ch iefly for t he u se

O f die sinkers bu t much ca n be do n e by t he o rd in ary tool s in

-
,

the shops Templ ets are u sed to gage t he p rog ress O f t he wo rk

.
,

in cl u d in g those of sh eet m eta l for back sect ion s an d those ,

wh ich rep resent t he actu al fo rg ings wh ich h av e to be fo rged ,

.

These are m ade of l ead or t in or a fi rst sampl e fo rg ing is

, ,

p repared Contact is in su red by t he tra n sference O f red lead

.

f rom t he temp let to t he recesses wh ich are being cu t .

Typing or Hu bhing Process

Ref erence has been m ade to t he t yp ing or h u bb in g process .

It bears an essent ial resembl an c e to t he op era t ion of sta mp ing

FI G . 78 .
—
T on gs for hol di n g dies .

m edal s an d co in s by a hard blow ; on ly t he op erat ion is t e

versed t he die itself be ing p roduced by stamp ing it wh il e
, ,

wh ite hot f rom a cold fo rg ing I t has t he advantage of being

, .

ch eaper than cutt ing d ies an d in c irc u l ar outl in es is accu rate

,

en ough but it is not w ell su ited for in t r icate sh apes

,
T he .

sp r in g swedges are f re qu ently m ad e i n th is way I n Obtain ing .

c irc u l ar shapes thu s t he hub or type is rotated between each

,

succ essiv e blow so co rrect i ng an y i n accu ra c ies th at m ight

,

fo rm T he edges are of n ecessit y p roduced w ith a sl ight

.

conv ex ity F ig 6 6 Bu t th is is an advan tage in p roduc ing

, . .

c irc u l ar fo rg ings wh ich are rotated in t he d ies I t is not .

 D R OP- FO RG E WO RK 61

necessa ry to have compl ete Circl es in such a case becau se m etal ,

squ eez ed ou t lat era lly an d wh at wo u ld soon fo r m a fi n

, be ,

com es obl itera ted by t he n ext blow wh en t he rotat ion into a

n ew posit ion takes pl ace .

I n on e of t he i l lu st ra t io n s Fig 5 1 dowels are shown , .

, ,

wh ich are in serted to serv e as g u id es to secu re t he a l ignment

of top an d bott om d ies Th ese are o n ly u sed when t he d ies
.

are not att ach ed i n an y way to t he an v il b elow an d t he ham

m er abov e as is often t he p ract ise in h eavy d ies

, Bu t ge n er .

al ly t he d ies are secu re d by dov etai l s an d key s as in F ig 5 3 , . .

I n som e cases locat ing sc rews are u sed on t he an v il for d ies

cut at t he co rn ers l ike F ig 6 7 an d t he dovetail is on ly on
, .
,

t he top T he locat ing sc re ws pe rm it of mak ing s l ight ad

.

ju stm en t s .

Forgin gs are often includ ed wholly in th eir d ies espec ial ly ,

in h yd rau l ic fo rg ing d ies an d are knocked out by a knock ou t

-
,
-

dev ice or are p ried out or pu sh ed out O ften a po rter bar is

, , .

u sed gen era ll y t he pl ain l ength of t he bar f rom wh ich t he

,

fo rg ings are be ing mad e as in Figs 5 5 an d 5 7 Th en t he

, . .

fo rg ing is easi ly n icked by reduc ing t he eye at t he n eck as ,

shown in F igs 5 5 an d 6 1 ; or a pair of cutters is fitted at t he

.

en d of t he d ies as in Fig 7 7
, . .

T he contents of th is Ch apter outl in e t he m ethod s of d rop

fo rg ing in u se from wh ich it is seen that t he p ract ise is d iv i
,

si bl e i nto th ree g reat g roups : th at don e u nd er h amm ers an d ,

th at in p resses an d a fu rth er su bd iv isio n between t he m ethod s

,

of he gen era l shop an d t he drop fo rgers who work for t he

J
-

t ra e .
 CH APT E R I I

DI E-S
I N KI N G AN D O I
EM B SS N G PRAC T SE I M ET H O DS ,
p RO C ESSEs,

MACH I N ES , AN D T OO LS

M aking Forces fi r Embossed Work

T HE p rocess of die sin k ing rel ates to t he engrav ing or
-

srn k in g of t he f em al e or lower d ies such as are u sed in t he ,

p ress wo rk ing of m etal s for j ewel ry silverware nov elt ies an d

-
, , ,

fo rg ings an d for p rod u c ing ra ised lettering an d o rn am en tat io n

,

upon n am e pl ates t in boxes pai l s an d sim i l ar wo rk T he

-
, , , .

p rocess of fo rce m ak ing rel ates to the m ak ing of t he m al e or

-

upper die to be u sed in conn ect ion w ith t he lower die in

stamp ing t he m eta l .

With t he except ion of large shops Where much embossed

wo rk is p roduced th ere are few manufactu ring concern s wh ich
,

employ die sinkers con sequ ently em bo ssing d ies are u su ally
-
,

sent out to a regu l ar die sinke r who eng ra ves or s inks t he

-
,

lower die an d ret u rn s it after h arden ing his part being done , .

N ext t he fo rce has to be m ade an d th is ca n not be don e

, ,

by t he die sinker in his l ittl e shop for two good reason s First
-
.
,

in most Cases he has no d rop p ress su itabl e to strike u p t he

- -

fo rce an d secon d ly t he fo rce p roperly m ad e shou ld be struck

, ,

up in t he p ress in wh ich t he d ies are to be wo rked Con se .

q u ently th is wo rk fal l s sho rt of t he d ie sinker an d com es to

-
,

t he m ach i n ist or tool m ak er in t he shop u sin g t he die

- .

Proper ly M ade For ces

Fo rces m ay p roperly be d iv id ed into two cl asses those ,

m ad e O f steel , an d those m ad e of copper T he easiest type of .

steel fo rce to m ake is that wh ich is termed a fo rce wh ich

flat ,

shou ld be u sed I n cases wh ere a flat back is wanted on t he

62
64 DR O P-
FO RGI N G , D I E-SI N KI N G , ET C .

be emov d f om the p ick p an d reh eated then fitted

r e r -u
,

i nto t he lower die as rap id ly as possibl e an d at once struck .

I f do n e p roper ly it w i l l l ift w ith t he p ick u p an d S hould

,
-

now be struck u n t il ev ery detail of t he die appears on the

force .

When t he Shape of t he outl in e is long an d n arrow t he ,

steel bl ank sho u ld be of t he d iam eter O f t he g reatest w idth of

t he d esign an d about 1 i nch longer th an it s l en gth

, T he .

whol e length of t he p iece should be fin ish ed smooth as t h is ,

p iece afte r h eat ing mu st be l aid sideways on t he die wh en

, ,

st r ik ing it .

T he reason for a lway s l eav in g t he most stock in t he center

of t he fo rce bl ank is that t he center of t he design is always t he
”
hardest to m ake com e up sh arp con sequ en tly we l eave t he ,

stock th ickest th ere so as to h elp it all possibl e Also a p iece .

“ ”
of th is shap e is easily p icked up wh ich would be almost ,

impo ssible w ith a flat p iec e of steel .

f Steel Forces or Flat Work

Steel fo rc es for flat wo rk such as n am epl ates t i n -can wo rk
, , ,

et c . requ ire v ery carefu l wo rk an d wh i l e th ey can be m ad e

, ,

by t he m ethod al read y d esc ri bed it is not t he v ery b est way , ,

for t he reason th at the steel being st ruck into t he die wh i l e

hot sh r inks upon cool ing an d resu lts in a fo rc e wh ich w il l not
,

fit t he die as it shou ld Th is fshrin kage is not iceabl e on all

.

hot struck fo rces but m atters l ittl e wh ere th ere is an y d epth

-
,

to t he die O n e m ethod of ov ercom ing th is t roubl e is t o

.

st r ik e t he fo rc e in t he d ie after it has be en b rought u p

'

enough ev ery few m inutes unt i l t he fo rc e has en t irely cool ed

, ,

bu t wh ere t he imp ressio n s i n the die are so v ery sh allow l ik e ,

t he l etters on a n am e pl ate t he co rrespond in g l ett ers on t he

-
,

fo rc e are v ery apt to be obl iterated du ring th is p rocess an d so ,

m ake t he fo rce u seless .

By far t he b est way to m ake such fo rc es is to start w ith a

pl ain p iece of steel whose fac e is t he exact shape of t he outl in e
of t he n am e pl ate an d th is should be b ev el ed off toward t he
-
,

b ack of the p iece about 1 0 d egrees T he th ickness of th is .

.
 DI E S N - I KI N G AN D EM B SS N O I G R
P AC T SE I O
M ET H D S

p iece should be from 1 to 1 0 inch es acco rd ing to t he siz e of ,

t he n am e pl at e-
.

Th is p iece shou ld now be g iven a th in coat of sold er on

it s face an d th en it shou ld be Carefu lly pl aced fac e dow n u po n
,

the die it is to fit t ak in g ca re t h at t he outl in e of t he fo rce

,

match es up w ith t he d esig n

of t he die After pl ac in g
.

both die an d fo rc e u n der

t he d rop h amm er it sho u ld
-

be st r uck on e sol id blow ,

an d on ly o n e I n do in g .

t his part of t he wo rk it is
not n ecessary to fasten t he
forc e to t he hamm er of
t he p ress but t he die
,

shou ld be fast ened to t he

Press bed "1 t m d‘e

Fm . 79 .
— Em bossed Pol ic e- shie l d
T hl S bem g don e, t he
,

way .
before an d a ft e r t r i m m i n g .

force shou ld be taken from

t he die an d it w i l l be Ob serv ed th at t he i mp rin t of ev ery l ett er
,

of t he die shows cl early upo n t he sold er coat ing of t he fo rce ,

wh ich mu st now be h eld in t he v ise wh il e t he sold er an d steel

around t he l etters should be remov ed w ith s m al l Ch isel s u nt i l

only t he l etters are l eft stand

in g T he fo rc e sho u ld now .

be fitt ed into t he die an d

st ruck agai n aft er wh ich t he ,

sold er on t he tops of t he

l etters m ay be fil ed O fl l eav ,

in g st il l a good i mp ression
on t he steel fo rce T he .

—
ch ipp i n g p roc ess S hou ld be
FI G 80 Em bossed ba dge b for e e
rep eat ed an d th en st ruck
.

an d a ft r t r i m m i g
e n .

again u n t il t he backg round ,

has been su ffi c iently taken away T he b ack of t he fo rc e m ay

.

n ow be dovet ai l ed so as to be k ey ed in to t he p ress as t he ,

p ick u p Can n ot be u sed w ith t his m et hod of fo rce m ak ing I n

- - .
66 D R OPFORGI N G
-
, D I E-S NI KI N G , ET C
.

som e shops fo rc es are h eld to t he h ead of t he p ress by m ean s

,

of sc rews but th is is n ot good p ra ct ise as t he con stant shock

, ,

an d v ib rat ion of t he p ress i n op era t ion t end s to loo sen th em

or sn ap th em i n two .

T he ch ipp in g out of the fo rces can be g reatly h elped by

u sin g p u nch es O f variou s shapes ; espec ially are th ese u sefu l in
d riv ing down stock in t he
cen ters of t he l etters an d oth er
pl aces hard to ch ip out .

Copper an d Bra ss Forces

Copper
fo rces do n ot re
qu ire n early as much (a re to
m ake as steel fo rc es as th ey ,

FI G 81 —Em bossed n u m ber

ar e a lw a y s 8 m m“ 1" t he Press
W
. .

p l a t e s .
h i le it is Often nec essary to

st rik e copp er fo rc es hot th e

y ,

can m an y t i m es be m ad e cold wh ich wa i to b e p ref erred

, y s ,

as t he copp er is much h ard er wh en str uck cold con sequ ently ,

t he fo rc e l asts long er wh en in u se T he stock for a copper

.

“
force do es not n eed to be round as it comes up wh en st ruck
v ery easily Copp er fo rces are always held in t he p ick u p
.
-
,

an d h av e t he adv antage th at th ey m ay be st ruck into the die

at an
y t i m e wh i l e in u se an d ,

thu s sh arp en up the d etai l s

of t he d esign as th ey become
wo rn .

I n t he absen ce O f copper ,

brass is som et i m es u sed for

s m a l l fo rc es but it cannot
,

be st rtick hot l ik e copper FIG 82 Em bl em a d blank

,
— . . n .

an d it spl its eas i ly if st ruck

too h ard an d for these reason s is undesira bl e tho u gh it ca n

, ,

be u sed in an em erg ency .

I n t he i l lu st rat io n s of embossed wo rk Figs 7 9 to 86 , .

,

som e h av e b een t ri mmed an d some n ot F igs 7 9 an d 80

. .

illu st rate germ an s ilv er st amp in gs for b adges ; F ig 8 1 shows .

 DI -
E S I N KI N G AN D EM B OSS I N G PRACT SEI M ET H O D S 67

a th in copper label st ruck up w ith a copper fo rc e; F ig 82 .

is a copp er o rn am ent struck w ith a flat fo rce as w i ll be seen ,

in t he rev erse sid e i llu st rat ion ; F igs 83 an d 84 show exampl es .

FI G 83
. .
-
Em bossed bel t bu c k l e i n sh eet - m et a l .

of stamped belt buckl es ; Fig 85 is a nam e pl ate of b rass m ade .

-
,

w ith a fo rce wh ich was m ad e by t he ch ipp ing p rocess as ,

desc ri bed an d Fig 86 shows a h eavy alum inum l abel m ad e

, .

w ith a copper fo rce I n t he illu strat ion s two cuts of each

.

p iece are show n face an d ,

reverse v iews F ig 87 . .

sho ws on e st yle of p ick

up die .

Cutting t he I mp ression in
D e n ng
i -Si ki

In hop employe rs
t he s ,

judge of m en s wo rk by t he ’
Fro 84 — Em boss d b c k l e . . e u .

amount th ey see an d when , ,

all th ere is i n sig ht to S how wh at t he die sink er has b een -

do ing for sev eral hou rs is a dotted l ine on a steel block t he ,

employ er is a t to h av e m isg iv ing L et hi m em emb er th at

p r .

“
wo rk well b egun is h alf do n e An O ld mov er of hou ses .

once said : Wh en I ve got a b u ild ing w el l load ed on my ’

roll ers I al low th at I v e got t he b iggest part of t he job don e

’
.

Wh en t he p rofil e of an imp ressio n is m arked on t he block of

stee l a good b eg i nn ing has b een m ad e T he l in es S how .
68 D RO P FO RGI N G
-
, D I E-I KI N G
S N , ET C .

wh at stock on t he su rface is to be remov ed ; th ey do not

S how t he d epth to wh ich th ey are to be cut aw ay n or t he ,

sh ap e of t he bottom Th ese are som et im es gaged as t he

.
,

wo rk p rog resses d irectly from t he mod el ; a better way is to

FI G 85 — Em bossed st a m i n
. .
p g .

m ark 0 3 a side v iew on t he S id e of t he die as it is v ery ,

co n v en ien t to hav e it th ere in sett ing t he d rill s to t he right

depth .

To illu st ra te the fund am en ta l p rinc ipl es th ese d ies are ,

suppo sed to be sunk w ith v ery s impl e tool s bu t not a ltog eth er ,

w ith the simpl est I t is fair ly to .

be su ppo sed that an y pl ac e th at

req u ires d ies has so S impl e a
m ach in e as a d r ill p ress at l east -
, .

T he s impl est tool s are those

wh ich a F ren chm an p roposed to
Fm 86 .
—
. Em bossed u se i n 1 86 1 wh en d ie sin kers
,
-

m
sta p i n g.
w er e i n d e m an d H e w as an ex .

p ert st eeI stamp cutter whose ex

-

i n ce had b een exclu siv ely on h an d wo r k I n apply in g

-
p er e .

for wo rk at sin k in g d ies he cl aim ed as a sp ec ial in duc em en t

,

to g iv e him employm en t th at he did not requ ire an y too l s ex

,

cept a cold ch isel a n d h amm er I t was su ggest ed to him

.

th at th is accompl ishm en t cu t n o figu re wh en d rill p resses -

 D -
IE S I N KI N G AN D EM B SS N O I G R
P AC T S EI M ET H DS O 69

were abu n d an tly p rov id ed an d could d ispl ace stock mo re

eco n om ica l ly .

No" n o " he excl aim ed g iv in g his arm a sw in g as if to

“ ”
,
“
st ri k e t he blow of a H ercul es I am st ro n g I cu t a l ittl e
. .

pl ace deep en o u gh th en I set my ch isel back j u st as m u ch as

,

I ca n cut an d I cut th at ch ip to t he bottom of t he hol e; th en

,

I tak e an oth er ch ip ; I a m n ot l azy ; th en I t a k e an oth er— all

—
j u st so d eep by an d by after a l ittl e wh il e I hav e t he stock
, ,

al l cut out .

The Fren chm an s t heory was co rrect perhaps although

’
, ,

ou r mech an ics wou ld p rob ably cu t c han n el s th rou gh w ith a

FI G . 87 .
-
Force- hol der.

cape ch isel , an d of half t he stock by b reaking b etween

get ri d
“
t he Gap i n g p rov id ed th ey had to
, kn ock a hol e in to that ere
block w ith a ch isel H e m ad e a fi rst cl ass die sin ker but he
.
- -
,

got b ra v ely ov er his part ial ity for m an u al l abo r after experi
m en t i n g w ith an d exper ien c in g t he b en efits of m ach i n ery .

Although most of t he stock is to be d ri ll ed out it w il l be ,

n ecessary to do som e ch ipp i n g A few sto u t b u l l Ch isel s m ay

.

be requ ired for h eavy cutt i n g A doz en or mo re Ch isel s

.

shou ld be p rov id ed of v ario us siz es an d sh ap es After becom .

in g acc u stom ed to th em it w ill be fo u n d th at it is v ery h an dy

to u se fi n ish in g Ch isel s m ad e of about yé in ch octago n steel 7 -
,

or 8 in ch es lo n g tap ered f rom about 2 % t o

, in ch for t he -

siz e of t he h ead an d f rom abo u t an i n ch f rom th at pl ac e t a

,

pered dow n to w ith in h alf an in ch of t he po in t wh ere it S hould

 D RO P- F ORGI N G ,
DI E S
- I N KI N G , ET C .

be l ittl e l ess th an t he size O f t he cu t to wh ich it w iden s at th at

po in t T h ey are co n v en ien tly k ept in a t in ca n on t he b en ch
.
,

po ints u p Som e folks are so inh erently m athem at ica l that

.

t he rul e of th ree dom in at es all th eir log ic Th ey in sist that .

if an in ch ch isel should be 8 inch es lo n g th en a qu arter inch ,

-

—
ch isel sho u ld be on e qu arter as long 4 in to 8 two t imes
-

h en ce a qu arter in ch ch isel shou ld be two in ch es long F ile

-
.

cutters Ch isel s are sho rt but in die sink ing mo re free hand
’

,
- -

wo rk is adv isabl e I f F ig 90 is n ot a very good rep resen ta

. .

t io n of t he ch isel d esc ribed do not lay all t he bl am e upon the

,

en g ra v er .

“
Break in g th rough Ch isel s for bu rst i ng out t he hon ey
-

comb l eft by t he d ri ll are stro n ger Th ey m ay be m ad e of yé .

FI G
“

FI G . 88 . . 89 . FI G 9 0. .

D ie Sin kers
'
C hise s l .

inch octago n steel th in n ed dow n back f rom t he po in t f rom an

inch an d a h alf to t wo in ch es to a l ittl e le ss th an t he siz e O f,

t he d ril l wh ich th ey are to follow A v ery good sh ape is .

shown i n F igs 88 an d 89 . T he u se of th ese Ch isel s in plow

.

in g f u rrow s th rough t he sta l act ic remain s after d ri ll ing is

app aren t .

Befo re p roc eed in g an y farth er it m ay be adv isabl e to m ak e

t rial templ ets , show n i n Fig 9 1 T empl ets for . .

t rial are som et im es preferred m ad e w ithout t he ov erhan g ing

en d s wh ich are h ere sho wn an d are d esig n ed to rest on t he,

su rf ac e of t he block to in d ica t e t he p rop er d epth

,
Wh en th ey .

are m ad e w ithout th ese en d s t he d epth is i nd icat ed by a m ark

d ra wn ac ross or n otch es fi l ed in t he edges of t he templ ets

,
.
72 O
DR -O RGI N G
P F , DI -
E SI N KI N G , ETC .

t he si e
d of the die,an d a stop on t he d ri l l p ress is adju sted to -

gage it T he lost mot ion shou ld be t aken up ou t of t he d rill

.

sp i ndl e
. O rd in ary care mu st be ex erc ised not to d ri l l too
deep an d to keep w ithi n l im its sid eways as an y excess in an y
, ,

d irect ion w ill necessitate pl an in g of? t he d ies .

D ri lling Ou t t he Stock
T he fo rm of t he imp res sio n at t he en d of the large part ,

gaged by templ et ( 2 ) suggests that if t he die was strapped on

t he f ac e pl at e O f a l ath e I n t he p rop er posit ion t he Imp ression
-
,

m ight easily be fo rm ed w ith a tu rn ing tool or t hat it m ight ,

be read ily m ad e on t he d ri l l p ress w ith a bo ring tool l ike a

-

cou n terbo re or en d m i ll in g cutter ; an d t he half round shap e of

t he oth er an d sm a ll er en d of t he i mp ression su gg ests th at t he

sam e m ean s m ight be adopted to sink th at a l so an d th ere ,

b ein g so m u ch of th is k in d of wo rk to do on t he d ies it wou ld ,

be eco n om ica l to m ak e a l ath e job of it an d so th ey m ight be ,

sent to t he l at h e . T he p ro po sit ion is v ery t empt in g an d ,

u n d er favo rabl e circu m st an ces m ight be accepted but really it

’
,

is n ot an y mo re d ifli cu lt to m ake th ese parts of t he die by

'

d rill in g an d ch ipp in g th an it wou ld be if th eir fo rm were n ot

so w el l adapted to be m ade by bo r ing or tu rn i ng an d t he ,

troubl e of mak in g arran gem ents for do ing it in t he l ath e or

sp ec ial tool s for bo ri n g it in t he d ri ll p ress m ight not be com

p e n sat ed for by i nc reased fac i l it y or p erf ect ion W e w i ll .

th erefo re lay it ou t an d d rill it as we did the fi rst part We .

w il l lay out an d d ri l l at th is t im e all of t he die wh ich is to be

su n k to a un ifo rm d epth . Afterward we w i ll lay out a row of
hol es at t he p roper d ist an ce from t he edge of t he round ed part
of t he d ie wh ich is to be sunk to templ et T h is rounded
part start s in at A an d run s to the dotted l ine shown th rough
the templ et an d sett in g t he d ril l to t he d epth n ear A it can be
,

kep t at th at d epth at an equ al d istan ce from t he p rofil e l in e

arou n d to t he dott ed l in e an d th en a n ew series of hol es O f a
,

d ifferent d epth from th ese bu t u n ifo rm w ith each oth er can be

, ,

d rill ed on a parall el l in e w ith th ese an d so on unt il th is sect ion

, ,

wh ich has a bottom of un equ al d epth has been du ly dril l ed ,

.
 DI E -S I N KI N G AN D EM B OSS I N G PRAC T S E I M ET H O DS 73

Using t he Brea king Ou t Chisel

The work of the b reak ing ou t ch isel is n ow in o rder an d ,

t he l abo r of fi v e m i nut es at th is stag e of t he p roc eed i ngs m akes

a bet ter S how t h an at an y oth er t im e The honeycomb is
.

qu ickly knocked ou t an d a ragged look in g hole appears - .

Giv ing the edges a skelp all aroun d reduces t he p rofil e to

smoothn ess an d p repar es the way for t he rea l ly g ood wo r k on

the die to comm ence Th is con sists in cutt ing the upper part
.

exactly to the p rofil e as del in eated on the su rface ; in follow i ng

,

down from the su rface outl ine at t he exact angle wh ich has
been d eterm ined upo n for the d raft in gett ing t he bottom of
the p roper shape an d in g et t ing the co rn ers wh ere the sides
, ,

m eet t he bottom into true an d regu l ar fo rm These th ings are

, .

all real ly d iffi cult to do w ith a ch isel wh i l e w it h a cutt ing tool

,

— a revolv ing cutter— t h ey are don e w it h bu t l it tle troubl e as

‘

t hey are larg ely gov ern ed by t he shape of t he tool s employ ed .

I f t he ch isel is not p roperly u sed an excessive amount of

t im e w i ll be requ ired to fin ish u p w ith t he sc rap er I t is .

aston ish in g how fast a m ech an ic i mp roves in clo se ch ipp ing

by p ract ise bu t it n eed n ot be wh en we refl ect th at a good

, ,

d eal of o rn am ental d esign s an d eng rav ing is done by foreig n

wo rkm en mostly w ith tool s wh ich they i mpel w ith l ight
,

h amm ers .

Good sh arp Ch isel s ca n on ly be kept sharp by hav ing th em

‘

made of t he best material so th ey w ill stand to be l eft h ard

,

enough n ot to lose th eir edge by batten ing T O do Close .

ch ipp in g requ ires an edge t h at is keen an d th at w il l rem ain ,

so — o n e th at w i l l not sl i nk away f rom its g rip but w i ll carry ,

t he ch ip cl ear th rough .

I n fin ish ing up the lower co m ers som e die si nkers make

,
-

u se of sets wh ich are s h ap ed so th at on e side of t he wo rk i ng

,

en d rests on the flat bo t tom of the die an d t he oth er r ises up

,

at the p rop er angle to give the right i ncl in at ion to the S id e .

These t ool s shou l d n ot be u sed to such an exten t as to cau se

u n equ al t en sio n in t he die by d r iv in g stock down wit h au ht
g
t o hav e bee n cu t away .
74 D RO P FO RGI N G
-
, D I E-S N I KI N G , ET C.

Rough ingtool s are u seful I n bottom in g ; th ey are made

on a m atrix wh ich rs simply a m ass of squ are po ints By dri .

v in g t he hot rough in g tool down on th is t he en d rs for m ed as ,

though it was a doz en ch isel edges c ro ssed w it h anoth er doz en

ch isel edges I t is afterward harden ed By driv ing it down
. .

an d mov ing it about it sta mp s fi n e ch ecks an d th ese are eas i ly ,

ru bb ed away w ith fi le or sc rap er l eav in g a smooth su rf ace

, .

Wh en the d ies are n early compl eted ready for t he fin al ,

fi n ish in g arrangem en ts are m ade by wh ich a l ead cast be taken

,

wh en t he d ies are cl amped togeth er as th ey are to go I f t he , .

edges as sh ow n by the l ead cas t do not co rrespond th ey mu st

be altered in t he d ies unt il th ey p erfectly m atch .

The Cha mp ney Di Sin king Pr ocess e-

Man y of k n ow wh at die sink in g is an d wh at it costs ; we

us -

are all f am i l iar w ith the cl ea n l ight shO p w ith it s p lan ets an d
, ,

s hap ers a n d d ri ll in g m ach in es an d it s rows of die sin k ing -

m ach in es all b eau t iful t ool s ; an d it s row of cl ean b right

, , ,

in tel l ig ent wo rkm en sitt in g in a no rt h l ight in du st riou sly an d ,

w ith conc en t rated attent ion s lowly sink in g t he sh ape of som e

p iece of wo rk down in to t he sol id m eta l of a steel block w ith ,

th eir qu eer shap ed fi l es an d del icate Ch isel s ; m ost of u s h av e

—
looked at a fi n ish ed j ob of die si nk in g an absolutely perf ect
-

fi t for t he irregu l ar su rfac es of t he p iece Wh ich it is to m ake ,

an d h av e secretly wo n de red at t he sk i l l of t he wo rkm an who

co u ld do suc h a job Som e of u s hav e seen a m arv elou sly

.

co n structed pan t ag raph trac ing it s thou sand s of cuts in a co in

die gu id ed by a l arg e mod el wh ich it s m ech an ism rep roduc es
,

in rev ersed m in iat u re i n t he block of steel to be u sed in t he

co in ing p ress an d we h av e al so adm ired an d wo n d ered at th is
,

beaut ifu lly exact p iece of h igh g rade m echan ism an d of cou rse ,

we k n o w a lot abo u t die sin k in g ; we k n ow what m ach i n es

-

mu st be u sed wh at cl ass of wo rkm en real ly art ists t he good

,
—
—
die sin kers m u st be what g ra d es of steel an d above all wh at
-
,

day s an d w eeks of pat ient l abo r m u st be u sed to m ake a fi n

ished die We k n o w it to d ay j u st as we k n ew i t twen t y y ears
.
,

ago ; die si nk in
- by t h ld-e t bl i h d m thod be ee n
g e O s a s e e s ca n s
 -
DI E S I N KI N G AN D EM EO SS I N G P RACT I SE M ET H O DS 75

in almost every good establ ishm ent in t he m eta l m an u fact u r

in g t rad e; t he u se of t he d rop h amm er an d t he power p ress
-
,

m ech an ical or hyd ra ul ic in m et al m anufactu ring t he old

, , ,

S low sk i lful w el l est abl ish ed m ethod s ; an d

-
e t Geo ge F
, , y r .

Champn ey eng in eer fo u nd ou t th irty fi v e y ears ago how he

, ,
-

co u ld m ake an y die for an y pu rpose f ro m the h eav iest forgin g ,

die to be u sed u nd er t he most pondero u s d rop to t he fin est ,

m ll on
ed a i o r —
co in ing die in on e in st ant in t he v ery b riefest
,

fract ion of a second w ith t he S impl e almost ru de tool s shown

, ,

in th ese eng ra v i ngs ; an d not only found out how to sink d ies
perf ect i n shape an d su rface but far superio r in qu al ity and
,

en du ra nc e to an d ies m a d e by oth m thod

y an
y er e .

History f
an d E v olution o t he Pr ocess

F ifteen y ears ago a gentl em an know i ng th at ano t her was ,

as on e of t he Athen ian s who h eld th at day lo st i n wh ich th ey

,
“
l earn n o n ew th in g said : The re is a m an in Bridg epo rt ,

Co n n who has a hamm er w ith a SO feet d rop ; he t akes a cast

.
,
-

iron fo rc e an y sh ape he wants an d fasten s it on t he botto m ,

of th is 5 0 feet fal l hamme r an d he puts a block of red hot

-
,

st eel on t he an v i l of th at h amm er w it h the fo rce on the ham

m er an d j u st d rop s the hamm er w ith t he fo rce on the bo t tom

,

O f it right down into t he steel at on e spat an d it m akes a per ,

feet die in t he steel an d don t hu rt t he cast iron fo rc e at all

’
-

—
doesn t ev en mark it you could not tel l by t he looks of the
’

cast iro n fo rce that it ev er had been n ear a p iece of steel much
-
,

l ess b een d riv en bod ily into t he sol id m eta l so as to p roduce ,

it s exac t an d p erf ect rev erse in t he block an d m ake a pe rfect ,

”
block in wh ich to p roduce it s own shape .

The oth er m an said to th is gentl em an that it did not seem

poss ibl e suc h th ings cou ld be; th at he shou ld th ink t he cast
iro n i m ag e or fo rc e wou ld be c ru sh ed to atom s an d t he hot ,

steel block on t he an v i l wo u ld sp read out so th at t he result O f ,

t he 5 0 foot d rop of t he h amm er wou ld be a couple of ru in s

-

a ru i n ed fo rc e an d a ru i n ed die block i n st ead of an i n st an t a

-
,

n eou sl
y m ad e a b solut ely p,erf ect die a n d an un i nju red fo rc e , .

To th is his info rm ant repl ied that he h imself wou ld hav e

76 DR P O -
F O RGI N G , DI -
E S I N KI N G , ETC .

t hough t t he sam e th in g bu t th at what did resu l t was a perfect

,

die exactly rep roduc in g in rev erse ev ery d etai l of t he p iece

,

put on t he bottom of the hamm er .

T he seek er after n ew th ings w en t to Bridgepo rt an d ask ed

at E P Bul l ard s m ach in e tool wo rks i f th ere was a m an in
’
. .

Bri dgepo rt who was m ak in g a d rop die by d ropp i ng a big -

h amm er 5 0 feet w ith t he fo rce on t he bottom of t he hamm er

, ,

into a block of hot steel an d m ak ing a p erf ect die at on e blow

, ,
.

“
T h is qu est ion was m et w ith a sm i l e an d t he reply N ot th at ,
” “
we ev er h eard of I said : You wou ld be l ikely to know if
.

such a th i ng was bei ng do n e ?

”
V ery l ikely in d eed was t he reply A search i n t he
, .

“
d irecto ry d isclosed t he n am e of T he Paten t D ie 88
Cannon Street an d at 88 Cannon St reet M r Ch ampn ey was
, .

found an d w ith a d rop of 5 2 feet an d a lot of die sinkers

, ,
-
,

an d a v ast numb er of t he mo st b eaut ifu l sp ec i m en s of t he d ies

con ceivabl e an d an o rder book fu ll of o rd ers f rom such fi rms

,
-
“

as t he Go r ham Comp an y .

Th irt y fi v e y ears ago the id ea st ruck M r Ch amp n ey th at

- .

at a su itabl e v eloc it y a cast iron m ed al or ev en a gold or s ilv er

-
,

co in cou ld be d riv en bodily into a block of hot steel so as to

, ,

roduc e a p erfect die in wh ich it s own sh ap e cou ld be dupl i

p
ca t ed by u se of t he co in i ng p ress Exp eri m ents co n v i nced .

him of t he truth of his th eo ry H e went to Eu rop e w ith th is .

in v ent ion an d rem ain ed ab road for t en or twelv e y ears in

, ,

close conn ect ion for a part of t he tim e w ith the Ru ssian
, ,

M in t wh ere he m ad e d ies wh ich gage from 3 0 to

,

imp ression s as again st ,

i mp ression s for the l if e of an y
d ie th ere m ad e by t he o rd in ary m ethod s for t he sam e p iece ,

an d was d eco rated by t he E mp ero r w ith t he o rd er of Stan

islau s for his i nv ent io n After th ese y ears in Eu rope M r

.
, .

Champn ey retu rn ed to Am erica an d p roc eed ed to p erf ect his ,

m ethod s so as to mak e th em appl icabl e to d ies of all S izes ; his

p rev iou s wo rk had been for co in ing pu rposes an d m edal s only .

H e start ed to wo rk in Bridg epo rt wh ere he m ad e m any d ies ,

for l ead in g fi rm s O f si lv ersm ith s an d m etal wo rkers a l l over

t he U n it ed St ates .
 DI E S N -
I KI N G AN D EM B SS O I NG PRACT SE I O
M ET H DS

H is o rig in al idea was simpl ic it y iv en a mod el for itself —

g
a p iece of wo rk to be p roduc ed in d ies the simpl est m ethod ,

possibl e is of cou rse to d rive th at mod el into a block of steel

, , ,

so as t o leav e it s p erfect i mag e in t he soft block ; th en t ak e t he

mod el out of t he die an d h arden t he die an d there it is As , .

is u su al bet ween t he h appy t h ought an d it s happy realizat ion

, ,

lay a waste of d reary dese rt y ears t he sto ry of wh ich M r , .

Ch ampn ey w i l l not hav e p rinted T he O ld sto ry no doubt .

, ,

of sh in in g mom en t s of success bu ried in speed ily fol low ing ,

failu res ; part ial gain s wh ich could n ot be m ade ent ire an d
co mpl ete an d total d isasters wh ich could not conqu er Ch amp
,

ney s faith In his th eo ries ; fin ally In Bridgé port th ere cam e to

’

be a sma ll establ ishm ent do ing good wo rk patron ized by t he ,

best m anufactu rers In t he country an d possibly t he nucl eu s of ,

a l arg e an d p ro spe rou s bu sin ess for t he closing years of M r .

Cham pn ey s l if e
’
.

M odeling Casting , , an d Dr opping

T he m ethod p ract ised at t he Bridgepo rt shops in t he begin

n ing wh ich was fifteen y ears ago in p roduc ing a h ard en ed
, ,

steel die from model was th is : T he mod el a bit of wax

, ,

shap ed to t he designer s fancy an d mou nted on a block of

’

wood a m edal a co in a pl aster cast of an y Obj ect a n at u ra l

, , , .
,

l eaf from a tree anyth ing in sho rt from wh ich a plas ter cast
,

cou ld be taken could hav e a die m ad e f rom it wh ich was n ot

,

an app rox i m ate rev ersed copy but was absolutely p erf ect in it s ,

rep roduct ion ; ev ery l in e ev ery el ev at ion an d eve ry d ep ress ion

, ,

of t he mod el were m ad e in thou sand s of dupl icat ion s f rom t he

d ies which were m echan ica lly cop ied f rom t he mod el s by
,

Cham p n ey s p rocesses
’
.

First if t he art icl e was not su itabl e for u se as a pattern to

,

be molded in sand a pl aster cast for u se as a patter n was taken

,

from it an d in th is pl aster east as a mold a second pl aster

, , ,

cast was m ad e wh ich was a dupl icate in fo rm of t he art icl e to

be reprod u ced N ext th is l ast cast was mold ed in fi n e T roy
.
,

found ry sand t he sam e as an y p iece of fine iron cast ing T h is

, .

safi d mold was fac ed by smok ing an d p rint ing t he patt er n

78 D R OP- FO RGI N G ,
DI E-
S N I KI N G , ET C .

back in t he mold u n t i l t he su rface of t he fi n ely d iv ided carbon

fac ing d eposited by t he smok in g p rocess gav e an absolutely
, ,

p erfect mold of t he mod el Th en th is mold was pou red w ith

.

Bar um
n
’
—
Rich ardson s car wh eel iro n j u st a good st ro n g
-
,

found ry iro n noth ing secret or spec ial about it M r Champ

, . .

ne
y m ad e t he mold s h i m self an d h e a l so pou r
,ed th em m elt ,

in g his iron in plumbago c ruc ibl es an d w ith a cok e fi re in the ,

fu rn ace shown in F ig 94 N ew c ruc ibl es are t o be seen

. .

stand ing on top of t he b rickwo rk of t he f u r n ac e an d one ,

FI G — Forge W here dies w ere hea t ed

. 94 . .

wh ich has been u sed is st and ing on t he floo r by it s side T he .

fu rnace was a pl ain iron band ed b rick wo rk aflair w ith an

,
-
,
-
,

o rd inary g rate of squ are bars loose fi re b rick doo rs an d an ash

,
-
,

p it , all of t he mo st common con st ruct io n At t he b eg in n ing .

of th is M r Champ n ey was n eith er a die sin ker n or an iro n

.
-
,

molder n or a st eel temp erer Bu t he beca m e all th ree an d

,
.
,

his iro n mold in g cam e v ery n ear p erfect io n H e showed at .

th at t im e a cast in gra y iron of a l arge m edall ion wh ich was

ab solut ely p erfect an d app eared to h av e b een ca refully an d
,

beau t ifu lly fi n ish ed all over bu t had really n ever b een touch ed
,
“ ”
s in c e l eav ing t he sa n d ; an ot her a waster n ot good en o u gh
, ,
80 D RO P FO RGI N G
-
, DI E S N-
I KI N G , ET C
.

or c ind er; t he c row n in g varied w ith t he siz e of t he block I t .

was qu ite h igh p erh aps

, inch in a block abou t 6 i n ch es lo n g
by 3 % inches w ide T he d ies w ere made about t he common
.

p ract ise for th ickn ess After t he fo rc e or mod el had been

.

”
d riven into t he hot steel t he m etal of t he d ies was ra ised up
,
‘

in a h igh bo rd er all arou n d t he b ase of t he fo rc e j u st as it ,

would be if t he fo rce had been d ropped into a m ass of very

wet cl ay an d th is ra ised edge lay up t ight again st the edge of
,

t he base of fo rc e T he ext rem e l ift of t he hamm er 5 2 feet

.
, ,

FIG . 96 .
—T he die- si n k ers .

was u sed only for t he l argest wo rk ; variou s d rops of t he ham

m er were u sed acco rd i ng to t he siz e of t he die
, T he l argest .

die m ad e at th at t im e by M r Ch ampn ey O f wh ich he could .

,

fi n d a reco rd m easu red 1 2 in ch es by 1 0 i nch es for t he top

,

open in g of t he die an d was 8 in ch es d eep from t he fin ish ed

,

su rf ace of t he die to t he bo ttom an d t he fin ish ed die weigh ed

,

2 1 2 pou n d s .

T he h amm er u sed by M r Ch amp n ey w eigh ed .

pou n d s an d had an exten sion wh ich co u ld be key ed to it s t op

, ,

wh ich weigh ed po u n d s th u s m ak in g t he g reatest ham

,

m er weight av ail abl e 2 5 00 po u nd s With 5 0 feet of d rop t he

—
, .
 DI E-
I KI N G
S N O I
AN D EM B SS N G p RACT I SE M ET HO D S 81

fi n al veloc it y of t he h amm er wo u ld be con sidera bly over 5 0

feet per second T h is was reduced som ewh at by t he V u p
.
-

rights wh ich
gu idé d t he h a mm er i n it s fall so th at t he ex ,

trem e v eloc it y atta in abl e was est im ated at 5 0 feet per seco n d .

T he hamm er was l ifted by a pow er d riven w in ch shown in -

F ig 9 5 ; a po rt ion O f t he h amm er is al so show n

. T he dim en .

sio n s of t he h amm er room did not p er m it pl ac in g t he cam era

-

so as to t ak e a S in gl e p ic t u re includ in g all of both T he l ift .

FIG . 97 .
— Sp ec i m en of w ork do n e .

in g chain was attach ed to t he top of t he h amm er an d ,

rel eased by t he h an d l in e seen co i l ed on t he l eft up r ight O f

-
,

t he h amm er gu id es
-
.

Th ese up rights are of wood h av ing cast iron V gu id es ,

- -

bolted to th eir in n er faces T he bottom of t he h amm er had

.

t he u su al dov eta i l an d k ey for hold i n g d ies .

I t was of cou rse essent ial that t he die block shou ld be

, ,
-

perfectly co n fi n ed sideway s .

“
T he stee l u sed was die steel m ad e by Farist in Bridge
, ,

port An y su itabl e steel m ight h ave been u sed as th ere was

.
,

noth ing spec ial abo u t t he steel .

82 DR OP -E
O RG I N G, DI -
E S I N KI N G ,
ET C.

M r Ch ampn ey said t he die blocks were heated to wh ite

.
-

“ ”
heat befo re being pl aced on t he an v i l for a d rive T he .

actu a l d eg rees of h eat was not g iv en T he h eat i ng was don e .

in t he fu rn ace shown as was al so t he h eat ing for temper in g

,
.

After t he d riv en block was cold it was pl an ed in an o rd i

nary sh aper ( t he only m ach in e tool in t he pl ace) an d pl an ed
flat on t he top dow n to t he p rop er h eight an d was th en passed ,

to t he die sin kers F ig 96 who did wh at was n eeded in t he

.
-
, .
,
“
way of fin ish in g an d m att ing to t he wo rk in g su rfac es of t he
d ies I f t he fo rce was absol u tely p erfect then t he die n eed not
.

have been touch ed by t he die sin kers an d was n ot

- -
, .

A h ead of Ru ben s f rom cellulo id imp ressio n m ad e i n a

,

Ch amp n ey die t he su rface of wh ich was n ev er touch ed by a

,

hand tool was O f an absolutely perfect fin ish as were a m edal

, ,

l ion h ead of Ar iad n e in copper an d a sm all er m ed al l ion al so

, ,

in copper Both t he h ead of Ru b en s wh ich was d riv en f rom

.
,

a cast ing m ad e f rom a pl ast er cast of a Bru ssel s m ed al l ion an d ,

t he copp er m ed a l s m ent ion ed w ere of t he mo st perfect su rfac e

conceivabl e an d all were st ruck in d ies wh ich had n ever been
,

touch ed by a h an d tool Bu t v ery m any d ies were m ad e in

.

t he Bridgepo rt shop s f rom mod el s in wax wh ich w ere by no ,

m ean s perfect in d eta i l ; t he petal s of t he flowers rep resented

wanted sh arp en ing at t he edges matted su rfaces were l eft ,

pl ain an d del icate l in es were om itted ent irely to be put in by

, ,

hand after t he die was d riven As m ight be gu essed t he v ery.

,

sm al l est an d fai ntest m arks on t he o rig i n al w ere rep roduc ed

w ith absolute fid el ity in t he Champ n ey d ies an d a die st ruck ,

“
fro m a $5 gold p iece w ith Ch amp n ey in sunk l etters was
, ,

ab solut ely f aultl ess i n ev ery d et ai l u nd er t he m ic ro scop e an d ,

”
t he die of t he H ead of Ru ben s had a p erfect pol ish i n ev ery
d etai l .

H ea ting a nd H a rdening of t he D ies

T he h eat in g an d d riv in g of t he d ies u nd er t he h amm er ,

an d t he h ard en in g an d temp eri ng w ere al l don e by M r .

Ch ampn ey h im self T he h eat in g for all p u rpo ses was do n e

.

in t he n atu ral d rau ght Leh igh coal f u rn ac e shown in Fig 94 .

,

j u st as it appeared after a l arge die had been taken f rom it to

 D I E-I KI N G
S N AN D EM B SS N O I G PRACT SEI M ET H DS O 83

go to t he hard en ing tub shown in Fig 9 8 Th is tub was . .

si mply a barrel cut down to m ake t he end s of a die hold i ng

gra t ing at the sides and not ch ed st il l lower at t he right for an

,

ov erflow .

Two barrel s on an ov erh ead pl atfo rm were fil l ed w ith water

fro m t he smal l v ert ical su p
ply p ipe an d a much l arger
,

st rea m was p rped f rom th ese

barrel s down to the h arden

in g tub ( cut down f rom a
l arger barrel ) below Th is .

large p ipe had an upward

bent O pen in t he tub som e ,

thing l ike 2 inches or 3

inch es b elow a g rat ing m ade
O f s m a ll w ires c ro ssing t wo

bent round rods hooked

over t he S ides of t he bar
rel, all as shown in F ig .

2 1 T he supply stream was

.

sm all an d t he b arrel s ov er
,

head were ample reser

i
v o rs.

Pu re wate r only was

u sed T he round w ire rods
.

were perhaps an inch or t wo

below the water l ine estab-

l ished by the overflo w at t he

r ight . The flow in t he
l arge d el iv ery p ipe was reg FI G 9 8 — Harden in g app l ian ces
. . .

u lat ed by t he h and v a lv e .

I n h eat ing the die t he face was n ot al lowed to com e in

d irect contact w ith t he fi re; bent p ieces of sh eet iron were -

w ired on the die so as to cover t he sides an d an i ron tray , ,

con siderably l arger th an t he face of t he die was p rov ided an d ,

fill ed w ith powd ered ch arcoal or bo n e Ch arco al as m ay be ,

tho u ght best T h is t ray was th en p u t in t he fi re an d th en t he

.
,
84 D R OP-FO RGI N G ,
-
DI E S N I KI N G , ET C .

die, h v ing it s
a d es d edges cloth ed w ith sh eet iron as
si an -

d esc ribed was l aid face down on t he tray of charcoal ; coal was
,

add ed around t he die an d t he fu r n ace doo r clo sed unt i l t he

,

die was hot ; th en t he die an d t ray were ta ken out tu rn ed ,

r ight Sid e up a n d the t ray was th en an d not unt i l th en

, , ,

remov ed f rom t he face of t he die thu s k eep ing t he d ie at al l ,

t im es fu ll of t he red hot charcoal or bon e du st T he die was - .

put bottom down on t he grat ing in t he harden ing t u b; t he

st rea m was tu rn ed on again st the bottom of the die unt i l it was

cool ed about h alf way up the hot ch arcoal st ill fill ing t he ,

cav it y of t he die an d perfectly p rotect in g it f rom t he air ; t he

,

die was tu rn ed face down on t he g rat ing an d t he ful l st ream

of water tu rn ed on so as to ru sh up into t he in sid e of t he die
an d cool it as qu ickly as po ssibl e; t he die was retu r n ed to t he

fu rn ace imm ed iately an d drawn rap idly after h arden ing ; both ,

h eat ing an d cool ing were don e as ra p idly as possibl e As an .

i ll u st rat ion of t he valu e of a l arge stream of w ater del iv ered

close to the face of t he die M r Champ n ey said th at a die , .
,

was b rought to him f rom t he Ru ssell E r win Facto ry N ew ,

Britain for h alf of a m eta l doo r k n ob an expen siv e p iec e of

,
-
,

die sink in g wh ich th ey had t ried th ree t im es t o h ard en an d

-
, ,

bel iev ed wou l d not h ard en at a ll; th is die M r Ch ampn ey .

hard en ed so that no fi le in his pl ace wo u ld to u ch it at t he fi rst ,

attempt by t he m ethods d esc r i bed

, T he Ru ssell 8: E rw in .

shops had a temper i n g tub p iped w ith an u p st ream bu t t he -

,

nozzl e was 1 8 in ches or so below t he g rat ing wh ich t he die

l aid on an d h ence t he h ard en in g st ream was too much dif
,

fu sed in M r Cham p n ey s op in io n t o be efi ect iv e

,
.
’
, .

Exa ct ness f
o Size f
o D ies

T he exact n ess of size of d ies m ad e by t he Bridgepo rt shops

was wo n d erful O n e set m ad e for exh ib it ion f rom half of a
.

common bal l peen m ach in ist s hamm er cut i n two in t he m id ’

dle l engthw ise was as perfect in everyth ing as can be im ag

,

in ed Bu t M r Ch ampn ey bel iev ed he coul d m ak e d ies con

. .

sid erably l arg er or sm all er th a n t he fo rc e an d c o u ld al so m ake ,

t he die d isk c rown mo re th an t he m od e ; th u s he sa id he could

-
 DI E -S I N KI N G AN D EM B SS N O I G PRAC T SE M ET H I O DS 85

m ake t he die d riven f rom a go ld p iece 3 ; or so l arger or 1

sm al l er in d iam eter th an t he model wh ich d rov e t he die an d ,

could a l so ra ise or lower the Cen ter of t he die at w i l l so as to ,

increase or d im i n ish t he w eight O f t he co in str uck in t he d ies .

H e did not expl ain t he m ean s by wh ic h he cou ld do th is but ,

said t he result was certai n an d as he w ish ed i nv ariable an d , ,

he added that he had n ev er lost or c racked a die in hard en ing .

Fina l Dev elop ment f

o Cha mpn ey Pr ocess

T he fu l l detail s of t he Ch ampney p rocess h av e been

secu red sinc e t he fo rego i ng was w r itten an d w ere for a long ,

t im e kept secret an d ev en to those who had a gen eral idea

,

of it t he en t ire p rocess was not very Cl ear H owev er I pub .

,

l ish h ere t he final devel opm ent of t he die-sink i ng p ract ise :

I f for exampl e a die for st rik ing up a d eep hollow ware
, ,
-

bowl was to be m ade M r Cham p n ey s pl an was to fi rst m ake

, .
’

a mod el of pl aster O f Paris From th is mod el a cast i ng was

.

m ade of t he fin est an d closest grain ed iron obtain able w ith a ,

l arge am ount of m eta l l eft b eh ind the model for stren gth .

The san d was th en Cl ea n ed f rom t he cast ing w ithout remov ing

the hard sca l e wh ich is an im po rtant featu re O f th is p rocess
, ,

an d it was th en k ey ed to t he h amm er of t he h ig h d rop Th is .

h igh d rop was rightly n am ed for although it was of t he u su al ,

d op press d esign t he ways are eighty feet h igh t he lower

r -
, ,

parts of iron an d t he up per O f wood faced t he whol e l ength ,

w ith steel T he h amm er itself is of cast iron an d weighs

.

pounds I t is abo u t two feet squ are an d th ree feet long

.
,

an d is raised by a W i ndl ass op erat ed by h and A pu l l on t he .

rope attach ed to t he rel ease l ev er a llow s t he huge w eight to-

d rop an d on t he way a l atch is fitted to catc h the hammer on

,

t he rebou n d for a doubl e blow is fata l to t he die

, .

To t he b ase of th is g reat d rop p ress wh ich was n ecessarily -

,

v ery h eavy is fitted a cast iro n r i n g wh ich is 3 feet in d iam

,
-
,

et er an d 1 0 i nches th ick T he open ing in t he center of th is

.

ring is squ are an d l arg e enough to tak e an o rd i n ary S ize of

y
die bl ank
- .After k ey ing t he cast iron hub ( or type) in to t he -

hamm er of t he d rop an d raisin g it to a h eight j udged by the

86 D RO P FO RGI N G
-
, DI E S N -
I KI N G , ET C.

operato r to be su fli cien t t he di blank S wh ich has been

, e-
,

h eated to a b right red is pl aced w ith in the squ are open ing in
,

t he r i ng at t he base of the p ress an d sh im s S pl aced around ,

it so as to compl etely fil l t he space b etween t he bl ank an d t he

i n sid e edge of t he ring The heavy hamm er is then rel eased
.
,

dr iv ing t he hub w it h it s fac ing of hard scal e into t he re d hot -

die bl ank
-
As t he d ispl aced steel could not go sideway s on
.

account of t he S h i m s it had to go upward an d h elp ed to b ri ng

,

t he result i ng im p ression up to shap e Af ter be ing st ru ck t he .

,

die was ann eal ed an d the sca le re mov ed by p ickl ing ; th en

enough was pl an ed f rom t he face to l eav e t he die t he p rop er

depth an d by m ean s of scrapers an d rifli ers t he i mp ression was

,

smooth ed an d fin ished as in t he o rd i n ary m ethods of die-si n k

“ ”
in g . N ext the die was sh anked to t he p ress in wh ic h it
was to be u sed an d after hard en i ng an d pol ish ing it was ready
,

for u se.

D i Sinking M achin es
e-

O n e of t he essent ial el em en t s of a m ach in e for sin k ing d ies

by cutt ing t he stock out f ro m t he i mp ression seem s to be a
S l ide bed w ith two l atera l mov em en ts at right angl es to each
-

oth er an d anoth er is a revolv ing sp in dl e perpen dicu l ar to t he

,
‘

bed w ith f ac i l it ies for g radu at in g t he d istance between t he two

, .

O t h er mov em ents of n ear ly equ a l i mpo rta nce are som et im es

in co rpo rated w ith t he mach in e Al l are mod ifi ed an d adju sted.

for t he pu rpose p roposed an d ev ery adju stment p rov ided,

wh ich w il l conduce to t h eir proper employm en t T he g rat ify .

in g reSu lt of t he whol e comb in at ion is a m ach in e wh ich is not

du ly app rec iated but wh ich is co n stantly d ev elop ing un looked
,

for possib i l it ies an d capab i l it ies I t is l ike a t ra de of wh ich

.

those who h ave wo rked at it t he longest an d l earn ed it t he ,

best w i ll say : We are always fin ding ou t some n ew th ing

,
“

about it

D ie sink i n g m ach in es as n ow m ade are i ntend ed to be

-
, ,

u sed wh en ev er oc cas ion requ ires as copy i n m ch i n es Th ey

, g a , .

are so arra nged th at a mod el die m a be fix d on t h bed

y e e

wh ich carries t he die t o be fo r m ed an d h en c e th ese two d ies ,

w ill be moved In concert hold in g at all t imes t he sam e position

,
 88 DR O P- FO GI G
R N , I -
D E S N I KI N G , ET C .

stoned Part ies h ave fitted t he th ree actu at ing screws w ith
.

m ic rom et rical ind ices by wh ic h its actu at in g mot ion s in an y

d irect ion m ay be gaged an d stated ve ry m inutely an d hav e so ,

bal anced it s movabl e parts as to rende r it del icately sen sit ive
to t he touch With th ese n ice appo intm ents determ inat ions
.
, ,

an d su sc ept i b i l it ies it is competent to as fi n e efo m

, p r r an ce as

t he copy ing m ach i n e noted in L ondon almo st on e hund red

,

an d twenty years a o for it s wo r k in copy ing med all ion s

g ,

wh ich mu st h ave had sim il ar capac it y of mot ion an d hav e ,

sub st it u ted a fixed g rave r for a revolv ing cutt er to h av e secu red

it s fin est effects .

The e remarks about t he die sink ing m ach ines are not
s -

intend ed for those who know of it but for those who kno w it ,

not I t is a p rompt ing of bu sin ess in st inct to se ize upon t he

.

advantag es to be de riv ed f rom the employm ent of m ach in ery

as soo n as t h ey are shown to ex ist w ith t he sa me av id it y an d ,

for the sa m e reas on that specks of gold are p icked up wh en

ev er th ey can be found So was t he wo rld s m ass of gold
’
.

g a th ered an d s o
, i nd iv idu a l w ea lth is accumu l at ed .

Closed a nd Open Dies f or Forgings

In most S hops where d rop fo rg ing d ies are u sed it w i l l pa
- y

to u se closed d ies on some forg in gs ev en when w it h good ,

contriv ance most O f the wo rk can be don e w ith open d ies .

T he d ifference be t ween a closed die an d an Op en die is t h is

I n a closed die t he stock can not escape but t he ov erplu s or , ,

whatever is taken into t he d ies mo re than enough to fill t hem ,

is th rown out as a fin an d is removed afterward by t rim m ing

,

in a punch p ress or w ith a ch isel or by g ri nd i ng but i n open

-
, ,
.

d ies t he stock is wo rked S id eways successively unt i l it is

b rought to t he p roper S ize an d shape an d t he overplu s stock , ,

if an y is wo rked out at t he ends an d simply requ ire s to be

, ,

cut or b roken off I t w i l l be O bserved then th at the open

.

d ies on ly requ ire to h ave bottom s of the i mpression s m ade to

t he righ t p rofil e bec au se th ese only i mp ress t he fo rm upon t he
stock but in clo sed d ies t he i mp ression mu st be co rrect on all
,

sides becau se t he stock fill s t he die an d t he sh ape of al l sid es

,
 DIE S
- I N KI N G AN D EM B SS N O I G PRACT SE I 89

is i mp re ssed upon it As th ere is very l ittl e strain upon open

.

d ies th ey can be m ade of cast iron often w ith g reat advan t age ,

an d ta k e t he p roper fo rm f rom the mold but closed dies h ave,

to su stain an eno rmo u s strain and th erefore have to be wo rked

ou t f rom sol id m eta l .

I t is adv isabl e in m any cases an d espec ial ly wh en un sk i ll ed

,

l abo r is employed at t he d rop h amm er to u se closed d ies

-
,

wh en t he extra cost of d ies t he cost of t rimm ing an d t he

, ,

expen se of ext ra was te of stock do es not m ak e t he full cost of

t he fo rg ings g reate r than it woul d be if m ade w ith open

d ies
For some wo rk W
.

h ich can be d ropped or fo rged either

way it m ay be made w ith on e or two blow s w ith closed d ies
, ,

wh ile it wou ld requ ire mo re than tw ice as many to m ake it

w ith open d ies an d yet it m ay be Ch eaper to u se t he open d ies
,

on account of sav ing of stock for being stru ck repeatedly fi rst

,

on th is sid e an d then on t he edge t he ext ra stock is fo rced

,

out at t he en d an d b ein g l eft on t he bar goes in to t he n ext

p iece in stead of being trimm ed off as a fin wh ich would be ,

n ecessary if it had been m ad e in a closed die T he cost of .

trimm ing is al so saved by t he u se of t he open die T he cost .

of fo rg ing is to be reckon ed f rom t he bar to t he p iece dc l iv

ered as a compl ete fo rg i ng an d as it includ es ev eryth ing
,

expend ed to roduc e it t he cost of all d ies t rimm i ng as

p , ,

well as fo rg ing mu st enter into t he account

, .

Va lu e f
o M odern M achin er
y
In t he m ajo rity of shops where d rops are employed it
would pay to hav e a die sink ing m ach in e not only that t he
-
,

cost of t he d ies is ch eapen ed by it s u se but al so becau se d ies

,

can be m ad e w ith it wh ich could not v ery wel l be p roduced

w ithout it by m echan ics not sk il l ed in t he spec ial ty of cutt in g

ou t accu rate imp ress ion s in steel Th is inc reased fac il ity of
.

mak in g t rimm ing as well as d rop d ies induces a g reater u se of

-

t he d rop an d ut i l izat io n of t he advantages it afl ords of p rodu

’

c ing un ifo rm ity Pieces so perfected are cheap er th an h and

.

fo rg in gs an d not o n ly in fi rst cost but al so in sav ing much of

, ,
90 DR O P FO RGI N G
-
, DI E-S NI KI N G , ETC .

t he al bo r wh ich wou ld have t o be spe n t on t hem if t hey were

so sh aped .

Som e m en seem to j udge of t he valu e of a m ach in e

acco rd ing to t he amount of t im e th ey can keep it runn ing .

They don t want to buy a tool th ey cannot keep con sta ntly
’

employ ed . That is not t he c riterion to go by Tool s .

are not to be v alu ed in p ropo rt ion to t he amount of t i m e

wh ich th ey mu st be employed to do t he wo rk but to t he ,

amount of t i m e wh ich th ey can rem ai n un employ ed an d st i ll

do t he wo rk A m anufactu rer wou ld h ardly th ink it w ise to

.

put a l arge po rt ion of his wo rk ing cap ita l into a m ach in e that
wou ld be Only u sed t wo weeks out of fi ft y two i n a year an d -
,

y et thou sa nd s of sm a ll cap ita l ist s h ave i nv est ed m i l l ion s of

doll ars w ith ampl e profi ts in ju st such mach in es Wh ere are .

t he m ach i n es ? Sta n d ing outdoo rs in t he fence co rn ers all

over t he wo rld Agricultu re m ach in es Yes ; farm ers fi n d
.
?

that it pays th em to hav e tool s to do th eir wo rk when t he field

is r ipe for t he h arv est an d to do it qu ick an d th en let t he
, ,

tool remain idl e unt il it can show it s wo rth again an d m an u ,

fact u rers can l earn t he sam e l esson .

I t m ay be O bserv ed that t he die sink in g m ach in e is not of

-

t he k i nd wh ich is imp rov ed by stand ing outdoo rs in t he fence

co rn ers ; the best care is none too good for it n or are t he ,

most intell igent an d careful m en too good to have charge of

th em .

Circum stances are of f requ ent occu r rence wh ich i llu st rate
t he ben efits wh ich m ay resu lt f rom t he ab il ity to m ake u n i
fo rm fo rg ings O n e in sta nce of m any l ike it was wh ere a
.

l arge number of m ach in es had been manufactu red an d sent out

by repu t abl e part ies I t was an old sta ndard m ach in e but
.
,

th ey had m ade som e Sl ight improvem ent in it an d as is O ften ,

t he way w ith s l ight imp rov em ents th is on e was found to h ave

,
“ ”
spo i l ed t he m ach in e for t he , sl ight a ltera t ion in on e part had

cau sed a great altera t ion in anoth er part V ar iou s pl an s w ere .

dev ised to rem edy t he d efect but all in volv ed too much t ro u
,

ble unt il at l ast it was d iscov ered th at a sin gl e f org ing if

, ,

mad e of a pec u l iar shape wou ld an swer t he pu rpose bu t t he

, ,
 DI E-S NI KI N G AN D EM B SS N O I G R
P AC T S E I 91

h pe was so in t ricate an d d iffi cult to m ake by han d that it

s a

would not h av e been th ought feas ibl e to m ake it if it had not

been poin ted out that d rop d ies could be cut w ith wh ich t he
-

p ieces could be made w ith un ifo rm ity at a moderate expen se .

Th is pl an being adapted an d t he p ieces sent out t he d efect was

rem ed ied an d t he expen se of retu rn ing t he m ach i n es for
,

repairs was avo id ed Th is is simply t he O ld sto ry of t he

.

adva nta ge of int er cha ngea blepa r ts ; th is v ers ion of it is o n ly to

S how th at t he b en efits of t he sy st em w ere obtain ed beca u se t he

mean s were right at hand to secu re th em at once .

Prev ision a nd Sup erv ision

Th is suggests an il l u st rat ion of that old sto ry t he value of ,

p re v is ion an d superv is ion I t m

. a
y seem ex aggera ted but it ,

is a cold fact Som e m en w ere once g rouped togeth er i n a

.

m a nufactu ring company who had st ruck a b u sin ess bo n anza

a m in e of w ea lth T he gold en san d s had ru n so f reely th at it
.

hadn t b een n ecessary for th em to know anyth ing about t he

’

real econom ies of m anufactu ring an d of co u rse wh en t hey

, , ,

felt in sp ired to p ract ise som eth in g of the k ind in t he n am e of

“ ”
bu sin ess th ey sav ed at the Sp igot an d slopped ov er at t he
,

open h ead of t he barrel Without bothering t h eir h ead s much

.

about t he m att er th ey carel essly cl assed t he co st O f sup erv ision

an d of tool m ak in g tog eth er

- an d both as u np rofitabl e ex
,
“
p e n dit u re or as on e of th em put it :
,
AS a st an d ing exp en se ;

l ike t he b rick wal l s of t he shop .

O n e day it h app en ed th at a m an cam e along who se eyes

set so far b ac k i n his h ead th at wh atev er he saw afi ect ed his

brain . H e looked a l ittl e into t he way those m en did bu si

n ess an d fin ally told them that th ey were not pay ing out
,

en ough for tool s an d sup er int end ence an d he cou ld p rov e it , .

T h ey took an un canny faith in th is m an told him t o go ,

ah ead paid him t he fee of a tru st l awyer to m an age t he

,

mech an ica l d epartm ent of their bu sin t s r an d he perm eated ,

t he whol e establ ishm ent w it h his p resence as t he sunl ight ,

floods t he en t ire pl an etary system H e put thou sands of .

dol lars wo rth of tool s into t he tool room an d set to wo rk six

-
,
92 D R O P F0 RGI N G
-
, DIE S N
- I KI N G ,
ET C .

t im es t he n u mber of t ool m akers th ey had employed befo re

-
.

I n sho rt he mod ern iz ed to t he l ast ext rem ity T he l atest an d

, .

best tool s an d m ethod s he wo u ld have an d he did h av e , .

Wh at was t he resu lt of th is h eadlong expen d itu re I t is

?

th at t he average cost of t he p roduct of t he establ ishm ent is

reduc ed to abo u t a th ird of wh at it was wh en he assu m ed con

t rol ; t he d eman d for t he mach in es th ey m ake has kept up

.

w ith his imp rovements ; t he o u tp u t has in c reased in p ropo r

FIG — Forg i d dies

. 99. n g an .

t ion ; mo re m en are employed ; t he avera ge of their wages

is h igher th an ev er ; ev ery on e is sat isfi ed an d p rosp erity ,

abound s .

Hob for Forgi ng Dies

I n Fig 99 a fo rg in g of wh ich a g reat n u m ber were to be
.
, ,

m ad e is shown at A As dies for m ak in g th is fo rg in g it

,
. .
,

bein g p rod u ced in g reat qu an t it ies had to be ren ewed qu ite ,

f requ ently t he m ak in g of t he fo rg in g d ies in t he u su al m an

,

n er beca m e q u it e exp en si v e I n t he shop wh ere th ese p ieces

.

were m an ufactu red h owev er t he expen se of m ak in g n ew d ies

, ,

was g reatly reduc ed by m ak in g a hob such as show n at B in ,

t he cut Th is hob was m ad e of tool steel an d h arden ed an d

.
-
,

had a p roj ect io n of ex actly t he sam e sh ap e as t he p iece to be

fo rged D ie an d p u n ch are sho wn at B
. .

T he bl ock for t he fo rg in g die in wh ich t he sh ape of t he ,

p iece to be m ad e was to be form ed was pl aced together w ith , ,

 DI -
E S I N K I NG AN D EM Eose G I
PRACT S E 93

t he hob in co rrect rel at ion sh ip in a hyd rau l ic p ress an d t he

, ,

hob fo rced in to t he die block t he req u ired d epth by hyd ra u l ic

-

p ressu re By fo rc ing t he hob in to t he die block t he m eta l

.
-
,

d ispl aced was th rown up around t he side of t he hob Th is .

s u rpl u s m etal was remov ed an d t he d ie h ard en ed

, By m a .

k in g t he d ies in th is m an n er it was possibl e to ren ew t he d ies

,

at a f ract ion of t he co st of t he d ies m ad e i n t he ord in ary wa

y .

For irregul ar shap ed fo rg ings it would so m et im es be n ecessary

—
to m ake two hobs on e for t he top an d on e for t he bottom die .
 C H APT E R I I I

DR O P- FORGI N G I I R D ES IG N
D ES, THE , C O N ST R U CT IO N AN D U SE ,

IN D R O P H AM M ER
-
D RO P PR ESS,
-
,
AN D F ORGI N G M AC H I N E -

Combina tion D rop Dies -

W d ro p die is fasten ed into pl ace wh ere it is to be

H EN a -

u sed it becom es a part O f t he p iece into wh ic h it is fasten ed

, .

T he mo re fi rmly it is bedd ed t he mo re sol id it w i l l becom e , ,

an d h ence t he b etter it w i ll fu lfil it s dut ies T he un ion of .

sev eral p iec es is i ntend ed to m ake substant ial ly on e sol e sol id ,

p iece I f it is a lower die fixed in t he drop bed it becom es a

.
-
,

po rt ion of the anv il an d if it is a top die fix ed in t he h amm er

,

h ead it becom es a po rt ion O f the h amm er

, .

I t is exceed i ngly d iffi cu lt to u n ite two p ieces of iron

togeth er w ithout weld ing so th at they w il l be as to t he effect
, , ,

of i mpact as sol id as on e p iece

, .

“
I f you tak e t he bl acks m ith s h amm er in you r r ight hand
’

an d let it fal l on t he a nv i l it w i ll rebound ; if to p rev ent th is

, , ,

you st iffen you r mu scl es an d exert you r w i ll an d b ring it

, ,

down w ith all you r fo rce st rain ing again st a rebound you w il l
, ,

only induce a stronger react ion I f now you take t he fl atter .

in you r l eft h and an d let it rest on t he peen of t he h amm er

wh il e you let t he hamm er fal l t he h amm er wi l l st rike flat an d,

dead w itho u t rising at all from t he anv il T he flatter an d

, .

hamm er togeth er are not as h eav y as t he sl edge but if you

, , ,

let t he s l edge fal l face down upo n the an v i l it w i l l rebou n d

, , .

Y ou take t he h amm er again in you r right h an d an d pl ace ,

you r l eft h and on t he peen wh ere you h eld t he flatter an d, ,

now let it fal l D O you stop all t he rebound N o it rises

.
?
,

sl ightly f rom t he an v i l an d t he t in gl in g of yo u r p a lm t el l s
,

wh at occ u rred at t he u n io n of t he h amm er an d t he han d You .

04
 D RO F O RGI
P- N G , DI E- I KI N G
S N , ET C.

in g t he comb in ed weight w il l be g iv en wh en t he weight of

,

t he upper part exc eed s th at of t he lower .

Co n sid erabl e d isappo i ntm ent is somet imes exper ienced

wh en it is found that add ing to t he weight of t he d ies does
not p ropo rt ion ately add to t he effect of t he blow T he rem edy .

is in add i n g to t he weight of t he h amm er but rel ief m ay some ,

t im es be O btain ed by gett ing t he dov etail ing of t he tenon to

perfectly m atch that of the die seat an d fit t he keys so that -
,

th ey w il l d raw t he die up as t ight as possibl e again st t he

, ,

hamm er .

Bu t wh atev er t he facts of t he case m ay be i n regard to t he

best m ethod Of fasten in g d ies for t he pu rpose of gett ing t he ,

f u l l est an d best possibl e resu lts of t he blow it is wel l to ,

rem emb er th at al l th i ngs i n d rop wo rk h av e to g iv e wa b efo re

-
y
exped iency . I f it is exped ient to fast en d ies in a d rop ham -

m er i n a certai n way for an y sp ec ia l reason wh eth er by th at

, ,

m ean s t he ful l effect of t he blow is sec u red or not th at is t he ,

way t o fasten th em ; an d if wh en thu s fast en ed t he efi ect of

, ,

t he blow of a c ert ai n siz ed h amm er is n ot su ffi c ient to accom

p l is h t he d es ire d obj ect th en a l arg er h am m er m a

, y be u sed .

T he p r inc ipl e of d rop fo rg ing is not persu asion it is com p u l

-
,

sion ; it req u ires t he fu rn ish i ng of power potent enough to ,

ov ercom e every interferencean d d r ive t he reluctant stock in to

t he d ies wh ere it fo rc es it to assu me t he fo r m of t he i mp res
,

sron .

D ie Blocks a nd I mp ression Blocks -

I t is
not alway s n ecessary to u se a p iece of steel for a die
wh ich is l arge enough to make a die block w ith a ten on of -

t he size wh ich t he bed of t he d rop requ ires T he die p roper .

,

or t he st eel bl o ck into wh ich t he imp ression is cut m ay

-
,

often be econom ical ly m ade of a much sm al l er pattern an d

h eld in a die block as well as hav e it all sol id in on e p iece
-
,
.

T he imp ress io n block can be let into a w rought iron or steel

- -

die block by d r il l ing an d ch isel in g ou t a recess i n t he block

-
,

or by pl an i ng ou t enough to receiv e it or it m ay h ave a block ,

of cast iron arou n d it .

 DR O P EO RG I N G
- I
D ES, THE IR DES IG N , ET C
. 97

Wh en t l is u sed as an impression bloc k it is thu s

t he s ee -
,

employed becau se it s wearing qu al it ies are d em and ed an d ,

the requ isite strength is part ially suppl ied by t he material of

t he bloc k on wh ich it is set .

There has always been a claim in regard to ra il road rail s -

th at they have two genera l fu n ct ion s : one to suppo rt strain ,

an d on e to endu re wear ; an d as it seem ed u sel ess to be

—
obl iged to renew t he whol e ra il whose cost augm ented w ith
—
it s we ight S i mply becau se it fai l ed in it s l ess m assiv e ,

fun ct ion by wearin g out eff orts hav e cont inu al ly been m ad e
, ,

to separate these funct ion s an d as t he g row ing tendency of

,

rail s is to i nc rease in we ight t h is co n siderat ion has t he same

,

tendency to increase in weight .

I n som e of th ese e ffo rts the schem e has been to m ake

,

separate parts to be pe rm anently l aid for upbeari ng St rength

, , ,

wh ile other parts intended for wear were m ade as l ight as was
, ,

con sistent w ith t he pu rpose an d cou ld be easily remov ed an d

,

repl aced w ith S i m i l ar p arts O th er pl an s c rossed t he p robl em

.
,

an d had t he ra i l m ad e doubl e h ead ed so th at e ithe r s id e cou ld

-
,

be u sed for w ear wh ile t he opposite sideal way s con t ribu t ed

,

it s quota of st ren gth .

M a king Die to Resist Wear

I n gen u ity in d ifferen t b ra nch es suggests sim il ar exped i
ents ; t he repl ac ing of t he wo rn p art O f a rai l is p ara l l el to the

mak ing of t he imp ression part O f a drop fo rg in g die of steel -

,

to resist wear only an d h ence m ak in g it n o longer than w il l

,

su ffi ce for this pu rpo se l eav i ng it to d erive suppo rt to resist

,

st ress f rom t he bed in wh ich it sets T he double h eaded ra il .

-

finds it s counterpart in a mod e of m ak ing flat faced d ies wh ich -

hav e a Squ are c ross sect ion so as to u se eac h of t he fou r flat

-
,

faces to sink im p ression s in After t he imp ression wh ich has

.

been cut in on e side is wo rn out anoth er impression can be ,

cut on either O f t he oth er sides each s ide serv ing in tu rn for,

a fac e
. I f t he d rop has a dov etai l ed die seat in the ha mm er -

or bed pack ing is m ad e of t he n ec essary fo rm or t he keys are

, ,

mod ified to su it D ies w ith st ra ight sides cannot be d rawn

.
98 D RO P- FO RGI N G , DI -
E S I N KI N G ,
ET C.

up agai n st t he seat w ith key s n or is th ere anyth ing but fric

,

t ion to hold th em fi rm in t he seat T he t im e wh en d ies sh ift .

in t he d rop wh eth er th ey are dove ta i l ed or straight is at that

, ,

instant su cceed in g t he impact wh en t he react ion t akes pl ace,

between t he die an d it s bedd in g t he react ion wh ich t ingl es ,

t he p alm of t he h and on t he pe en of t he h amm er .

T he sam e object ion l ies again st th ese fou r faced d ies that -

is ra ised again st dou bl e h ead ed ra il s wh ich is th at wh il e on e

-
, ,

sid e is u sed for a bed an d t he oth er for a face t he bed sid e

, ,
-

gets so b ru ised th at it is not fit for a face an d t he face gets so ,

cut an d wo rn that it is not fit for a bed I f t he imp ress io n be .

d eep howev er it is much less troubl e to red ress t he b ru ised

, ,

sid es th an to pl an e away t he whol e wo rn imp ression to obta in ,

on th at on e side a n ew face
, .

Th is pl an wo rks better on hamm ers wh ich are w ide be

tween t he up rights t han on t hose wh ich are n arrow as t he ,

st rength of t he ch eeks — wh ich th ey much n eed to resist t he

exc essiv e stra in of k ey ing— is n ot so much impaired by rem ov
in g t he stock to get t he extra w idth of t he die seat -
.

Wi de Sea t Dies
Keying -

I n t he w id e die seats it is often v ery conven ient to key in

-

an op en block i ng die alongsid e t he fi n ishin g die

- Th ese d ies -
.

are o n ly as w id e as t he stock is l ikely to sp read in th em wh en

wo rked an d are O ften t he sca nt p rofil e of t he fi n ish ed fo rg ing

,

as th eir u se is for sh ap i n g t he stock sid eways so th at it w i ll

d rop in to t he fi n ish imp rint Th eir d u rab il ity is not t he sam e

.

as th at of t he fi n ishin g d ies an d th eref ore it is an adv antag e t o

-
,

h av e th em separate th eref rom in o rd er th at t he w earin g out

,
-
,

or f ai lu re of on e m ay not n ec essitate t he ren ewal of both

,
It .

is t he g en era l ru l e th at a p air of block ing d ies w i ll o u tl ast -

sev era l p airs of fi n ishin g d ies - .

I t is v ery conv en ient to h av e key ed in to t he die seat alo n g -

,

w ith t he d ies som e k in d of cutt in g O H tool to cut 0 3 p ieces

,
-
,

wh ich are m ade from t he bar after all t he wo rk has b een do n e

,

on th em wh ich it is d esira bl e to do b efo re th ey are d etach ed .

Th ese tool s are l iabl e to acc id ent an d requ ire frequ en t sh arp
1 00 D RO P FO RGI N G
-
, DI E S N-
I KI N G ,
ET C .

to loosen th em As lo n g as a m an ru n s his own hamm er

.

exclu siv ely he cou ld k eep his sm all stock of d ies in p retty

decent fitt in g but when t he hamm er was of gen eral u se t he

, ,

d ies soon b ecam e of n o u se an d would d rop out som et im es

, , ,

wh en t he hamm er was ru nn in g ; so for su ch hamm ers g roov es ,

were cut an d key s u sed in Lowell Waltham an d Saco wh ere , , ,

t rip hamm ers were employ ed at m ak in g cotton m ill sp indl es

- -

an d oth er m ach in ery wo rk wh ich is h ard on d ies an d requ ires

, ,

th at th ey shall accu ra t ely m atch an d rest ra in th eir po sit ion .

Th ey soon cam e in to un iv ersal u se in scyth e an d gu n shops ,

wh ich were t he p r in c ipal pl aces wh ere t he t rip h amm ers were -

u sed Sm al l t rip hamm er h eads are l iabl e to spl it in d riv ing

.
-

keys an d wh en g in s or slots w ere fi rst u sed th ey were cut

,
a

sh al low t he t enon s of t he d ies w ere sho rt an d t he k eys n arrow

, , .

T he mo rt ise is st rong er th an a slot for it holds l ike a b and on ,

al l sid es I t appears to be t he b est way to fasten imp ress ion

.

d ies into t he die blocks - .

Bolt H ea ding Dies

Wh en ever w rought iron m i ld steel tool steel is u sed in

, , or -

qu ant it ies as s pec ial or stan dard fo rg in gs th ere t he d esign er ,

an d fitt er of fo rge d ies an d fo r m ers fi n d s employm en t an d

-
,

u su a lly at i nc reased wages ov er those of t he ord in arv m ach in

ist an d tool m aker

-
.

I t som et im es happen s th at t he simpl est look in g p iec e is

rea lly t he h ard est to get a p er f ect wo rk ing fo rm er for as m any -
,

hav e fou n d to th eir v exat ion Bolt h ead ing d ies are perh aps.
-

t he s impl est an d b est u n d erstood bu t as w ith ev eryth ing el se , , ,

th ere are c ertain th ings wh ich if ov erlooked in p reparin g th em

in t he m ach in e shop often h ind er th eir p rop er wo rk in g
-
, T he .

common m istake w ith th ese d ies is in pl an in g t he d ies separ

ately . Th ey shou ld be cl amped on t he pl an er or sh ap er ,

an d pl an ed in p a irs an d t he h a lv es n u mb ered With t he two .

d ies pl an ed at t he on e t im e ev en if t he d ies do com e out of

,

t he ch u ck a l ittl e ou t of sq u are both d ies w i l l be n earer al ike

,

an d fit b ett er th an if m ach in ed sep arat ely Wh at has to be .

looked for in eith er case howev er is th at t he en d be sq u are

, ,
 D RO P FO RGI N G
-
D I ES, I
T H E R D ES IG N ,
ET C . 1 01

with t he sides T he two d ies if pl an ed togeth er do n ot have

.
, ,

to be perfect ly t ru e on t he sid es or bearing su rfaces They .

w il l com e togeth er as th ey should but of cou rse t he ends

, ,

should m eet squ arely or sh imm ing w i ll be requ ired an d this

, ,

sho u ld be avo id ed if at all po ssi bl e .

Wh en t he d ies h ave b een pl an ed on th eir fou r outside su r

faces t he wo rk in g su rfaces are ready for attent ion T he p ieces
, .

should be cl amp ed en d to en d so th at t he cu t is tak en l en gth

,

w ise an d after t he su rfaces are fin ish ed an d befo re removal

,

from t he chu ck a V chan n el Sh o u ld be cut for t he gu ide for

-

t he c en ter of t he d r i l l in t he m iddl e of t he two faces After .

t he d ies are taken f rom t he chuck i f t he end s do not com e ,

squ are an d ev en m ake th em so an d th ey are th en ready to be

, ,

cl amped togeth er an d d ril l ed T he cl amps shou ld hav e t wo

.

hol es d ri ll ed for comp ressio n bolts j u st far enough apart to

-
,

g ive yé in ch cl eara n ce for t he d ies to en ter easily T he d ies .

shou ld be m ated on a su rfac e pl ate an d t he two en d s th at ,

match t he b est b rou ght togeth er A fi In Ch p iece of sh eet .

-

iron S hould be pl aced betw een t he d ies Th is m akes t he hol e .

sl ightly oblo n g an d comp resses t he iron wh en t he d ies com e

togeth er for h ead ing t he bolt O th erw ise t he iron would

.

sl ip th rou gh t he d ies wh en th ey op erate T he d ri ll s should .

be th e sam e size as t he iron ; bu t for n eat accu ra te wo rk a , ,

ream er shou ld be u sed for fi n ish in g as a tw ist d r i l l som et i m es

,

m akes a v ery ro u gh hol e When ream ed to t he p roper size

.
,

an d b efo re remov in g f rom t he cl amp s t he p iece S hould ,

be m arked 1 an d 2 on on e en d an d 3 an d 4 on t he oth er
en d for t he gu id an ce of t he m ach in e opera to r To keep .

t he d ies st eady wh en d ri l l ing a c ross cl amp a l so s hould be

,

prov ided to bolt t he d ies to t he d r ill tabl e I f l eft free to .

mov e w ith t he d ril l t he hol e is apt to ru n c rooked The d ies .

are th en ready to h av e al l t he S h arp edg es remov ed with a

coarse fi le T he qu al ity of t he wo rk an d al so t he amount

.

p roduced d epend s a g reat d ea l on how t he d ies are fin ish ed .

I f th ey p inch t he iron on t he co r n ers of t he d ies mo re th an at

t he m iddl e of each sem ic ircl e th ey w il l not do on e th ird of t he -

wo rk To get th is hearin g t he co rn ers shou ld be fil ed ro u n d

.
 DR O -
P EO RG I N G , DI -
E S I N KI N G ,
ETC .

in g . harp w ire edges should be removed al so from t he

T he S

ends an d m ad e s l ightly cou n tersunk T he d ies should be .

made of tool steel and in harden ing h eat to a low ch erry red
-
,
-

an d cool in oil T he t empe r n eed not be d rawn

. .

T he h eat i ng blocks are t he n ext to receive attent ion

-
.

After all t he su rfaces are pl an ed t ru e an d to S ize as near that ,

of t he g ripp ing d ies as poss ibl e th ey are ready to be harden ed , .

Th ey should be h eated to a Ch erry red an d d ipped in water -

an d not d rawn as th ey s hou ld h av e v ery h ard wo rk i n g su r

,

faces .

T he h eaders g iv e more t roubl e th an eith er t he d ies or the

blocks for th ey are hard to hold i n t he lath e an d t he work ing
,

su rfac e on th em has to be

fi n ish ed as an
y rough su r ,

faces make a bad job on

t he h ead of t he bolt an d ,

t he wo rk i ng l ife of t he -

header is cut dow n .

T he h ead er gen era lly

FI G 1 00. He d fo l i C h bo l t
—
a u sed is 1 % x 2 x 1 2 i n d i es
er r - n .

T he rul e for t he h ead ing

en d of th ese h ead ers is on e an d on e h alf t im es t he d iam eter -
,

w ith 1 ; inch added for t he th ick n ess an d of cou rse 2 %

1
,

i nch es w id e or w ider if wan ted For i l lu st rat ion we w i ll take

.

a 1 i nch bolt ; th is wou ld g iv e a h ead er as per F ig 1 00 both

- .
,

end s al ike T he ru l e for recessing t he en d s is : yé i nch l ess

.

than t he w idth of t he h eader for t he in side c ircl e i nch ,

mo re th an t he d ist ance ac ross t he co rn ers for t he Outsid e cir

Cle an d on e qu art er t he d iam ete r of t he iron for d epth of
,
-

rec ess For l in ch bolts t he d im en sion s of t he h eader wou ld

.
-

be 1 1 ; i n ch es for i n sid e c ircl e an d

7 i nch for d epth ,
.

For fin ish in g t he recess a coupl e of flat fil es sh aped on t he ,

en d to t he p rofil e of t he recess an d u sed to sc ra pe t he rough

'

su rface after tu rn i n g w i ll be fou n d v ery ha ndy ; th ey should

,

be g round t ru e to s iz e an d m ad e v ery h ard Th ey can be .

m ad e to Clamp in t he tool post but th ey are mo re handy an d -

,

qu icker u sed as h an d tool s After t he h ead ers are scraped ou t .

 DR P O - FO RGI N G , DI E SI N
- KI N G, ETC .

wo rk I f t he h ead er is not w id e enough to hav e M inch stock

.
-

— —
outsi de t he recess }é inch would be better have t he head er
-

upset The riv et produced is shown by F ig 1 03 Th is g ives

. . .

p ra ct ical ly t he sam e rul e for th ese heads as for t he con e h eads ,

except th at t he d epth is 1 ; i nch l ess th an t he d iam eter of

1

t he i ron .

I t is a v ery common m ista ke for a m ach in ist to d ri l l both

en d s of a pair of d ies t he s a m e an d m ake both en ds of a h ead er

t he sa m e but th is sho u ld n ev er be don e unl ess you want fou r

, ,

pairs of d ies an d fou r h ead ers for t he sam e

siz e of bolts Wh ere both ends are m ade t he
.

sam e th ey ca n t be rep aired wh en wo r n out

’

unt il both end s are gon e an d that hangs th em ,

up an d puts t he mach ine out on th at size

FIG 1 03
.

unt
.

il th ey ca n be fixed up ; bu t if you h ave say

Riv et head
,

inch on on e en d an d SS inch on t he oth er

.

an d t wo pa irs of each wh en a p air n eed s repa iri ng you st i ll

,

have a pair in reserve an d t he h eaders the sam e

, .

Forgi ng Pr ess Dies

-
f or M a king H ammers
The advantag e of fo rg ing h amm ers an d sim il ar tool s so as
to p reserv e u n ifo rm shapes an d den sity of m etal was recogn ized
befo re t he adv ent of t he fo rg ing press but th is has h elped -
,

m att ers a great deal an d it s good po ints have been ut il ized by

,

many fi rm s I t is rap id an d can h an dl e a l arge variety O f

.

wo rk t he cost of t he wo rk depend ing l argely on t he d ies u sed

, ,

as th ey d irectly aff ect t he t i m e ta ken for a m an to h andl e t he

difl eren t p iec es .

I w i l l end eavo r to show th eir p roper con st ruct ion in as sim

p le a wa
y as p ossi bl e a n d b eg i n on t he simpl er fo r m s fi rst
,
.

Sa v ing Unnecessa ry M ov ements

T he m ain obj ect in t he d ies should be to do as much as
possibl e an d concen t ra te th em in rotat ion , so th at each ope ra
t ion w i ll follow t he other w itho u t t he wo rkm an hav ing to lose
t im e by do in g u n n ecessary t ra v el in g f rom en d t o en d O f t he
p ress Th is takes t im e an d t he steel gets cold, m ak ing it
.
 O
D R P-FO R GI N G D I ES, I
T H E R D ES IG N , ET C . 1 05

harder on t he d ies an d p ress an d v ery often hard on a man s

,
’

pat ience .

F irst com es t he sh ear bl ad es wh ic h are of pecu l iar sh ape ,

as th ey are d esign ed for noth ing but hot sh eari ng an d mu st ,

cu t t he bar as squ are as poss ibl e oth er ,

w ise t he steel buckl es in squ aring t he face

of t he hamm er an d requ ires ext ra work
, .

I n F ig 1 04 B shows t he bottom bl ad e
.
,

w ith t he gu ide to keep t he top bl ade f rom

ov erl app ing but st il l g iv in g a t ight contact
,

for good wo rk A shows t he top bl ad e

.

an d on it s sharpn ess an d p roper set d epends

t he squ aren ess of t he cut an d l en gth of t he

“ ”
p iece for wh en dul l it sl id es t he p iece
,

in sh earin g an d cau ses v ar iat ion s in weight ,

an d as ev ery p iec e should be of t he sam e

FIG 1 04 . .

B ot t om bl ade .

siz e an ext ra yé i nch w i l l co u nt up to qu ite

,

a l arge amount in a day s ru n T he p u nch p u nch block

’
-
.
,

an d st r ipp er com e n ext an d t he adj u stabl e gag es on t he

'

pu n ch block for locat ing t he eye of d iff erent siz e h amm ers
- .

FIG . 1 05 -
C om p l et e ou t fi t .

I n F ig 1 05 C shows t he
.
, gages atta ch ed to block T he f ront .

an d back is p ra ct ica lly t he sam e T he st ripper is shown ov er

.

it an d t he p u n ch hold er w ith t he pu n ch u sed

,
-
Wh ere mo re .

than on e p ress is in t he shop t he pu nch holders should all be -

1 06 D R O P-F0 R GI N G , D IE-
SI N K NI G , ET C .

m ad e t he sam e so both punches and holders are interchan ge

,

abl e for an m ch i n
y a e .

M a king a Dou ble-Faced Ha mmer

Suppose we want to m ake a doubl faced hamm er l ike N e-
, ,

F ig 9 . Th is requ ires top an d bottom d rift d ies E an d F

.
,

F ig 1 05 smooth i ng d ies G an d H both top an d bottom

.
, ,

being t he same in th is case an d be su re that t he wo rk ing su r

,

faces be rounded n icely to avo id cutt ing t he hot Steel .

T he b reak ing down d ies I an d J are t he sa m e as d ies G

-
, ,

an d H except h av i ng
, inch mo re spac e b etw een th em for

FIG . 1 06 . FIG . 1 07 . FIG . 1 08

.

Mak i n g a dou bl e- faced ham m er .

t he e dges of t he h amm er T he su rfac in g die is m erely a.

-

b road flat top u sed to keep t he hamm ers of on e l en gth b efo re

punch ing an d should be m ad e sho rt enough to take in t he
,

l argest h amm er m ade T he d ifference i n siz e an d l en gth of

.

h amm ers is m ad e up by d ifferent th ickn esses of iro n pl ates -

l aid on t he bottom die tabl e - .

T h ese d ies w i l l m ake f rom six to t en sizes of h amm ers by ,

mak ing th em for t he l argest size fi rst an d p u tt ing yé in c h

l in ers und er t he d ies for each sm all er siz e h amm er m ade All .

d ies shown are in pl ace on t he p ress for each operat ion in F ig .

1 08.

The Fi nishing f
o the Dies

Greatcare is req u ired that t hed ies sho u l d be fin ish ed as

smooth an d t ru e as possibl e as , an y tool m ar ks w i l l wo rk in to
-
1 08 —
o n o p ro nom c , DI -
E S I N KI N G ,
ET C .

to strength en t he sid es T he .

steel fac es s ho u ld be at l east

on e th ird t he h eight of t he fi n
-

ished die Wh en mad e too

.

th in they soon get soft wear

, ,

out of shape an d buckl e for

, ,

th ey are con stantly subj ected

to g reat h eat an d strains wh il e
in u se .

Few Dies N eeded fi r For

wo u ld seem at fi rst
It
—
FI G 1 1 1
. . Swagi n g di s gl an ce that t he variety of
e .

work on a forg ing mach in e -

p ress wou ld requ ire a very l arge number of d ies but such is ,

not t he case . For w ith t he add it ion of s u bblocks a great

m any d ies can be u sed for difi eren t pu rposes an d ev en w ith ,

out th em it mu st be rem emb ered th at a l at itu de of i n ch es

FI G . I ll -
Arra n gem en t of dies .
 D RO P FORGI N G
-
I
D ES, I
T H E R D ES IG N , ET C.

is possibl e. I n tool wo r k we seldo m fo rge a p iece ov er 3

-

in ch es sq u are, an d on e set of d ies w il l an swer for f rom 1 0 to

1 5 difi eren t S iz e art icl es, as 1 ; in ch tak en off or put on t he
1

hamm er m akes qu ite a d ifference in t he weight, an d often

t he o n ly v ariat ion w i ll be i n t he l en gth , wh ic h m akes sev
era l pou n d s difl eren ce i n t he w eight .

We w il l take for ex ampl e a sin gl e an d dou bl e-faced spal l

FIG . 1 13 .
—
F org i n g- m ac hi n e j obs .

in g
- hamm er an d an o rd in ary sto n e s l edge O n e set of d ies .

w ill m ake all of th ese tool s t he only d iff eren ce bein g in t he

,

bevel s an d t he p inch ing d ies for t he c u tt in g en ds T he

- .

st ra ight s id es are all t he sam e for no u p sett i ng d ies are u sed

,
-

on th ese h amm ers as t he b ev el ing d ies to b reak d ow n t he

,
-

edges on t he sto n e s l edges take th eir pl ac e A cert ain amo u n t .

of stock m u st be added to both h amm ers as th ey k ick back ,

1 10 D RO P FO RGI N G
-
, DI -
E S I N KI N G , ETC .

l
u n ess p in ch ed down so as to l eave about ,
i n ch to be
sh eared ofl T he sh ear bl ad es should be sh arp for th is as
’ -
.
,

wh en th ey are d u l l th ey d rag an d th is fi n mu st be ground off , .

M ost of t he d ies for th is job

are S im i l ar to those S hown i n

F ig 1 05. .

Set o f Tools f or Forgi ng a

Fu lcru m Br a cket

c nt years much D u rin g re e

p rogress has been made in for

g ing an d in sm ith wo rk gen -

eral ly T he old an d mo re .

ted iou s m ethod s are dy ing out ,

as fo rg i ng m ach in es an d a li -
pp
an ces are adapted to t he wo rk .

Among th ese t he swag ing m a -

ch in e deserv es part icu l ar at

tent io n an d on straight w ork ,

FI G 1 1 4
.
—Mac hi di s
. ne
it is r
e
e a
.
l ly a l a bo r sa v ing d e v ice -

in ev ery sen se of t he wo rd I .

Wish to il lu strate a set of tool s u sed in t he mach in e for m ak in g

a fulc rum b racket - in conn ect ion w ith rai lway b rake gear -
.

Th ese tool s however are not co n fi n ed to th is part icu l ar j ob

, , .

As w i ll be seen t he j ob is adm irably su ited for t he swag in g

,

m ach ine ; to d rop fo rge it would be a

-

waste of t im e an d m aterial F ig 1 09 . .

show s a set of b reak ing dow n d ies

-
,

F ig 1 1 0 a set of fo r m ers for S hap in g

.

t he eye F ig 1 1 1 an o rd i n ary set of

,
.

h i
,
1 a ,
n d l yé i n ch sw ag i ng d ie s -
,

F ig 1 1 5 a set of cutters t he const ru c

.

t ion of wh ich w ill be read i ly u nder FI G 1 1 5 —

Pi nd . , n -e ,

s tood f rom t he s k e tch e s F i g 1 1 2 . .

s how s t he arra ng e m e n t of th e s e d ie s i n t h e m a ch i n e an d t h e

m ethod of secu r in g in pl ace T he st rok e of t he upper ram s .

is in ch an d
,
th e y m ak e 6 0 0 wo r k i n g st rok e s p e r m i n u t e - .
1 12 D RO P FO RGI N G
-
, DI -
E S I N KI N G , ET C .

ra p idly perfo rm ed two h eats b ein g requ ired to fin ish t he

,

p iece I t wil l be n ot ic ed th at d ies F igs 1 09 1 1 0 an d 1 1 4

.
, .
, , ,

are so set as to p rod u c e t he fi n ish ed s iz e w ithout an dju t

y a s

m ent .

T he p iece at e Fig 1 1 3 is an oth er fo rg in g p roduced on

, .
,

th is m ach in e at suc h a p rice an d w ith

su ch a fin ish as t o g iv e p erf ect sat isfac

t ion all arou nd .

Forgi ng Dies f or Pin -En ds

jobs set down as im pos

One of t he
FI G 1 1 8 s ibl e to be don e on t he fo rg i ng m ach in e -

T he h de ea r “ ”
was t he fo rk i ng of p in ends for sw itch
'
-

wo rk but it was found by a l ittl e experim ent in g that th ey

,

co u ld be m ade v ery n icely an d rap idly so that what fo rm erly ,

cost 1 8 cents each co u ld be m ade for 2 cents each by t he n ew

p rocess T he p in en d is shown at A F ig 1 1 5 an d t he d ies
.
-
, .
,

at Fig 1 1 7
. F ig 1 1 6 shows t he iron as it co m es f rom t he
. .

squ eez er en l arg ed t he sm a ll wa of t he iron an d b ent to a

, y
sh arp angl e so th at t he h ead er w i ll fo rce it in to t he d ies
, T he .

b en d in g is don e by t he op erato r as t he d ies squ eez e t he iron ,

he fo rc in g his en d up to fo r m t he b end T he sq u eez in g an d .

bend ing is t he fi rst operat ion an d t he p iece is reheated for t he ,

FI G 1 19 —S i n g die
. .
q u ee7 . .

fi n ish in g upset an d shou ld be very hot t o do a good job

,
.

T he mov in g die in t he p i n rec ess sho u ld be g iv en pl enty of

- -

taper an d sho u ld be v ery smooth so th at t he iron w il l sl ide ,

i nto t he recess w itho u t an y t ro u bl e wh en t he h ead er st rikes i t .

An y sh arp co r n ers sho u ld be carefu lly fil ed off or th ey cu t t he ,

 D RO -
P EO RG I NG I
D ES, THE IR D ES IG N ,
ETC. 1 13

iron d t he job looks bad

an

wh en fin ish ed T he h eader
.

shou ld be tool stee l-

T he .

in sid e co r n er wh ich com es

next t he bar should be g iven
a -
inch round i ng to fo r m
a fi llit I t shou ld be g iven
.

an oil d i
-
p at a low h eat .

I t is som et im es n ecessary
that a job requ ires so much
e xtra stock that to upset it
wou ld requ ire go in g ov er
It m any t i m es an d WOU ld —
,
FI G 1 2 0 T he die c on st ru c t ion . . .

make the job so expe n sive

th at it wou ld be ch eaper to do it by hand Such an oh .

“
sta cl e was encount ered in m ak ing a pair of d ies for head
rods
”
on sw itch wo rk We tried upsett ing the stock but
'

-
. ,

found t hat t he outer en d wou ld waste away befo re we cou ld

g et t he d es ired amount of stock as w e h ad to h ea t th em fou r
,

t i m es an d the j ob wh en compl eted was v ery u n sat isfacto ry

, , ,
.

We dec ided to weld on a p iece to gain t he desired stock an d ,

so cut t he h eats down an d at t he sa m e t i m e t he expen se al so .

T he bar b eing x 2 % i nch es we took a p iec e 1 % x 2 % x 5 ,

' '
—
FI G . 121 . I he die c o n st r u c t io n .
 D RO P FO R -
GI N G , D I E-SI N KI N G , ET C .

i nches an d l aid on t he bar h eated it to a fair weld ing h eat

it ,

an d up set in t he m ach i n e t he d ies b ein g so arranged as

,
“
to rou nd t he back of t he dab n ext t he operator T he .

con st ruct ion of the d ies h eader an d pu nch is g iven in

, ,

F igs 1 2 0 to 1 2 3
. .

I n th is op era t ion th ere n eed be no h eat at t he

po rt ion n ext to t he op erato r as th is part is ,

p u nch ed ou t bu t t he part n ext t he plunger

,
“ ”
should be a n ic e soft snowb a ll as th ey exp ress ,

it . B F ig 1 2 3 show ing t he posit ion of t he

, .
,

iron as t he pl u n ger up sets it w i ll m ak e t he ,

”
m ean ing cl ear an d al so show t he dab as it
com es f rom t he f u rnace T he operat ion co n sists .

“ ”
in pl ac ing t he dab or p iec e abo u t inch far , ,

th er back th an it s fi n al posit ion th en pl ac in g it ,

carefu lly i n t he fu r n ac e ( s ho u ld be an oil fu r -

n ac e) an d wh en a good soft h eat is reach ed t he

,
“ ”
dab w i l l be stuck an d t he bar can be h andl ed
eas i ly Get it i n to t he upp er po rt ion of t he
.

d ies an d let t he m ach in e squ eez e it ; th en d rop to

t he lower rec ess an d upset it Th is l eav es t he .

en d ready for pu n ch ing .

T he arran gem ent of d ies for punch i ng t he slot is p ract ical ly

t he sam e as p rev iou sly shown O f co u rse t he fin ish of t he
.

d ies t he Cl earanc e t he g rips a n d t he m atch in g of th em pl ays

, , ,

FIG . 1 23 .
— T he die c on st ru c t io n .

an impo rtant part I f t he w orkm an sh ip of t he l ittl e detail s be

.

n egl ect ed by the m ach i n ist an exp en sive fai lu re is a t to resu lt

, p .

I h av e on e mo re die to S how wh ich is ent irely out of t he

o rd in ary l in e of wo rk don e o n th ese m ach in es an d do es a v ery ,
 D RO -
P EO RG I N G, -
DI E S I N KI N G , ET C.

possibl e to get th em Care S hou ld be taken al so th at th ey are

.

j u st sl ightly l arger th an t he fin ish ed eye I f too big the eye .

w il l n ot be good an d if too sm all th ey red u ce the sides of the

,

iron an d th is is real ly wo rse th an b ei ng too l arge

, A good .

pl an is to u se an eye j u st t he right size m ade by a bl acksm ith , ,

an d fit t he d ies to th is pattern h av i ng th em so th at t he eye

,

wor ks in t he d ies loose N o grip .

is u sed as t he b end er on t he fi rst ,

operat ion p rev en ts t he iro n f rom

s l ipp i ng .

Forging Die: f or Rou nd a nd

FI G 1 2 6
. . Squa r e Upsetting
O e in c h eye rod
Wo rk in g d ies of th is type
n - .

-
for
fo rg i ng m ach in es should gen erally be m ade of cast basic steel
-
,

as th is m at erial is eas i ly wo rk ed an d can be d ep end ed upon to

l ast I p refer it to tool steel as t he l atter often c racks a n d

.
-
,

peel s off w ith l ittl e u se T he tool steel al so often has hard

.
-

spots a lmo st i mp ossibl e to m ach in e Cast i ron is u sed q u it e .

ext en siv ely for th ese d ies an d to i ll u st rate t he difi eren ce be

,

FI G ]2 7 —U die
. .
p set t i n g .

tw n
ee two m t l
t he th is p u rpose on e pair of cast iron
e a s for ,
-

d ies for t ru ss rod s l asted abo u t th ree days an d th en had to be

-

wo rked ov er wh il e t he basic steel on t he sam e wo rk Ia n six

,

month s an d was st i l l in good cond it ion .

Perh aps t he simpl est d ies for th ese m ach i n es are t he t ru ss

rod d ies m ent ion ed abov e T hey shou ld be pl an ed in pa irs
.
 D RO P FO RGI N G
-
D ES,I T HE IR D ES IG N , ET C . 1 17

an dperfectly squ are T he d im ension s of cou rse v ary but 8

.
,

x 8 x 1 2 inch es is v ery good an d w i ll gen era lly m eet all req u ire
m ents except i n ve ry long upsets an d in th is case t he d ies
, ,

shou ld be as lon g as the mach i ne w i l l tak e A hole should .

be co red th rough the center t o pass a rod th rough to h andl e

th em with T he sketch Fig 1 2 8 g iv es t he gen era l dim en
.
, .
,

sion s for I V i n ch rods upset to 1 % i nches as u sed in b rid ge

-
,

FIG . 128 — . U p se t r od.

and car upset b ei ng 6 in ch es long A V to gu ide

wo rk, t he .

the d ril l shou ld be pl an ed in t he center of each face befo re

remov al f rom the pl an er to serv e as a gu id e for t he po int In .

boring th ese d ies sh eet iron str ips 3 , i nch th ick are pl aced
1 -
, ,

in t he j o i nt befo re the 1 % i nch hol e is bo red ; th is p rov id es

-

for t he grip of t he iron T he strip s S hou ld be remov ed befo re

.

counterbo ri ng for t he upset as if th is is ov erlooked the upset

, , ,

FI G . 1 29 — . U pset t in g die .

wi ll be oblong an d shy of stock on two sides an d full on t he ,

top an d bott om I t w il l be not iced that there is a

.
-i nch
counterbore 3 inch es deep below t he g rip in t he back port ion
of the die Th is p ract ical ly doubl es t he wo rk ing capac ity or
.
,

l ife of t he d ies T he plunger in upsett ing t he iron wears the

,
.
, ,

outer port ion of the d ies q u ite rap idly an d t he end of the rod
is l eft too l arge Th is ca u ses trou bl e wh en t he wo rk goes t o
.
1 18 DR O P FO RGI N G
-
, DI E S N-
I KI N G ,
ETC .

t he th reader as t he en d wo n t enter t he th read i n g d ies T he

,
’
.

co u nterbo re is to wo rk th is en l arged en d down to t he rig ht

s ize an d a n sw ers t he p u rpo se n ic ely I t S ho u ld be p u t i n .

ev ery p air of d ies .

D r op-Forgi ng Diet f or Gun Work

I had at on e t i m e a n umb er of dupl icate set s of d rop for -

g ing d ies to sink by t he p iece an d wh en t he m en on t he j ob ,

l earn ed the p rice I too k th em for th ey sm i l ed an d said th at I ,

wou ld not m ake day pay Th ere was not only day pay but
.
,

t he l i m it of p iec e wo rk pay reach ed an d som e t i m e to loaf t o

-
,

m ake th ings ba l ance .

T he p iece to be fo rged was part of a ri fle wh ich fi gu red

exten siv ely i n our settl em en t w ith Spai n I t con sisted of .

m agaz i n e pl ate t r igger st ra p an d ,

-
,

lo wer tang comb i n ed in on e p iec e ,

mm
an d was l i ke F ig 1 3 1 at A as .
, ,

n ear as I can rem emb er it T he .

UPSETTI N G am mo ro sq u a r e fi rst operat ion was to m ake t he

.

u su a l z i n c t empl et fi rst d raw i ng

FIG 1 3 0
. .
,

t he fi n ish l in es an d th en add in g -

fin ish an d d ra ft as w i ll be u nd erstood by all die sinkers

,
-
'
.

N ext a p iec e of t ool steel was got ou t inch th ick and th e , ,

siz e of t he fac e of t he fi n ishin g d ies wh ich I b el iev e was abo u t -

,

8 x 12 . T he block i ng d ies wh ich i n th is case w ere steel al so

-
, ,

were about 1 2 x 1 2 bu t by wo rk in g f rom on e side an d en d

,

t he d ifi eren ce in s iz e d id n ot m atter After squ aring t he .

pl ate n icely fou r hol es were d ri ll ed i n t he corn ers as show n

, , ,

care bei ng ta ken to see that th ey went th rough squ are so that ,

t he pl ate wo u ld rev erse w ithout b ei ng out of squ are on t he

die .

T he z inc templ et was th en cl amped on t he pl ate i n t he

requ ired po sit ion a n d m ark ed around an d t he pl ate was d ri ll ed ,

an d fil ed ou t to t he fo r m of t he templ et as shown i n B T wo , .

sm al l t empl ets C an d D w ere th en m ad e t he sh ape of t he

, ,

i n sid e of t he t rigger st ra p w ith p roj ect ion s as Shown to fit i n

-
, , ,

t he l arge t empl et an d w ith t he loc at i ng m ark s put on

,
Th ese .
120 D RO P FO RGI N G
-
, DI -
E S I N KI N G , ET C.

T he l i n es 0 were put on for stop marks an d t he sh ank y of t he

-

cutter serv ed as a fo rm er p in on t he templ et As t he imp res .

sion was of d ifferent d epth s cutters had to be m ade w ith a

,

l en gth of taper co rrespond ing to each d epth T he on ly Ch ip .

p ing was at t he c ircl e x an d from 7 to R the t rigger st rap ,

-

being w ider th an t he tan g T he cutter wo rked so n icely th at

.
.

it was o n ly n ecessary to fi le wh ere th ere was ch ipp i ng After .

cutt ing ou t for stock cl earance an d p u tt ing in t he sp ru e cut ,

FIG . l 32.
— T he ax e l in t hree st ages .

t he d ies were flashed an d a cast was taken t o p rove the

ch ipp in g only t he m atch b eing perfect ev ery t ime
, .

I w il l say h ere th at th ere were six pairs of fi n ishin g d ies -

an d S ix block i n g d ies m ak ing t wenty fou r imp ression s an d

-
,
-
,

t he b a l anc e on t he fi rst of t he month was v ery sat isfact o ry .

Un usu a l Job f
o D r op Forging
-

fo rg in g in qu est ion
T he is that of an au tomob il e axl e ,

w hich f rom it s l ength m akes it an unu su al ly difli cu lt p iec e to

'
 D Ro -
p EO RG I NG I
D ES, T HE IR DES IG N , ET C. 12 1

fo rge; so much so th at automob i l e m anufactu rers h ave p re

ferred to u se b ronze cast ings or welded axl es rather than ,

attempt t he task of fo rg i ng t he axl e out of a sol id bar Spec ia l .

int erest is al so atta ch ed to th is job as th ere h av e been m any ,

att emp t s to fo rge th ese axl es experi men t s h av i ng b een con

,

ducted by som e of t he lead ing manufact u re rs of the count ry ,

wh ich h ave resu lted in costly failu res T he job is all t he .

mo re rem arkabl e in that t he axles are being made in a smal l

shop w ith the too l s av ai l abl e
, .

I n F ig 1 3 2 to t he l eft is shown t he compl eted axl e

.
, , ,

dril l ed an d ream ed an d fi tted ready to be assem bl ed I n t he .

ra m

FI G . 1 33 .
— F orgin g dim en sion s .

center is shown a fin ish ed fo rg i ng befo re it receives t he final,

bend ing T he axl e l eav es t he fo rge shop in th is cond it ion

.
-
,

o wing to t he fact th at for d ifferent a utomob il es d ifferent ,

bends are requ ired t he axl es being oth erw ise id ent ical F ig
, . .

1 3 3 g iv es t he gen era l d im en sion s of t he fo rg ing .

“ ”
T he fo rg i ng is mad e of Cl ipper steel an d is of stock
2 % i nch es squ are an d cut to l en gth each p iece w eigh ing ,

about 44 pound s . The heat i ng is don e in a coke fi re g reat ,

(a re b ei ng ex erc ised to secu re a u n ifo r m h eat .

T he b reak ing down d ies are shown i n F ig 1 3 4 an d p resent

- .
,

no unu su al featu res T he stock is struck into t he die at t he

.

left u nt i l t he t wo bal l s h av e app eared wh en it is struck in ,

122 D RO P FORGI N G -
, DI E -S
I N KI N G ,
ET C .

t he d ies at fo rm t he pad at X F ig 1 3 3 T h ese

t he ri g/rt , t o , . .

dies are cast iro n u sed j u st as th ey cam e f rom t he san d w ith

, ,

out ev en bein g touch ed w ith a fi le .

T he b reak in g down is do n e u nd er a po u nd steam -

h amm er of t he u su al type AS a part of th is b reak ing dow n .

-
,

t he fo rg i n g is taken to a po u nd d rop h amm er n ear by - -

,

an d at t he sa m e h eat t he m iddl e p art of t he axl e j u st i n sid e ,

t he pad is b rok e
,
n dow n an d rough ed to S iz e Th ere are no .

gages or stops of an y k ind on t he b reak ing down d ies for -

lo cat ing th is pad th is b ein g don e ent irely by t he j u dgm en t

,

of t he operato r .

T he b roken down axl e is shown at t he l eft i n F ig 1 3 2

-
.
,

t he b reak ing down ope ra t io n b eing of cou rse t he sam e for each
-

FIG . 1 34 — . T he break in g dow n - an d fi n ishi n g di es .

en d . b end at t he ends is don e by a h elper an d sl edge as

T he ,

t he axl e l ies on t he anv i l of t he d rop h amm er aft er t he b reak -

in g down is compl ete Th is op era t ion is al so l eft to t he judg

-
.

m ent of t he operato r an d wh il e it is a crud e way to d esc ribe

, ,

is rea lly v ery qu ickly do n e an d a l so v ery accu ra tely do n e .

T he fi n ishin g d ies F ig 1 3 4 at t he right are of steel an d

-
,
.
, ,

p resen t noth ing u nu su al T he iron ban d show n sh ru n k in .

pl ace is t o hold in posit ion an add it io n to t he die th at was

fou nd d es ira bl e as it p rov ed mo re sat isfacto ry to m ake th ese
,

dies tak e i n as m u ch of t he axl e as po ssibl e I n th is operat ion .

t he pad is i n serted i n t he low er die an d if n ec essary t he s l edge ,

is u sed to b ri n g t he ext rem e en d ov er t he die in it s p rop er

pl ace Great care m u st be u sed wh en h eat in g t he stock d u rin g
.

th is operat ion t he h eat ing req u iri ng mo re t im e than t he wo rk

,

of fo r g i n g .
 1 24 D RO -
P F O R0 1 N G , DI -
E S IN KI N G, ET C .

mob il e show in Ch icago in 1 907 an d att racted con siderabl e

, ,

att ent ion T h ey are b eing fo rged by t he Bates Fo rge Com

.

pany of I n d ianapol is
, .

Tri mming Wren ch Bla nks in Die:

H av i ng v
l thou sand w rench h amm ers to round up
se era -

an d st ra ight en on t he b ack it was found n ec essary to find

,

som e m eth od speed ier an d ch eaper th an m i ll i ng T he ham .

m ers being fo rged had t he u su al fi n an d th is had to be gotten

, , ,

ofi . T he arra n gem ent shown is wh at was u sed Fig 1 3 5 . .

shows a sect ion of bed an d cutters an d an el ev at io n of t he ,

FI G . 1 36 .
— Pl an of die .

punch or sl id e T he bed has t he incl in ed g roov es to receiv e

.

t he cutters A A wh ich are h eld i n pl ac e by t he cl amp s B B

, .

Adj u stm ent is obtain ed w ith t he wedges C C T he pu n ch D

'
.

has t he h ard en ed steel p iece E sec u red by cap sc rews

- Sp rin g .

Cl ip s F F h el d by on e of t he sc rews on each sid e hold t he

, , ,

wo rk wh en it is pl aced i n posit ion Fig 1 3 5 at upper l eft . .

,

an d right ,shows sect io n s an d pl an s of t he cutters T he .

serrat ed cutt ers are u sed to tak e a rou ghi n g cut after wh ic h t he ,

wo rk is passed th rough th ree t im es w ith t he pl ain cutters t he ,

l ast cu t bei ng set to take not mo re than 001 5 inch at a cut .

,

t ing speed of feet per m in u te T h is speed seem s slow .

in face of t he fact th at t he co rru gat i ng was don e at a speed of

feet per m inute .
 D R O P F O RGI N G
- I
D ES, THE IR D ES IG N ,
ET C . 125

ca n see no reason why t his shou ld be

I
so. I know as a m att er of fact th at we
, ,

cou ld get sat isfacto ry resu lts at wh at wou ld

seem on ly a m od era te cutt i ng spe ed .

The cutters requ ire cl earance of 2 % de

grees I t is not absolutely n ecessary to set
.

t he cutt ers at an angle as shown but it m akes ,

them easier to gri nd an d keep in o rder T he .

best resu lts were obta in ed w ith a v ery sl ight

top ra ke on the cutters n ot mo re th an t he
,

concav ity th at a fou r inch wh eel wou ld g rind

-
.

Too much rake is wo rse th a n non e .

We u sed severa l g rad es of steel for cut

ters an d found v ery l ittl e difi eren ce wh en
properly h arden ed I got t he best results
.

by h eat ing in gas an d h ard

c u i ng i n wat er at 7 8 to 80

d eg rees F an d fin ish ing

.

t he cool i ng in vasel in e ,

w ith out d raw ing u sing FIG 1 3 7

,
. .

pl enty of cyan ide D o not \V ren ch befor

. e

d epend upon t he cyan ide t r i m m i g n .

to do t he h arden i ng but h eat you r steel ,

as hot as t he qu al ity of st eel w i ll sta nd w ith

ou t d am age .

I t ru st t he reader w i l l pardon m e if I
d igress an d r id e a pet hobby a lap or two ,

but t he subj ect of h arden i n g an d temper

in g th is cl ass of tool s is on e wh ich should
rec eiv e mo re attent ion I fi n d th at t he av .

era g e bl acksm ith do es not app rec iat e wh at

is requ ired of a tool of th is so rt H e alway s .

knows ju st wh at you want an d u su ally ,

do es j u st what you do n t wan t H e w ill ’

.

concoct solut ion s w ith all t he g rav ity an d

,
“ ”
my stery of a voodoo docto r wh en pu re ,

water w il l do better Solut io n s w ithout

.
126 D RO PFORGI N G
-
, D I E-S N I KI N G , ET C .

p roper h eat ing of t he steel are deceiv i ng ; th ey only case

hard en A tool for h eavy duty mu st be harden ed th rough
. .

I f t he right d eg ree of h ard n ess can be obtain ed w ithout d raw

i n g so m u ch t he b etter Th is is not so h ard to do as it seem s
, . .

Cl ean water at t he r ight t empe ratu re a good h eat i n c harcoal ,

FI G 1 39 —B e t u c hl
. .
p n .

or g ,
a s t im e enough in t he water to secu re su ffic ient hardn ess ,

th en a qu ick t ra n sfer to a h eavy bod ied oil to fin ish cool ing .

T o get b ack to t he w rench job : lub r icat ion is a f eatu re

th at mu st n ot be ov er looked I u sed a h eavy solut io n of .

—
i

vegetabl e oil soft soap an d water 5 pou n ds of soap to t he

-
,

gallon of water Th is did b etter wo r k th an the oil t he su p

. .
,

ply b eing at about 1 5 po u nds p ressu re th rou gh inch noz ,

-

z les attach ed to a su pply p ipe .

Trimming Cheap Ha rdwar e

the m anufact u re of the cheaper grades of hardware

In ,

m all eabl e iron is largely u sed in stead of steel castings or

- -

FI G . 1 40 .
— Pl an of die for t r i m m in g A Fig 1 3 9
, . .

fo rg in gs T he low p rice at wh ich t he art icl es are sold w il l

.

not allow an y expensive work such as m ill ing to be done on , ,

them Th ey are u su ally j u st d ril l ed an d pu t togeth er I n t he

. .

b etter g rad es of th is cl ass of h ardware such as belt punch es ,

-
,

et c . m ak ing the j o int at A F ig 1 3 9 is t he p rinc ipal expen se

, , .
, ,
12 8 D R OPFO
-
GI G
R N ,
-S
DI E I N KI N G , ET C.
 DR O P F O RGI N G
- I
D ES , I
T H E R D ES IG N ,
ET C . 129

of d estruct ion wh en h andl ing b i l l ets at a whit e heat T he .

.

h eight has been d esign ed to confo rm to th at of t he fu rnace

doo r an d to top of t he bottom die on t he steam hamm ers in -

u se. A h eav y hot sl ab m ay be pu ll ed f rom t he fu rn ace an d

wh eel ed ov er to t he anv i l of t he steam h amm er w ith greatest -

ease .T he con st ruct ion is very si mpl e an d i n expen siv e T he .

axl e is m ad e of 3 x 3 i nch w rought i ron an d t he t wo wh eel s are

-
,

2 4 i nch es i n d iam eter 3 % i nch th read an d m ad e of cast iron

,
-
, .

T he sl ab rest A is m ad e of 3 x i nch w rought iron su p -

,

po rted by t he 3 x i n ch b races B w ith a p iec e of 1 inch

-
,

w rought iron p ipe C act i ng as a st rut T he whol e is bolted

- .

down th rough t he axl e by a inch bolt pass i ng th rough t he

-

p ipe an d each en d riv eted ov er T he suppo rt D is of x 2

, .

inch w rought iron m ad e in U S h apes an d is v ery r ig id -

T he , .

FI G . l 44 .
-
Han d-v ise han dl e before an d aft er l
C os i n g .

h andl e is of 1 % inch round w rought iron welded to a x 3

-
,

inch yoke T he h and bar is 1 i n ch in d iam et er by 2 4 i nch es

.

long for t he accommodat ion of two m en T he t ruck as a .

,

whol e has been found v ery u sefu l an d substant ial an d since

, ,

its tr ial m any oth ers h av e b een co n st ructed .

The Possibilities f
o Planing Tools fi r Finishing Forgi ngs

We h ave had occasion a number of t im es in m anufact u ring

to do wo rk with spec ial sh av ing or pl an ing tool s Th is has .

p roven a much mo re accu rate an d a ch eaper m et hod th an t he

u su al way of m il l i ng We ask ou rselv es has t he m ill i ng cut
.
,

t er so m u ch ad v antage ov er t he pl an i ng tool i n remov i ng stock -

an d m ach i n i ng a t ru e su rf ac e ? We all k n o w that a cutter to ,

wo rk f ree mu st have su ffi c ien t rake to al low t he ch ips to be

,

remov ed w ithout t oo much b reak i ng up an d th ere mu st be ,

130 D RO P- F O RG I N G , D I E-e e G, ET C .

e nough m etal back i ng up t he c u tt ing edge to w ith stand t he

st ra i n of t he cut T h is is t he case w ith all cutt ing tool s
.
-
,

wh eth er a d ril l a m ill i ng cutter or a pl an er tool T he pl an er

,
-
,
-
.

tool has t he big advantage in th at it can h ave ampl e rake for

,

f ree cutt ing an d at t he sam e t ime h av e pl enty of back in g to

,

suppo rt t he cutt i ng edge -

.

N ow why not g iv e t he pl an ing tool mo re cutt ing edges

,
? -

G iv e it a w id er cut a n d m ake it in ser ies to fi rst b reak up t he

, ,

su rfac e w ith serrated tool s an d th en follo w w ith tool s to t e

mov e t he stock an d m ake t he fi n ishin g cut T he qu est ion -

.

that p resents itself is : what is t he l im it of siz e of cut t hat can

be taken ? Giv en a m ach in e of su ffi c ien t st rength an d p roper

FI G I 4S
. .
-
Han d ise forgi n gs
-v before an d aft er,

shav i n gs .

tool s m ay not a su rface be m ach in ed in one st roke th at

,
i n t he
old way s takes hu n d red s ?

Worh on Ha nd Vise Forgings -

With a p rofil i ng fixt u re t he h and v ise j aws Shown kept a

,
-

m an comfo rta bly bu sy to t u r n out 1 5 0 i n t en hou rs Wit h .

t he set of d ies i llu st rat ed a boy easily fi n ish ed in t hree op era

, ,

t ion s 400 in 9 % ho u rs With a st roke of su ffi c ien t l en gth

,
. ,

an d by bu i ld i n g t he die in series th is could as w ell be i n ,

c reased to p ieces i n t he sam e t im e T he l ength of t he .

cut around t he v ise is about n in e inch es an d it was mad e ,

at about 1 5 f eet per m i n ut e I f a 9 i n ch cut is po ssibl e an d

.
-

p ract icabl e why not 1 8 in ch or 3 6 in ch

,
- ? -

Anoth er exampl e is t he ch eck er in g an d V g roov in g on t he -

 132 DR O P-FO RGI N G , D l E-S N I KI N G , ET C.

depth Th ey were put th rough a d raw i ng or c losing die to

.
-

b ring t he sides para ll el as at h befo re putt in g th em th rough

, ,

t he sh av i ng d ies At t he center of t he p ictu re is a fo rg i ng

-
.

aft er it has b een th rough t he ro u gh ing die show i ng t he serra -

,

t ion s wh ere t he cut was h eav iest At t he right are shown

, .

som e of t he fo rg ings aft er t he fi n ish i n g operat ion s T he d ies .

shown i n F ig 1 46 were m ad e t he rev erse f rom t he u su al

.

way T he punch was fitted to a die block on the bol ster pl ate
.
- -
,

an d t he d ies to a hold er in t he ram Th is arrangem ent m ade .

it easy to pl ace an d to hold t he fo rg i ngs in posit ion by cen ,

— T oo l s for
’

FI G . 1 47 . c hec ker i n g an d groov i n g v se i j aws .

tering t he slot on t he p roj ect ion on t he p u n c h T he wo rk .

was flooded by pump ing oil th rough a tube conn ected w ith
t he die hold er shown at t he r ight i n Fig 1 46
-
,
T he d ies . .

were 1 % inch es th ick m ad e st ra ight on t he in side an d w ith a

,

3 0 d eg ree ra ke on t he cutt in g edge T he cut was taken by -

.

rough ing d ies an d v ar ied f rom

- 005 to 040 i nch being . .
,

h eav iest around t he boss wh ere t he die was serrated T he .

second die was en ough sm a ll er th an t he fi rst to cl ea n up t he

serrat ion s T he th ird or fi n ishin g die had a un ifo rm cut of

.
,
-
,

about 002 inch . .

T he tool for do i n g the ch eckerin g on t he f ace of t he j aw

is about 2 % inch es w ide an d was m ad e to f asten d irect to t he
cl apper block T he cutt ing part of t he tool p roj ected back of
-
.
-

t he c en ter of t he cl app er block u n d er t he ram T he cutt in g

-
, .

edges of t he tool were m ade by a ser ies of steps of abo u t 005 .

 D RO P F O RGI N G
- I
D ES, I
T H E R D ES IG N , ET C . 133

i nch , d were g iv en a rake of about 1 5 d eg rees

an Th is was .

found su ffi c ient to g iv e a f ree cutt ing edge T he obj ect of

-
.

putt ing t he c u tt ing-edges back of t he center of t he cl apper

block was to prevent t he cutter f rom hogg ing With t he “
.

cutter in th is posit ion t he tendency is to Sp ring away f rom t he

wo rk und er a h eavy cut T he cutter for m ak i ng t he g roov es
.

was sim i l ar to t he on e do in g t he ch ecker i ng F ig 1 47 . .

S hows t he cutters an d t he wo rk .

Forging Under St eam-Ha mmer

For p ieces of con s id era bl e S iz e an d

b lk t m hamm er u t he s ea -

is subst ituted for t he h ard fo rg in g p rocess I n th is m ethod of

-
.

fo rg ing t he h amm er should be of a S ize to su it t he siz e of t he

,

wo rk T he h amm er m an mu st exerc ise a good dea l of sk il l

.
-

an d j udgm ent as to t he pow er an d sp eed of t he blows de

l iv ered to t he p iece as a too powerfu l blow w il l c ru sh it an d

, ,

in t he case of h ig h perc entage of n ickel fi ssu res an d c racks ,

are l iabl e to d ev elop wh ich it w i l l be d iffi cu lt to get out ,

an d wh ich m ay S how i n t he fin ish ed p roduct .

Th is is esp ec ially t ru e if t he p iece is allowed to fal l below

t he fo rg i ng t emp eratu re or i f t he blows are not d ist r ibut ed
,

ev enly . I f t he blows are f rom a l ight t rip ha mm er d el ivered -

,

at h igh sp eed only t he su rf ac e of t he m etal w i ll be b ru ised

,

an d t he co re not affected thu s cau s in g t he co re to be coarse

,

grai n ed w ithout t he p roper coh esion to in su re t he necessary

st ren gth .

A h eavy h amm er d escen d i ng on wo rk wh ich is h eld at t he

proper temperatu re at a slow speed w il l pen etrat e t he m ass
, ,

to t he cen ter an d al low t he part icl es of m etal to flow to th eir

p roper pos it ion an d i n su re a fi n e g ra in of ev en textu re an d be
un ifo rm th roughout it s en t ire Size .

Forging La rge Pieces

T he keep i n g of t he h eat t o a good forg ing temperatu re is

mo re d iffi cult th an in t he h and fo rg in g p rocess ow ing ch iefly
-
,

to t he difl eren ce in t he siz e of t he p iece fo rged as t he h an d

’
,

fo rged p iece is u su al ly sm al l en o u gh for t he sm it h to put in

 -
D R0 P FO RGI N G , DI E- I KI N G
S N ,
ET C.

t he fi re h t it t he m inute t he temperatu re fal l s below

an d re ea

t he b est fo rg i ng h eat -
Bu t t he h amm er fo rg ed p iece is m a ny
.
-

t im es l arge en ough to be h an dl ed w ith a c ra n e an d is t here ,

fo re l iabl e to be kept u n d er t he h amm er as long as a blow w i ll

h av e an y cfl ect on it
’
.

T h is resu lts i n a v ery un ev en st ructu re as wh en t he m eta l

‘

is hot t he blows w i l l p en et ra te to t he c enter an d as it cool s ,

th ey h av e l ess an d l ess pen etrat io n u nt i l only t he S k in is ,

afi ect ed an d t he an n ea l i ng wh ich is reso rt ed to aft erward ca n

, , ,

n ot b ring it back to t he p rop er homog en eity as som e p art s ,

w il l h ave a d en ser g rain than oth ers an d th erefo re be st ro n ger .

D rop -Ha mmer Forging

When enough p ieces of h p wan ted to wear out

on e s a e are

a set of d ies t he ch eap est an d b est way of p rod u c in g t hese in

,

t he h igh g rad e al loy steel s is by t he d rop fo rg i n g p roc ess

-
,
- .

T h ey can th en be m ad e in on e p iece w ithout w eld s except in ,

p ieces wh ich are m any t im es lo n ger th an a sect io n th rough

th em an d th ese are so d iffi cult to keep at t he p roper tempera
,

t u re th at th ey are u su al ly fo rged in two or mo re p ieces an d

th en el ectrical ly welded togeth er T he oxygen acetyl en e .
-

blowp ipe has been b rought into u se for welds of th is ch ara c

t er as w el l as al l oth er fo r m s of w eld ing an d as good resu lts
, ,

are b ein g obta i n ed w ith th is as w ith el ect r ic w eld i ng .

A good i l lu st rat ion of th is is t he f ront axl e of an au t om o

b i l e wh ich is u su al ly forged in I b eam sect io n s 4 inch es f rom
,
'
-
,

t he top to t he bottom of t he I 2 % in ch es ac ross t he fl an g e

, ,

with t he web of an in ch th ick an d a l ength of f rom 48 to

,

54 inch es Th ese are gen erally fo rged in two h alv es an d

.

el ect r ica lly w el ded i n t he c en ter bu t a few of th em are fo rged

,

in on e p iece,a lthough t he fi rst cost of t he d ies an d t he l iabil

it y of th eir b reak in g ow in g to t he axl e cool in g b efo re t he for
,

g in g operat ion is compl eted has m ad e th is m ethod v ery

,

expen siv e .

p F
D ro
o rgi ng or Squ eezing
-

I n t he d rop -fo rg in g p rocess t wo m ethod s are employ ed ,

on e b e i n g t he o rd i n ary d rop -f o rg i
n g p rocess w hic h h amm ers ,
1 36 DR P O -F0 GI N G
R , DI E S N -
I KI N G , ET C.

bath of a d iluted solut ion of su lfu ric ac id to d issolve t he

, ,

ox ide or scal e after wh ich th ey can be subm itted to a sand

,

bl ast if a st ill b etter su rface is d esired

, .

T he cost of d rop fo rg ings d epen ds on t he n umber n eed ed

-

an d the numb er th at can be tu r n ed ou t at on e sett i ng of t he

d ies as well as on t he qu al ity of t he steel u sed

, .

Forgi ng H igh Gr a de Steels

T han ks to t he el ect ric an d au t ogen eou s weld in g-process in ,

comb inat ion w ith die fo rg in g w ith eit her t he d rop h amm er or
- -

t he hyd raul ic p ress al l of t he h ig hest g rad es of a lloy ed steel

-
,

can be tu rn ed i nto fo rg i ngs successful ly an d th eir strength an d

elongat ion retain ed ; but th is is a lmo st i mposs ibl e by t he hand

or h amm er fo rg i ng p rocess espec ia l ly i f w eld s are m ad e n eces

-
,

sary by t he sh ape of t he p iec e O n e of t he al loy steel s th at is

.

bein g m anufactu red in to die fo rg in gs has t he fol low in g Ch em

-

ica l composit ion : Ch rom ium p er c ent ; n ick el , p er .

,

cent ; carbon
.
,p er c ent ; m anga n ese
p er c ent
.
; , .

si l ico n , p er cent ; phospho ru s .

p er c ent ; sulfu r , .
,

p er c ent .

I n t he ann ea l ed st at e th is shows t he follow in g physical

c hara cterist ics : Ten sil e strength pounds per squ are ,

inch ; el ast ic l im it pounds per squ are inch ; elonga

,

t io n in 2 inch es 2 0 p er cent ; reduct ion of area 5 8 per cent

, .
, .

Wh en p roper ly h eat t reated that is qu ench ed in oil an d

-
,

d ra wn th ese ch aracterist ics becom e : Ten si l e strength 2 02

, , ,

000 po u n ds p er squ are i nch ; el ast ic l im it pounds per ,

squ are inch ; elongat ion i n 2 i nch es 1 2 p er cent ; reduct ion of , .

area 3 4 p er c en t
, .

Efi ct s
f
o Allo i
y gn M a t eri a ls

Ch rom iu m p roduc es a m in era l h ardn ess i n steel , an d steel s

contain in g th is alloy are d iffi cu lt to fo rge, but if t he tempe ra
tu re is k ept abov e d eg rees F or a b right y el low an d ,

n ev er all owed to fal l below th is it can be fo rged success

fu l ly .

Th is would requ ire f requ en t reh eat ing , as t he m elt ing-po int
 DR O P- FO RGI N G D I ES , I
T H E R D ES IG N , ET C.

is degrees F an d it ca nnot reach th is temperatu re With .

th is steel it is b est to m ake t he d ies w it h S ho rt er steps between

t he d iff erent pairs th an for o rd i nary carbon steel s - .

Steel s conta i n ing n ickel are mo re easi ly fo rged but th ey ,

mu st be h andl ed carefully ow ing to it s tenden cy to p roduce

,

fissu res .

T he van ad ium st eel s are mo re easi ly fo rged th an eith er of

these an d if du e care is taken to inc rease t he h eat gradu ally at
,

—
fi rst th at is th is st eel should not be plunged i nto t he beat al l
,

at once — no t roubl e w ill be experienced afterward .

Si l ico n in sm all p ercenta g es does not afi ect t he fo rgeab i l ity

of steel bu t in l arge amount it g iv es steel a fib rou s gra in an d
, ,

is th erefo re u sed p ri nc ipally for sp ri ngs Bu t in t he l ast few .

years th is steel has been fo rged into gear bl anks to qu ite an

ext ent . I n th is case t he bl anks shou ld be m ad e in t he fo rm
of fo rged rol l s an d not cut f rom bars in o rder to avo id t he
, ,

fib rou s structu re .

T he alum i num tu ngs t en t itan iu m m anga n ese an d oth er

, , ,

al loy ed st eel s are not u sed to an y ext ent for fo rg i ngs as tho se ,

befo re m ent ion ed Show superior qu al it ies an d som e of t he l ast ,

nam ed are much h igh er in p rice .

Hydr au lic Press Gi ves Best Resu lt s

'

T he inferio r qu al ity of m any di fo rg i ngs is undoubtedly

e-

du e to t he drop h amm er p roc ess, as th is has a t end ency to

-

p rod u ce only a bru ising efi ect , ow ing to t he top die descend ing
at a h igh rate of speed an d del iv ering a l ight blow wh ich has
no penet rat ion T he hyd raul ic p ress on t he oth er han d p ro
.
, ,

duces forg ings of a far superio r qu al ity becau se it slowly ,

squ eez es t he m eta l i nto t he sh ape of t he d ies thu s a l low ing it ,

mo re t im e to flow i nto pl ace an d assum e it s n ew sh ape an d ,

th erefo re mak ing it mo re u n ifo rm in qu al ity w ith a great deal

lower d egree of internal st rain s To remov e t he intern al.

st rai n s cau sed by wo rk i ng t he m eta l al l fo rg i ngs n o m atter

, ,

how th ey are made should be an n eal ed befo re u sing as t he

, ,

shock s to wh ich t he fo rg in g m a be subm itted w i ll conc en t rat e

y
at t he po i n t wh ere th ese i nt er n al st rain s are t he st rong est ,
13 8 D RO FORGI N G
P- , D -
IE e x I N G, ET C .

cau sing it to b reak at th at po int T he resu lts are v ery sim il ar

.

to t he mach in ist notchi ng a bar in o rder to b reak it off .

H ea ting Too Sudden ly

M any poo r fo rg in gs l o tu rned out by raisin g t he
are a s

t emperatu re of t he m etal too sudd en ly Certain mol ecu l ar

.

changes take pl ace in t he h eat ing of all steel s an d of t he alloy

,

St eel s i n part icul ar wh ich are l iabl e to ca u se fi ssu res i n the co re

,

of t he m etal an d th ese m ay not Show in t he fin ish ed p roduct

, ,

as th ey do not a lw ays b reak th rough t he sk i n or out er S h el l

of t he fo rg in g T hu s by h eat ing sudd enly t he outer sh ell

.
, ,

becom es red befo re t he co re has had an oppo rtu n ity t o a bsorb

an y h eat an d t he out er sh ell expand s cau s ing g reat st ra i n s on
,

t he co re of the p ieCe .

I n t he case of a h igh percentage of n ick el th ese fi ssu res

becom e mo re p ronounced than w ith t he oth er al loy s .

At a temperatu re of about 6 00 d egrees F or a b right blu e ,

most steel s lose th eir duct i l ity an d are not fitted t o resist
st ra in s i mpo sed u pon th em by t he difi eren t ial expan s ion of an

u n ev en ly h eated m etal Th erefo re t he rise in temperatu re

.

from t he n o rm al to 6 00 d eg rees shou ld be a gradu al on e but ,

aft er th is it m ay be b rought up to t he fo rg ing h eat as qu ickly

as is d esired .
 D RO P- FO RGI N G ,
-
DI E S I N KI N G , ET C
.

f rom excessiv e l ight by S l ant S h u tters t he sl ats bein g set at 45 ,

degrees an d about 3 i nch es apart adj u st abl e for about 1 foot ,

at t he top Th is arrangem ent g iv es a subdu ed l ig ht al low in g

.
,

t he h ard en er to d ist i ng u ish his colo rs w it h a g reater d eg ree of

accu racy T he S l ight adju stm ent at t he top is su ffi c ient to

.

keep t he interio r b right an d evenly l ighted regardl ess of t he ,

outsid e cond it ions O n e 1 6 candl e power l ight hung 7 feet

.
- -
,

f rom t he floo r shou ld be p rov ided for every 1 50 squ are feet of
,

floo r space in th is departm ent

-
.

T he eng ra v i ng F ig 1 48 show s t he pl an of such a bu ild i ng

, .
,

as p r im ari ly l a id out as part of a l arg e m anufactu r i n g pl a nt .

T he equ ipm ent shown in Fig 1 48 is l aid out on t he basis of .

m in imu m cl eara nce desirabl e i n t he fo rge Shop -

.

Loca tion f
o Di Sinking Dep a rtment
e-

T he di nk ing an d in spect ing d epartm ents are set at t he

e-
Si

en d of t he bu i ld in g bot h to i n su re better l ight an d to be far

, ,

th er away f rom t he j ar of t he l arger d rop h amm ers T he j ar -

.

i n a d epartm ent so loca t ed is su ffi c ien t to m at er ial ly afi ect t he

qu al ity of t he wo rk p rov ided t he part it ion s are of b rick and
,

ext end w el l b elow t he fl oo r l i n e T he rough stock for d ies -

.

is to be b rought in at t he doo r n ear t he en d of t he bu ild

— —
in g pl an ed u p dov etai l ed to fit t he die blocks in t en foot - -
,

l ength s an d th en rough sawed to size d esired in a power

,
-

h ack saw T he fin ish ed d ies are to be stored in t he fi rep

.

vault assign ed to them on racks wit h sh elves 6 inch es ,

w ide Th irt y inch passage ways b ein g su ffi c iently w ide to

.
-
,

adm it t r u ck s are a l lowed b etween t he rack s

, .

Boa rd, St ea m, Hel ve, Tr ip , f

a nd D r op Ha mmers

I n t hemod ern ized shop at l east it is b est po l icy to in stal l

-S
, ,

comparat iv ely l arge drop h amm ers on account of th eir b roader

-
,

rang e of u t i l ity T he gen era l p ract ise is to in sta ll board ham

.
-

m ers no siz e sm al l er th an 400 pounds an d to in stal l steam ,

d rops where t he wo rk requ ires siz es l arger th an pou nd s .

T he st ea m d rops i n l arge siz es h av e t he adv antage of b ei ng

-

abl e to b reak down th eir own wo rk but on sm a l l p art s the ,

 O
DR PFO RGI N G
- AN D H ARDEN ING PLAN T S 1 41
1 42 DR O PFO RGI N G
-
, DI -
E S I N KI N G , ET C.

e xperience has been that m any fo rg ings are spoi l ed by catch

in g in t he qu ick st roke .

I n the illu st rat ion t he l arger board d rops h av e b een set in

,
-

conju nct ion w ith a h elv e h am m er so arranged that it m ay

-
,

b reak down for two of th em Th is resu lt m ay be obtain ed .

equ al ly w el l by sett ing t he h elv e h amme r b etw een two d rops -

an d f aced the same wa but w ith t he nv i l block t bout 3 -

y a , se a

feet in front of t he base l in e of the d rop hamm ers thu s per

- -
,

m itt ing t he bl acksm ith to sw ing his stock d irectly f rom one
to t he oth er .

T he l argest h am m ers are set n earest t he m ain c rossing or

passageways to m ake possibl e l ess t ravel for t he l arger stock
,

an d t he fin ished p rod u ct T he fo rg ings are of cou rse hot

.
, ,

trimm ed in t he t ri mm ing p resses an d by sp ru e cu t ters set

in conj unct ion w ith each h amm er but b efo re go i ng to t he ,

m ach in e Shop th ey are accu rat ely t rimmed to t he siz e requ ired
-

for th eir rec ept ion i nto th eir v ariou s j igs an d fixtu res i n t he ,

presses of t he cold t rimm in g d epartment .

T he two t rip h amm ers are u sed in conj unct ion w ith tool
-

d ressin g an d gen eral wo rk T he two bl acksm ith fo rges n ear

.
-

t he die S ink i ng d epartm ent are u sed for gen era l wo rk du ring
-

t he day an d for n ight an d ov ert im e wo rk wh en t he m ain shop

,

is n ot ru n n ing Th ey are blow n from an ov er h ead blower

.
,

moto r d riven an d are hung f rom t he t ru sses th eir exh au sts

-
, ,

b eing taken out th rough t he roof With t heexcept ion of .

th ese two fi res the u se of fu el oil is u n iversal th rou ghout t he -

ent ire S hop Th is subj ect w il l be fu rt h er d iscu ssed l ater

. .

Both t he fo rge an d h arden ing d epartm ent s sho u ld be in gen

era l ch arg e of on e m an who se o ffi c e is c ent rally located betw een

th em but each shou ld hav e a separate subfo rem an

,
.

Layou t f
o H a rdening D epa rtinent
T he gen era l l ayo u t of t he h ard en ing d epart m en t is self
expl an ato ry but t he d etai l s m ay req u ire expl an at ion
,
I n front .

of t he sm all open fi res l ead pots et c w ith 43 in ch es cl ear

, , .
,

spac e is set a row of b r i n e an d wh a l e oil t ank s a lt er n at ing

-
, , ,

on e of each k i n d b eing su ffi c ien t for two fi res .

1 44 O
DR PF O RGI
- N G ,
-
D E e
I e G, ET C.

inl et p ipe is read ily removab le t he ut i l ity of the tank as ,

appl ied to gen eral h ard en i ng is i n no wa l i m it ed O n e hun

y .

<1e an d fifty ga llon s r m i nut hou ld b e t mpo rari ly avai l

pe e s e

abl e for th is ta nk A 5 inch cas t iron so il p ipe takes care of

.
- - -

t he ov erflow .

A 4 foot d iam eter wha l e oil ta nk one regu lar b rin e t a nk

- -
,
-
,

an d a po rt abl e f resh wat er t ank compl et e t he equ ipm ent re

-

qu ired for t he case hard en ing fu rnaces These tanks are

-
.

serv ed by a c ran e T he po rtabl e f res h wat er ta nk is 3 0 inches

.
-

d iam eter by 3 0 inch es deep an d wh en not el sewh ere in u se is

,

set i n a conc reted d ep ression i n t he floo r 4 feet d iam eter by ,

6 i nch es d eep an d th is dep res ,

sio n is d ra i n ed th rough a sc reen

th rough a 4 inch t il e d ra in - .

T he ch ief u se of th is tank is
for water m ark i ng sc rews an d -

oth er sm all part s T he t ank .

is d rain ed at t he bottom
th rough a 2 inch sp igot A -
.

l arge part of t he bl ack bon e

u sed is cau ght by t he sc reen in
the dep ression f rom wh ich it ,

FIG 1 5 0 Spec ial brin e t an k

.
— m a
y b
-e re a d.
i ly shov el ed out .

E v en w ith th is p recaut ion ,

however it is desirabl e that t he d rai n ru n w ith as steep a p itch

,

as po ss ibl e d irect to t he catch basi n both to p rev ent stoppage-

,

an d to m ake easy t he cl ean ing out should stoppage occu r , .

T he d ra in w ill su rely g iv e t roubl e if l aid w ith m any tu rn s .

O n opposite sides of th is tank are lugs an d hooks to re

ceiv e pol es by wh ich two m en carry t he tank about t he job ,

wh erev er it s u se is requ ired .

I n f ront of t he open fi res is a spec ial b rin e tank u sed for -

harden ing cutters ream ers et c A sect ion of th is spec ial tank
, , .

is shown in F ig 1 5 0 T he b ri n e is adm itted at t he bo t tom

. .

th rough a 2 inch b ra ss inl et p ipe an d spouts th rough a l arge

- -
,

number of inch hol es d r i l l ed i n t he 1 2 in ch cast iron inn er

- - -

tank T he comb in ed areas of these hol es is design ed to be

.
 DR O P-
F O RGI N G I
AN D HARDEN N G PLAN TS

abou t 2 0 per cent in excess of t he area of t he inl et p ipe A

.
-
.

4 inch cas t iron so i l p ipe takes care of t he overflow

- - - T he .

adv an tage cl aim ed for t hrs tank is that t he b ri n e spu rt ing ,

th ro u gh t he sm al l hol es on all S id es st rikes all t he teeth or

,

flutes of t he cutter or ream er at t he sam e t im e thu s tend ing to ,

p rev ent c ra ck ing .

A 5 in ch by 4 inch cent rifuga l c ircu l at ing pump set in t he

- -
,

it i n t he co r n er of t he bu i ld i ng a n d d riv en by a 1 5 ho rse -
p
power moto r suppl ies the b rin e system
, T he requ ired .

p ressu re wh ich mu st be kept on th is system to secu re good

SPECIAL E ND

AIR mt g;

FIG . I SL — Refi n ed bl as t -forge for oi l fu el .

efli cien cy pound s per squ are inch T he pump is set

is 1 5 .

su ffi c iently low to be alway s p rim ed f rom t he sto ra ge tank -

bu ilt in t he ground outsid e t he bu i ld ing Th at b rin e m ay .

be k ept su ffi c iently cool i n t he summ er month s th is sto ra ge ,

tank mu st h av e a capac ity eq u al to a fi ft een m inute su pply for -

t he ent ire sy st em wh en al l ta n k s are i n opera t io n at fu l l

capacrt y . T he b rin e ov erflow f rom al l serv e tanks is retu rn ed -

by g ra v ity to t he sto ra ge tan k th rough the open d ra i n shown

-

cl early in F ig 1 48
. .

T he regu l ar oil tanks are 20 in ch es d iam et er by 2 f et d eep

- -
.

in sid e but t he sh el l is m ad e 3 0 i n ch es h igh to b r i n g th eir

,

tops at t he sam e l ev el as t he b rin e tanks T he cool ing appar

-
.
1 46 DR P O FO RGI N G
-
,
-
DI E e x I N G, ETC.

at u s consists of a co il of i nch b ra ss p ipe th rough wh ich

- -

a part of the facto ry ser v ic e water is c ircul ated T he l arg e .

4 foot oi l t ank is of t he sam e d epth an d is cool ed th rough a

- -

1 i nch b rass co il
-
I t is n ot n ec essary to keep t he oil as cool
.

as t he b ri n e A 2 in ch by 3 inch b elt d r iv en c ent rifuga l

.
- - -

pump suppl ies t he c ircu l at ing water Certa in concerns cool .

their oil by c ircul at in g it th rough a series o f trombon e co il s

pl aced in t he mon ito r of t he h arden ing room bu t t he p ra ct ise -
,

has n ev er appeal ed to t he b est exp ert s T he expen se n eces .

is comparat iv ely g reat t he oil m akes hard wo rk for the

,

FI G . 1 52 .
— R efi t t ed l ead p ot
- fu rn ac e for oi l fu e l .

pump an d th en t he m ain h eat from

,
t he bu ild in g mu st pass
out around th ese co il s if so pl aced .

Advantages of Oil Fu el
H av in g in gen era l w
aa
y d esc r i b ed t he equ ipm ent of each
d epartm ent let u s retu rn to t he quest ion of fu el T he fi rst
, .

con sid erat ion s cont roll ing t he effi c iency of such departments
are of cou rse t he case of regu l at ion an d h eat i ng capac ity of

th eir fi res I t is in th is regard ev en mo re than i n t he redu e

.
,

t ion of fu el costs th at t he g reatest reduct ion an d economy is

,

attai n ed by t he u se of fu el oil The reason s are at once cl ear

- . .

T he bl acksm ith s t im e m ay be ent irely g iv en to his wo rk in

’

hand since once t he valves are p rope r ly adj u sted th ey requ ire
,
1 48 D RO P FORGI N G
-
,
DI E-
S N I KI N G ,
ET C .

them being u sed in conj u n ct io n w ith a mod erately low p res -

su re sy st em By th is I m ean a p ressu re of about 2 pou nd s

.

p e r s qu are i nch wh ich can of cou rs

, e b e re ad i ly d isc harg ed, ,
“
by t he o rd inary h igh p ressu re blower w itho u t requ iring t he
-
,

i n sta ll at ion of an y air comp resso r as is of co u rse n ecessary

-
,

w ith a system u sing f rom 1 5 to 1 8 pound s p ressu re .

Rej itted Coa l Forges

‘
f - a nd Fu rn a ces or Fuel Oil
I n fitt i ng coal fo rg es an d fu rn ac es to u se fu el oil it is
- -
,

desira bl e as far as po ssibl e to g iv e t he sp ray a wh irl ing mot ion

, ,

—
FI G . 1 54 . Refi t t ed B row n 8: Sha rp e c ase harden in g fu rn ac e for
-

o i l fu e l .

wh ich ten d s to mo re compl etely v apor iz e t he oi l an d al so ,

m akes a m u ch l ess n oisy fl am e t han is t he case wh ere t he o il

st r ik es aga i n st flat su rf ac es I n t he l att er case wh ere t he oil
.
,

st r ik es flat agai n st t he wh it e hot t i l e it cau ses wh at app ears to ,

be a series of ra p id expl osio n s su ffi c ien tly lo u d in a l arge shop ,

to be a sou rce of an noyan ce .

F ig 1 5 1 i l l u st rates a m et hod o f refitt in g a c ommon bl ast

.

fo rge Comm o n arch ed fi rebr ick an d skew bac ks are u sed an d

.
,

a few sp ec ial t il es wh ich m ay be read i ly g rou n d to f or m on t he

 DR P O -
F O RGI N G AN D HARDEN N G PLAN TS I

common g rindstone Common red b rick m ay be u sed as

.

back ing A spec ial cast ing is requ ired t he en d of wh ich

.
,

m ay be m ad e to bolt onto t he o rig in al side cast i ngs I n v ery - .

l arge sizes it is som et im es adv isabl e to in stal l a bu rn er at each

en d of t he fo r e wh ich arra ng em en t is v ery sat isfacto ry an d
g , ,

g ives an inten se h eat at the cen ter of t he fi re box -

.

Figs 1 5 2 an d 1 5 3 S how ho rizonta l an d v ert ica l sect ion s of

.

t he common fo r m of l ead pot fu r n ac e refitt ed E ith er w edge

-
.

or cupol a b rick m ay be u sed Two cou rses f rom t he bottom.

t il e an d fo rm i ng t he top of t he m ix ing ch amber is a t il e

, ,
‘

FI G . 155 — Refi n ed B r ow n Sha rp e c ase- har den in g fu rn ac e for

o i l fu e l .

th rough wh ich are d ill ed at an angl e six 1 % inch hol es For

r , ,
-
.

th is ope rat ion a common star d ril l m ay w ith care be u sed -

, , .

I n t he top two [cou rses fou r b ricks each are om itted at 45

,

degrees for v ents As befo re t he fi rebrick is backed up w ith

.
,

common red b rick .

Figs 1 54 an d 1 5 5 S how c ross sect ion s an d long itud i nal

.
-

sect ion s of a refitt ed N o 2 Brown Sh arpe case h ard en ing

.
-

fu rnace I n th is case t he coal gages are l eft in pl ac e an d

.
-

simply pav ed w ith fi re b r ick l aid on th eir s id es

-
A 3 inch fi re .
-
1 50 DR O P FO RGI N G
-
,
-
DI E e e G, ET C .

t il e g round to fo rm shown is cent ra lly located in the fi rebox

, ,

to act as a baffl e I f t he fu rnace is to be set up n ew for u se as

.

fu el oil it is desirabl e that t he b ridge wall be S loped as shown

-
,
-
,

to l eave an open ing at the back of 2 i nches ov er the wal l an d ,

4 i nc hes at t he f ront T he reason for t he con st ruct io n is t o

.

countera ct t he tendency of t he heat to d riv e to the back of the

o v en Th is tendency ex ists but it is not m arked that in cases
.
, ,

where the fu rn ace is al ready set up it hardl y pays to rebu ild

t he b ridge wal l A spec ial fi re doo r cast ing d esign ed to take
-
.
-
,

t he bu rne r mu st take t he pl ac e of the fo rme r v ert ica l s l id i ng

,

d oo r These few exampl es w ill g ive t he reader a gen era l idea

.

of t he chan ges n ecessary to remod el an in st a ll at ion of coa l

fu rnaces .

Ar rangement of Piping
I n t he two d epart m ents u nder d iscu ssion t he oil is su p ,

pl ied to all fu rnaces th rough a 1 % in ch w rought iron p ipe - -

m ain m ak ing a compl ete closed loop around each departm ent
,

in o rd er to keep t he p ressu re ev en A 1 inch steam p ipe .

- -

mu st be l aid w ith it to keep t he oil f rom congeal ing in cold

weather Th ese two p ipes S hou ld be l aid preferabl y in t he
.

g rou nd itself an d not in a t rench an d shoul d n ev er be l aid ,

abov e t he floo r t he reason b eing th at t he gases f rom all pet ro

,

l eum d ist i ll ates are h eav ier th an air an d w ill ru n to t he low ,

part s of t he floo r or t he t rench T h ese gases though not .

,

them sel v es explosiv e m ay b ecom e so if comb in ed w ith a

,

l arger p ropo rt ion of air .

The air p ip i ng shou ld be su spended o v erhead w ith outl ets

-

look ing down into t he risers f rom t he oil main s T he speed -

.

of t he air in th ese p ipes shou ld not exceed 1 5 feet per second

i n t he fi rst in sta l l at ion wh ich w i ll perm it of about 3 0 per
,

cent i ncrease du e to growth w ithout t he speed becom i ng

.
, ,

exc essiv e A ru l e of thumb m easu rem ent som et im es u sed is

.
- -

that t he area of t he air p ipe shall equ al six t im es t he area of

-

t he j et but t he fo rego ing m ethod is much safer for t he com

,

putat ion T o fac il itate calcu l at ion s t he fol low ing notes w i l l
. ,

p rove of i n terest .

At 2 pou nds p ressu re there w i l l be requ ired at t he blower

1 52 D RO P F O RGI N G
-
, DI E S N
-
I KI N G , ET C.

natu of an
re off -
hand es t im ate based on
, t he j udgm ent of t he
eng in eer .

Fi n ishing D ep a rtment

In fin ish ing departm ent t he follow ing recom m en da

t he

t ion s shou ld be followed in o rd er that t he best resu lts both

,

as to econom ic an d effi c ient p roduct ion an d safety an d cont ent

m ent of t he h elp m ay attain .

E m ery du st sho u ld be exh au st ed ful ly f rom t he g r ind ing

departm ent as such d u st is detrim enta l to h ealth an d efli
,

FI G 1 5 1
.
-
D ou bl e op en i n g forge for c en t er heat in g .

Cien cy, t he floo rs of t he shops an d sim il ar d epart m ents shou ld

be cov ered w ith iron pl ates wh ich p romote cl ea n l in ess both
, ,

for m en an d m ach in ery I n a p roper ly equ ipped an d operated

.

fo rge shop i n d iv idu al ch imn eys for each fi re an d u su al fac i l

-
,

t ies of v en t i l at ion by w indows an d by ov erh ead fan l ights ,

cl ean f resh air sho u ld be d ra wn in f rom a po in t h igh above

,

t he roof by pow erf u l fan s an d d ist r ibut ed th rough each fo rg e

bu ild in g u n t il it d esc en ds over each m an s h ead th rough a ’

,

fl ex ibl e p ipe u n d er his cont rol thu s assu rin g an abundan ce of

,
 DR P O -
F O RGI N G AN D HARDEN I N G PLAN TS 1 53

O l
. .. B u rner

81 4: Elev ati on

FIG . 1 59.
—
D ou bl e op en in g
forge .

Fron t Elev at ion

FI G . 1 58 .
-
D ou bl e op en i n g forge .

Pl an of B ri c k work
a rou n d V en t .

FI G . 160 .
—
D ou bl e op en i n g FIG . 161 .
—
D ou bl e op en i n g
fo rge forge .
1 54 D RO P PO RGI N G
-
, DI E-
SI N R I N G , ET C
.

cool pu re air I n on e fo rge say where th ere are over th irty

, .
,

fu rn aces runn ing u nd er fo rced bl ast it w ill be fou n d if t he

, , ,

abov e is carr ied out that even in hot weath er t he cool in g

,

sy st em w i l l cau se t he m en to wo rk st ead i ly t he output w i l l be ,

kept up an d t he shop w i ll not be compel l ed to S hut down on

,

ext rem ely war m d ay s as is u su al ly t he case

, Th is sy stem w il l .

pl ease both t he m en an d t he ow n ers .

Wh i l e t he above cond it ion s outl in ed are essent ial to an y

fi rst Cl ass drop fo rge shop th ey are as n oth ing compared w ith
- -
,

FI G . 162 .
— Adj u st abl e t p s
o - o t o l
i l- forge fu rn a c e .

the fact of ju st an d fair t reatm ent of h elp \Vages Should be .

adv anced volunt ar ily an d not wh en a g en era l d em and is m ad e

,

for adv anc ed pay N ev er m ak e a g en era l reduct ion of pay

. .

Those who k n ow facto ry cond it ion s f rom t he grou n d up w il l

ag ree th at t he p iec e wo rk rat es shou ld neve r be cut u n t i l com
-

pet it ion makes it ab solutely n ecessary .

Oil-Bu rn ing Forges a nd Heaters

In t dy advanc e in t he imp rov em ent of m ach in ery
t he s ea

an d app arat u s th at has b een go i ng on for y ears t he old coal ,

1 56 DR O P EO RG I N G
-
,
-
DI E S I N KI N G , ET C
.

an y d esired temperatu re an d that t emperatu re m ain tained per

,

m an en t ly by sett ing t he v alv es wh ich adm it t he oi l an d air to

t he b u r n er Th is is a v ery desira bl e featu re of t he oil or gas
.

fi red fo rges an d on e that cou ld not be accompl ish ed w ith the

,

old fo rg e .

Single and D ou ble Ooening Forge Furn a ces

I n F igs 1 5 6 . hown two styl es of t he most

an d 1 57 are s

common type of fo rge fu rnaces one of wh ich has t he open ing

-
,

on on e S ide on ly an d is u sed for h eat ing smal l p ieces or the

, ,

end s of l arg er one s T he oth er has an op en i ng on both sides

.
,

opposite each oth er so th at lon gbars can be shov ed in th rough

,

FI G . 1 64 — . M et hod of i n st a ll i n g app ara t u s

.

an d h eated in the m iddl e Th is open ing is left 5 inches h igh

.

on th is siz e of fu rnace an d it ca n th en be b ricked u p to m ake

t he op en ing s mal l enough to su it t he wo rk Bu rn ers are .

located on each en d of t hese fo rges so that t he chamber w il l ,

h av e a u n ifo rm h eat it s ent ire l ength .

A doubl e steel pl at e is locat ed above t he open ing to p rotect

-

t he operato r f rom t he h eat of t he fu rn ace an d i n conj unct ion ,

w ith th is an air blast is sent th rough t he p ipe an d com es up

-

th rough t he floo r an d ru n s along t he ent ire front of t he fu rnace

i mm ed iat ely b elow t he op en ing Th is air bl ast d riv es t he h eat
.
-

wh ich m ight com e th rough t he open ing up t he back of t he

steel pl at e so th at t he opera to r can wo r k i n comfo rt
-
, .

T he d et ai l s of t he co n st ruct ion of t he doubl e open ing -

fo rge are shown in F igs 1 5 8 to 1 6 1 T he S ingl e open ing

. .
-
 D RO P F O RGI N G
- AN D H ARD EN N I G PLAN TS 1 57

fo rge is p ract ically of t he sam e con st ruct ion w ith t he except ion ,

that t he on e open ing is closed up w ith fi re b rick an d fo rm s -

t he back of t he fu r n ac e wh i l e t he sh eet m eta l h eat p rot ecto r

,
- -

an d air bl ast are remov ed f rom th at sid e of t he fu rn ac e

- .

Top Slot -
a nd E d
n - Hea ting Forges
Forwo rk wh ich cannot be read ily handl ed in the abov e
fo rges an adju stabl e top slot fu rn ace l ike t he on e shown in-
,

1 6 2 is m anufactu red
, An adj u stabl e cl amp for hold in g .

FI G . 165 .
—
T oo l -dressi n g forge- fu rn ac e .

t he b rick wh ich cov ers t he open in g is f u rn ish ed w ith th is

fo rge an d t he open ing can be m ad e an y siz e su itabl e for t he
,

wo rk As w i l l be seen th ese fo rges are simpl e in con st ru e

.
,

t ion easy of cont rol tak ing p ract ica lly no n e of t he opera to r s
, ,
’

t im e for th at part of t he wo rk an d are m ad e so th at n early an y ,

k ind size or sh ape of p iece m ay be h andl ed

, , .

I n F ig 1 6 3 is shown an en d h eat i n g f u rn ace fitt ed w ith a

.
-

doo r wh ich can be ra ised or lowered to open or cl ose t he fu rn ace .

1 58 D RO P-
FO RG IN G ,
I
D E-S
N I KI N G ,
ET C.

I nsta lla tion o f Forges

I n Fig 1 6 4 is
. hown t he m ethod s of in sta l l ing th ese fu r
s ~

n ac es w ith th eir apparatu s for oil an d air As w il l be seen t he .

,

two p ipes are l aid u n d er t he floo r on e to d el iv er t he oil an d ,

t he ot h er t he air bl ast an d t he fu r n ac es conn ect ed up to th ese

-
, .

—
FI G . 166 . \V i re- braz i n g fu rn ac e .

th is is t he best m ethod wh en co n d it ion s are su ch as to

,

m ake it d es irabl e th ese p ipes Sho u ld be carried to t he c eil ing

,

in st ead of u nd er t he floo r Gages such as n atu ral gas coal

.
,
-
,

g a s
, w at e-
r gas p
,
rod u c er gas et c can b e-
u sed ,
i n th ese sa
. m,c

fo rges as read ily as oil by chang in g t he bu rn ers to those th at

are s u it abl e .

T he most i mpo rt an t th in g is to see th at th ey are p roperly

i n stall ed so th at t he a ir an d f u el p ressu res be st ead y u n ifo rm
, ,
 D RO P FO RG I N G , -
D E SI N
I KI N G , ET C.

Bu rn ers
T he bu rn er to be u sed is an i mpo rtant facto r in t he eco
n om ical p roduct ion of wo rk w ith th ese fo rges an d th erefo re ,

it is not p ract icabl e to h av e on e bu rn er th at w i ll do all k i nd s of

wo rk Wh et her h igh or low p ressu re air or steam is to be
.

u sed for the bl ast m akes a d ifference In the ki nd of bu rn er

,

FI G 168 — fi red ladl hea t er

. . G as- e-
.

th at should be u sed to get t he g reatest efli cien cy w ith t he

m in imum of fu el con su mpt ion as well as t he temperatu re that
,

it is n ecessary to m aintai n i n t he fo rge an d t he n atu re of t he

,

wo rk that is to be do n e .

By Fig 1 6 5 is shown a tool d ressing fo rge fu r n ac e that has

.
- -

been d esig n ed espec ially for shap ing up l ath e or pl an er tool s

or p iec es of a l ik e ch aract er an d s iz e wh eth er th ey be m ad e of
,

h igh speed or carbo n steel s .

 O
D R P Po RG rN G AN D H A DEN N
-
R I G PLAN TS 16 1

Bra z ing Fu rna ces

A fi n e l in e of b raz ing fu rn aces is of t he type hown in s

Figs 1 6 6 an d 1 6 7
. F ig 1 6 6 shows t he w ire b raz i ng fu r
. .
-

nace an d t he c ra nk to t he right opera tes a cl amp that holds

on e w ire . A cl amp is al so located on the opposite side of
t he fu rn ace so th at t he two w ires can be h eld i n perfect
,

a l ig n m ent if desired or the oth er w ire can be h eld by t he

,

FIG . 1 69 .
—
D et a i l s of as
g
- fi red l dla e- heat er .

ope o r A troll ey w ire can be b ra zed every th ree m inutes

rat .
-

w ith th is styl e of fu rn ace t he n ecessary h eat com ing out

,

through a hol e in t he top of t he fu rn ace .

T he tub e b raz ing fu rn ace shown i n F ig 1 6 7 is design ed

-
.

for b raz ing b ra ss copp er or Steel tub es T he bu rn er dis

charges a ribbon of cl ear hot flam e f rom t he top dow
.
, ,

n upon ,

t he tub e w ith an i ncl i n at ion to ward t he rear ; t he pl ac e to be

,

brazed b eing n ear t he f ront in fu ll v iew of t he operato r The .

162 D RG P P -
ORGI N G ,
D I E-S I N x I N G , ET C
.

bottom of chamb er m ay be ra ised or lowered to accom

t he

m odat e difl eren t siz ed tub es by t he sm al l wh eel s an d sc rew

und ern eath t he fu rn ace V alves for cont rol l ing t he tempera
.

tu re are locat ed w ith i n easy reach T hu s t he op era to r can

.

regu l ate t he fi re to su it his wo r k an d d raw t he tub es fo r ward

w ithout chan g ing his posit ion T he escap ing gases pass ou t
.

at the rear en d an d w ar m up t he incom in g tub es as well as ,

m ak ing it comfo rt abl e for t he ope rato r by conduct ing th em

away f rom t he f ront .

Hea ters

I n F igs 1 6 8
. an d 1 6 9 is i llu st rated
l adl e h eater that rs
a -

simpl e i n d esig n does not take up much room an d yet does

, ,

t he wo rk perf ectly I t can be u sed w ith eith er c ity or n atu ra l

.

g as. F ig 1 6 9
. is a l i n e c u t s how i ng d etai l s of con st ruct ion of

t he sam e .
16 4 D RO P Po
- RGI N G ,
-
D I E SI N x I N G, ET C.

parts T he art of forg ing in d ies at that date was t he weak

.

po int D rop h amm ers had not com e in to u se an d all t he

.
-
,

fo rg in gs were m ad e by the old hand swedgin g p rocesses rep re ,

sent ed by F ig 1 A b ase of cast iron w ith su itabl e open i ng

. .
,

in t he top for key ing t he gu id e stock an d lower die was set -

up t he upper die b eing m ade to wo rk f reely up a n d down in

,

t he gu id e stock I n t he faces of t he two d ies were cu t t he

- .

fo rm s of t he parts to be fo rged T he power u sed was ham .

m er an d s l edge w ield ed by t he sm ith an d h elper

, .

So far as can be l ear n ed d rop h amm ers were fi rst u sed by

,
-

Colon el Samu el Colt about t he y ear 1 85 3 i n t he m anufactu re

, ,

of t he c el eb rated revolv ing fi rearm th at bears his n am e .

T he h amm er of t he Colt d rop was ra ised by a v ert ica l

revolv i ng sc rew I n t he fi rst y ear of t he Civ i l War Gold ing
.
,

Ch en ey obtain ed a U n ited Stat es paten t on a d rop h amm er -

,

t he p ri nc ip al featu re of wh ich was ra isin g t he h amm er by a

l eath er belt b etween f rict ion rol l s T h ese f rict io n rol l s are in
-
.
-

u se to da on wh
- at are con s id ered t he b est h amm ers for d rop
y
fo rg ing I n oth er respects th ere h av e been g reat i mp rov e
.

m ents Some of t he l atest of th ese improv em ents are ex

.

pl ain ed in t he follow ing .

Counterhalanced Tr eadle

Th is t readl e is m ade f rom on e p iece of steel forging - .

T he adv antage of th is con st ruct ion is that it does not b ecom e

“ ”
sh ackly f rom wear an d wh en t he pressu re is put on on e
,

sid e t he opposit e sid e acts simultan eou s ly an d t he m ech an ism ,

on eith er sid e of t he m ach in e do es it s wo rk as it was d esig n ed

to do I n stead of sp rings to hold t he t readl e in a raised posi
.

t ion cou nte rbal ance is p rov id ed wh ich ru n s acro ss t he back

,

of base an d is attached at eith er en d to l evers whose fu lc rum s

are p in e d ri v en in to t he sid es of t he b ase t he S ho rt ends of
-
,

t he l ev ers h av i ng p roj ect ing po in t s extend i ng und ern eath t he

sid es of t he t readle an d hold i ng it i n t he ra ised po sit ion

d esired .

T he i mp rov em ents cl aim ed for t he count erb al anc ing

t readl e are that t he p ressu re requ ired is the sam e at t he start as
 O I
D R P HAMM E RS : T H E R DEV EL PM EN T,
- O ET C . 16 5

at t he fin ish of t he movem ent of t he treadl e an d that t he con ,

st ruct io n is such th at repa irs are not f requ en tly n eed ed as i n ,

t he cases wh ere t he sp ri ngs or pul l ey s an d ch ai n s are u sed .

Comp ou nd l ev er Dev ice fé r Op era ting t he I sfi ing or Head

M echa nism
Th is dev ice was design ed w ith a v iew to l essen the shock
of t he blow g iv en to t he f rict ion bar by t he h amme r when i n
-

operat io n I t con sists of a cl amp on t he frict ion bar hav ing a

.
-
,

p roj ect ion on t he in n er sid e wh ich acts as t he fu lcru m of t he

,

l ev er whose S ho rt en d is a fo rk wh ich engages w ith p in s p ro

,

ct i n g f rom t he l eft h and up right an d who se long en d is

j e ,

actu at ed by a p in i n t he h amm er wh ich p in is pl ac ed as n ear

,

t he ri ght h an d sid e of t he h amm er as is p ract ica bl e i n o rd er to ,

en abl e t he long arm of t he l ev er to be m ad e as g reat a l ength

as po ssibl e ,thereby reduc in g t he speed of t he movem ent

g iv en t o t he f rict ion bar an d inc identally t he shock of t he
-
,

blow .

All th is tends to obv iate t he n ecessity of repairs as it re ,

duces t he tendency of t he f rict ion bar to becom e c rystall ized

-
,

an d it i mparts to all t he f rict io n m ech an ism a mod era t e easy ,

movem en t wh ich is conduc iv e to t he du ra b il ity of th at part

,

of the m ach in e .

Anoth er featu re of th is d ev ice is t he ease w ith wh ich it is

adju st ed for t he d ifferent he ights f rom wh ich the h amm er fal l s .

T h ere is o n ly on e n u t to tu rn an d wh en th is is loosen ed the

,

cl amp is perfectly f ree upon t he bar an d w il l d rop from it s

ow n w eight or ca n be raised w ith on e h and
, Th is on e nut is
.

su fli cien t to hold the cl amp i n pl ac e as the l atter is not su b

,

j e ct ed to t he S h arp blo w as i n the old m ethod .

Jointed Swinghead Constru ction

The m ain id ea of th is const ruct ion is to l essen the expen se
of repairs T he t wo sides of t he h ead are con nected by a
.

h eavy web at t he botto m edges th rough wh ich th ere is a

,

rectangu l ar hol e to accommodate the board T he upper .

halv es of the two sides are fastened to t he main h ead cast ing -
166 D RO P- FORGI N G , D E SI N
I -
KI N G , ET C.

by a h in ge jo int at t he rear an d are p r im arily h eld i n pl ace by

-
,

t he sm a l l sw iv el bolts t he sam e as u sed on a l ath e c en ter rest

,
-
,

an d inc id enta l ly by two of t he h ead bolt s wh ich pass th rough -

t he upp er an d lower parts as well of t he h ead an d th rough

t he top of t he up r ight s .

O n both sid es of t he m ach in e runn ing ho rizontally ,

th rough t he upper part of t he up rights th rough t he web of ,

t he low er p art of t he h ead an d into t he recta ngu l ar hol e i n t he

l atter good stout bolts are u sed wh ich hold t he upper part of
,

t he m ach in e rig idly togeth er an d rel iev e t he h ead bolt s p roper

,
-

THE: OL D WAY .

FI G . 1 70
.
—
T he fi rst i n t erc ha n geabl e bl ac k sm i t h
.

f rom all sh earing st rain an d al so obv iate t he elo n gat ion by

w ear of t he hol es in t he up rights T he eccentrics are m ade .

of steel cast ings wh ich are st ronger an d mo re d u rabl e than

-
,

b ronz e or gu n m etal These are chamb ered an d babb itt l in ed

.
-
,

th is l in ing b ein g easily repl aced wh en wo rn out T he sl id ing .

rear box es for adju st in g t he f rict ion are op erat ed i n t he u su al

way .

Paper Pu lleys

E xperienc e has hown th at iron pu l l eys are not rel iabl e

s

for d rop h amm ers

-
T h ey b ecom e c ry stal l ized an d b reak an d
.
,

som e on e is l ikely to get hu rt Wood pu ll eys w ith iron hubs .

168 D RO O RG I N G ,
P E
-
D I E SI N x I N G ,
- ET C.

are v ery good but t he comp ressed paper pull eys g iv e t he best
,

resu lt s an d sat isfact ion Th ey are l ight as compared w ith

.

their st ren gth are el ast ic an d g iv e excell ent belt su rface

, ,
.

M ethod of Fa stening Boa r d in Ha mmer

An oblong cav ity f rom to

, 4 8 i nch es lo n g an d about 5
i nch es deep by 1 % inch es w ide , is m ach i n ed in t he top of

— B oard fast en in g
FI G . 1 73 . .

t he hamm er That S ide of t he cav ity wh ich is toward t he back

.

of t he hamm er has a bev el of abo u t 1 5 d egrees t he cav ity ,

being s m al l er at t he top th an at t he bottom T he f ront sid e .

of t he cav ity bein g st raight t he rear side of t he l ift ing board

,
-

has a b ev el co rrespond in g to th at i n t he rear sid e of t he cav ity ,

a st eel pl at e pl aced agai n st t he f ront s id e of board an d t wo or

-
,

th ree steel w edges l ightly d riven w ith a h and h amm er between -

t he board a n d t he f ront sid e of t he cav ity At every blow of .

 DR O P H
- I
AM M ERS : T H E R DEV EL PM ENT, ET C O . 169

the hamm er wh en the m ach in e is wo rk ing these wedges be

, ,

com e t ighter an d t he board mo re fi rmly h eld .

Fou nda tions : — Ra tio of Base as Compa red with Weight of

Hammer
Th ere seem s to be a variance of op in ion in regard to t he
p roper fou ndat ion s for a d rop hamm er Several art icl es have
-
.

appeared i n t he t echn ica l jo u rn al s i n regard to sam e Sev era l .

favo r a rig id rockl ike foundat io n an d oth ers favo r an el ast ic

, ,

con st ruct ion I t seem s to m e th at t he we ight of t he base of

.

t he m ach in e as compared to t he w eight

,

of t he blow g iv en by t he h amm er should ,

have mo re or l ess con siderat ion in deter

m in ing t he con st ruct ion O f t he fou n da
t ion I t is apparent that if a m an t ried
.

to do som e hand fo rg ing w ith an o rd inary

-

flat i ro n h eld bottom up b etween his

kn ees for an anv i l t he resu lt wo u ld not
,

be altogether sat isfacto ry but if it were ,

possibl e for him to hold a p iece of iron

weigh in g say 400 pounds on his kn ees
, , ,

he would do mo re ex ecut ion w ith his

hamm er an d in add it ion could stand som e
p retty st ro n g blows from his helper s ’

S l edge . F rom th is illu st ra t ion I argue

FI G 1 7 4 —
B oard
th at if t he b ase of a d rop h amm er cou ld -
fast en in g
. .

be m ad e h eavy enough no fou n dat ion ,

whatev er wo u ld be requ ired T he in ert ia of t he m ass of

.

m etal wo u ld be su fli cien t to ab so rb t he efl ect s of t he sh ock

impart ed by t he blow of t he h amm er .

T he cost an d d iffi cult ies of h a ndl ing however m ake such , ,

an arran gem ent out of t he qu est ion With in t he past years an

.

i nc rease i n t he w eight of t he bases of d rop hamm ers has b een -

a mov e i n t he r ight d irect ion I n d ec id ing th is po int a cer

.
,

tain ra t io between t he weight of t he h amm er p roper an d t he

base is con sidered I n fo rm er years t he ra t io of 6 to 1 was
.

con sidered su fli cien t Th is was inc reased by som e m ach in e

.
1 70 DR O -
P EO RG I N G, DI E S N
-
I KI N G , ET C .

bu ilders to 1 0 to 1 an d now t he most modern p ract ise adv o

,

cates a ra t io of 1 5 to 1 .

T o ret u rn to t he subj ect of found at ion s I would not v en ,

tu re to say wh ich con st ruct ion w i l l g ive the best results ow ing ,

i n a m easu re to t he variati on s of cond it ion s part icul arly t he ,

foundat ions of the earth wh ere t he m ach in e is to be located .

FI G I
. 7S —. D r0 p - ham m er fou n dat i on s .

In fairly h ard g round such as cl ay or wh ere hard pan can

, ,

be reached w ith in fifteen f eet of t he su rfac e t he follow ing con

,

st ru ct ion w il l g iv e sat isfact io n : At t he bottom of t he excava

t ion put in two or th ree feet of b roken ston e an d Portl and
c em ent ; on top of th is pl ace ch estnut t imbe rs on en d These .

t imbers to be sawed on fo u r sid es an d bolted togeth er the ,

sect io n of t he block to be of su ffi c ient size to accommod at e t he

1 72 DR O PFO RGI N G
-
,
-
DI E S I N KI N G ,
ETC
.

m ers wheth er steam h amm ers or d rop hamm ers N umerou s

,
- -
.

exper i m ents h av e b een t r ied w ith both el ast ic or y ield i ng

fou ndat ion s an d w ith those in wh ich eve ry p recaut ion has been
taken to m ake them as sol id as possible T he bu ild ers of t he .

d rop hamm ers qu ite n atu ra l ly hav e experim ented an d accu

-

m u lat ed experience of th eir own i n th is l in e a n d mu st be ,

assum ed to know mo st of wh at is attain abl e on t he subj ect .

0 n
Bol t : t r long

rm I n apnoe a -
om
t hem wi t h cement
when base has been

FI G . 1 77 — D rop - ham m er fou n dat ion s

. .

present herew ith ( Figs 1 7 6 1 7 7 ) a stan dard d ra w ing of

I .
,

a d rop h amm er foundat ion of t he Pra tt 8: Wh itn ey Company

- .

Th ey say : We do not advocate much woodwo rk under th ese

“

hamm ers but would adv ise bu ild ing a foundat ion of concrete
,

or sq u are block of ston e or cast iron b ed ded down to hard ,

 DR O P H
-
I O
AM M ERs : T H E R DEV EL PM EN T, ETC . 173

FI G . 1 78
.
— F ro i
n t V ew o f Am bl er FI G .l 79.
—
Side V iew of
drop ham m er
-
. Am bl er drop ham m er
- .
174 D RO P- PO RG rN G , -
DI E S N I KI N G , ET C .

bottom . T h is is qu ite a d epartu re f rom the u su al way O f

sett ing a hammer , but it has been fou n d to be much better ,

mo re e ffect iv e an d l ess l iabl e to b reak

,

age th an w ith a wood fou ndat ion All .

t he cu sh ion n ec essary w ith th is fou n

dat ion is but on e l ayer of l eath er u h

der t he bed p iece -
Too m u ch at ten
.

t ion cannot be paid to t he fou n dat io n s

of d rop h amm ers I n all cases exca
-
.

v ate to h ard bottom or better st il l , , ,

to rock Th is in fo rmat ion th erefo re

.

seem s to be of l ittl e u se wh ere n eith er

hard bottom n or rock is to be fou n d .

T he d ra w in g shows a fou n dat ion

b u ilt up of hard b r ick O f cou rse .

l arge stone mason ry is m u ch better

-
,

bu t a cast iron box set in to t he g ro u n d

-
,

an d fill ed w ith Po rtl and cemen t is ,

best Sol id sto n e m aso n ry is u sed by

.
-

t he G o rh am Silv er Pl ate Com pan

.

Prov iden c e R I ,
Th ey hav e d rop
. .

hamm ers of po u n d s weight of

ra m work i n g on these fo u ndat ion s .

D r op Ha mmer Efi
- cts

T he M in er 8c Peck M an u fact u r
in g Co mpan y of N ew H av en , Conn ,
, .

have d eterm in ed t he rel at iv e effects

produced by h amm ers of d rops fall in g
f rom d ifferent h eights T h ey show .

t he economy of u si ng h eav ier h a mm ers

— T h dro
w ith sho rt l ifts Th is is i l lu st rated
.

FI G 1 80 p e “
in t he foll ow i n g way : I f you are op
. .

rod .

cra t in g a h amm er of say 1 00 pounds , , ,

at t he sam e h eight you w il l O btai n a resu lt fou r t im es as g reat

w ith an expend it u re of fo u r t im es t he ho rse power ; wh ile if

’

you ra ise you r 1 00 pound h amm e r fou r t imes as h igh you

-
17 6 D RO P FO RGI N G
-
, D I E SI N
-
KI N G ,
ET C .

w ill pen d fo u r t im es t he h orse power i n do ing SO

ex -
T he .

tabl e shows t he t im e co n sum ed t he v el oc ity an d t he dyn am ic

, ,

effect ( exp ressed i n pou n d s of stat ic p ressu re) p rod u c ed by a

sol id body w eigh in g o n e po u nd fal l ing

f reely f rom rest by t he fo rce of grav ity .

The Ambler D r op - Ha mmer

T he du rance
en d rop h amm er
of -

d ies an d the qu al ity O f t he wo rk t u r n ed

ou t by th em d epen d very much of
co u rse u po n t he hamm er w ith wh ich
th e wo rk is don e \V e i ll u st rate h ere
.

w ith a h amm er d esign ed by A A . .

Ambl er who for m an y y ears m ad e a

,

spec ialty o f d rop h amm er wo rk -

in
co n n ect io n w ith vario u s m an u factu rin g
co n c ern s an d is n ow su perin ten den t
,

o f t he F0 0 3 M an u factu r in g Company ,

O f Sp r in gfi eld O h io , b u ild ers of t he

,

h amm er T he c u ts show on e O f t he
.

h amm ers as u sed in t he sm ith shop -

of t he compan y T he v iews in F igs

. .

1 7 8 an d 1 7 9 are m ad e f rom d ra w ings .

I t w ill h ere be seen th at t he m eth od of

fasten ing t he ho u sin gs t o t he anv il
block is u n u su al two bolts passing ,
FI G 1 83 C o st r
n uc
th ro u gh each at a n angl e as shown
. .

t io n d t il
e a s
.
,

th ese ten din g n ot on ly t o k eep t he

hou s i n gs fi rml y seat ed with in t he rec ess i n t he block bu t al so ,

fi rm ly again st t he adj u st in g sc rews by m ean s of wh ich t he

g u id e s ar e adj u st ed to p rop er po sit io n I t w. i l l be not ic e d
t hat there are locks for these sc rews th at p rev en t them b ein g
d istu rb ed by t he shock T h is is show n m ore fu lly at F igs
. .

1 8 1 a n d 1 82 . At t he t op t he ho u s in gs are attached to t he
c rossp iece by th rou g h bo lts an d are seat ed t o wh at really
,

co n st it u t es a d o v et a i l ; l oc k i n g a ll t o get he r v er y fi rml y t he ,

su rfaces are abo u t 1 8 i nch es w id e an d t he bolt s h av e el ast ic

 D RO P H
- AM M E Rs z T H E IR V
D E EL O PM EN T , ET C
. 177

wash ers u n d er t he nut an d h eads T h is is al so shown in .

Figs 1 81 an d 1 82
. .

T he d rop rod C ( show n separately i n Fig 1 80) is jo int ed

- .

an d op erat es t he eccent ric po sit iv ely as it is alway s k ept v er

,

t ical D is t he automat ic tr ip rod w ith a steel l atch E keyed

.
-

to it an d t ripp i ng dog F adju st ing col l ar G and to rs io n al

,

sp ri ng H ,by wh ich it is seen that when the hamm er head -

d rops t he wedge shaped port ion I engages w ith t he dog F

-
,

t u rn ing t he t r ip rod an d l atch su ffi c iently to rel ease t he d rop

-

rod SO it ca n fall By m ean s of t he to rsion al sp ring H t he

.

t rip rod D is m ad e v ery flex ibl e an d sen sit ive at t he t op an d

-
,

by m ea ns of t he v er n ier spac in g of t he hol es in t he adju st ing

FI G . 1 84 —. Con stru c t ion det a i l s .

coll ar G almost an y flexu re of t he t rip rod R is O btain ed

,
-
.

T he t r ipp i ng dog F is adju stabl e v ert ica l ly on t he t rip to be

mad e at t he most advantageou s po ints whethe r t he d ies in u se ,

are h igh or low .

Th ere is al so an imp roved c u sh io n bumper for t he d rop -

rod wh ich has p rov en by ext en siv e t ests to g iv e a posit iv e but

easy act ion to t he rod ent irely avo id ing l ev ers an d si m i l ar

,

compl icat ions T h is const ruct ion requ ires no mo re attent ion
.

i n ch ang ing f rom a h igh to a low st roke th an if t he bu mp er

were mad e of sol id steel block -
.

I t is recogn iz ed that in all fr ict ion rol l h amme rs perfect -

,

cont rol of t he act ion of the h amm er can be O btain ed th ro u gh

t he l ift i n g board only wh en it is ent irely f ree f rom fo reign
,
 D RO P PO RGI N G ,
DIE S N
-
I KI N G , ET C .

s ubstances esp ec ially oil I n recogn it ion of th is fact t he

, .

h amm er u n d er co n s iderat io n is p rov ided w ith a Spec ial d ev ice

for avo id ing t roubl e f rom th is sou rc e T he b ear i n gs a ll h ave
.

ch ambers hold in g t he o il in ch eck unt il requ ired for lub rica

t ion an d in case an y O f it sho u ld escape it is fo rc ed to t he
,

en d O f t he roll an d by t he cent rifuga l fo rce to the cav ity

,

packed w ith wool or oth er abso rben t material an d th ere re

rain ed thu s p rev ent i ng it f rom ev er reach in g t he wo rk ing
,

su rface of t he rol l or g ett i ng on to t he bo ard A po rt ion of .

t he t ro u bl e w ith t he h amm er board s is fo u n d to resu lt f rom

-

t he fact th at th ey are su bj ected to an exc ess of h eat upon on e

S id e th is h eat com in g f rom ,

t he f u rn ac e I n th is ham .

m er t he board is so key ed
i n to t he h amm er p rop er th at
it ca n be rev ersed sid e by ,

s id e a n d en d for en d thu s ,

eq u a l iz in g a ll c o n d it io n s an d

wear .

T h ese h amm ers are a ll

d esign ed up on a g en era l ra
FI G 1 85 —
Met hod of s c r i g e u n
t io of 1 5 to 1 w ith ref erenc e
. .

ham m er heads - .

to t he weight of an v il an d
h amm er h ead -
I n serv ice t he requ irem en ts d em an ded of
.

th ese h amm ers h av e been espec ially sev ere an d exact in g .

For i n stan c e in t he Sp r in gfi eld wo rks of t he I nt er n at ion al

,

H arv ester Compan y wh ere ha mm ers are u sed pl ac ed w ith in

,

a n inch of t he n at u ra l bed rock th ey hav e retain ed th eir

-
,

adju stm e n t s sat isfacto r ily .

Secu r ing Ha mm er - Hea ds

F ig 1 85 i llu st ra t es a m ethod for secu ring h amm er h ead s
.
-

to p iston rods A sm al l spac e l eft b elow t he bottom of t he

-
.

rod a llows t he t aper po rt ion inch t o 1 foot l ength O f taper

equ al t o tw ic e t he d iam et er of rod ) to d r iv e in to t he ra m g ood

an d sol id T he p in is for t he p u rpo se of ra isin g t he ra m du r

.

in g t he fi rst st roke or two of t he h amm er When t he p ist on .

1 80 O P FO RGI G
DR - N , I - I KI N G
D E S N , ET C
.

1 87 .
—
D rop - ham m er for heav y w ork .
 D RO P HA
- M M E Rs : T H EI R O
D EV EL PM EN T, ET C .

good sat isfact ion an d se rv ice b esides sav ing a lot of t im e an d

,

work in m ak i ng t he d ies .

As ou r wo r k was steel we u sed on the l arger siz es of wo rk

,

a sm a ll bl ast to blow t he sca l e off t he d ies i n st ead of u si ng ,

water O n t he sm al l siz es we did not u se anyth ing as gen er

.
,

ally t he sca l e did not g iv e much t rouble These d ies were .

m ade of blocks that we got about t he right sizes from t he

ste el m akers
- The re were about twenty d ifferen t sizes T he
. .

d ies had to be d ressed over about once a month an d m ak ing ,

new on es an d keep ing t he old ones in repair was about as

mu ch as on e m an wanted to do .

I mp rov ed a nd Up -to-Da te D rop-Hammer

M odern m anufact u ring d em ands h eav ier wo rk in de all

t m en t s an d t he fo rg i ng pl ant has in m any cases outgrown

-
p ar ,

t he l ight er h amme r of a few y ears ago To m eet n ew cond i .

t ion s an d as a resu lt of experience in it s own pl ant t he

, ,

Bil l ings 81 Spenc er Compan y of H artfo rd Con n now, , .

,

bu ild a n ew drop hamm er known as mod el C an d shown in

-
,

Fig 1 87
. .

An i mp roved bo d cl amp catch p is employ ed wh ich

ar - -u
,

does away w ith t he l atch an d conn ect ion at t he side for hold
in g up t he ram T he board cl amp is O f an ent irely n ew
.

design an d is located at t he extrem e top of t he m ach in e abov e

,

t he f ri ct ion roll s or l ift i ng d ev ic e

-
Th is m akes it impossibl e
.

for oil to get b etween t he cl amp s an d board wh ich has h ere ,

tofo re been t he cau se of much inconv en ience where t he board

cl amps h av e been u sed Posit iv e act ion is assu red i n t he
.

cl amps by t he ope ra t io n of cam s or eccentrics control l ed by a

foot leVer attach ed to the base of t he m ach ine .

Anoth er featu re is a n ovel adj u stm ent of the rear frict ion
rol l by m ean s of an ecc ent ric a dupl icat e of th at u sed i n,

en gag i ng t he f ront f rict ion ro ll t he two roll s-

w ith their
, ,

eccen t rics b eing i nterch an geabl e By th is m ean s of adj u st .

m ent a t ru e al ignment between t he li ft ing board an d ro ll s is -

a lway s p reserv ed .
1 82 DR O -
P EO RG I N G, D I E-S I N x I N G, ET C.

A fo rm of b ronze bu sh ing is in t roduced on the eccen

n ew

t ric bearings wh ich is easil y an d qu ickly remov ed an d re

,

pl aced T he sam e eccentric adju stm ent is al so employ ed on

.

t he rear bo ard cl amp -

Th ese adju stm ents O f the rear f rict ion
.

roll an d rear board cl amp are m ade by m ean s of bars at tach ed

-

to t he eccentrics an d ru nn ing down para l l el to the u p right to

w ith in easy reach of the operato r on t he floo r An improved .

m ethod is al so employed in attach ing t he head to t he u p

right .

T he up rights u sed on t he new mod el are espec ial ly de

s ign ed to red u c e t he l iab i l ity of b reakag e the d ist ri but ion of
,

m eta l be ing such as t o affo rd ~the m ax imu m st rength T he .

c ross sect ion of t he uprights is that of a l etter V t he apex

-
,

fo rm i ng t he gu ide for t he ram w ith a long itud inal r ib runn ing

it s ent ire l ength to add st rength An impo rtant f eatu re in
.

t he con st ruct ion of th is m ach in e l ies i n t he fact th at the u p

r ight s rem ain sol id th ro u ghout th eir l ength s no weak en ing ,

perfo rat io n s b ei ng necessary in t he pl ac ing of attachm ents .

An imp roved adju stm ent for t he up rights is employ ed at t he

j u n ct ion of t he base an d up rights .

T he rel easing l ev er attach ed to t he outsid e of t he l eft

hand up right has an imp rov ed adju stm ent Th is adj u st m ent .

is i n t he fo rm of a mod ifi ed ra ck i nterv al s of 1 % inch es ,

al low i ng the ra m to be rel eased at an y d esired h eight .

Capa city f
o Steam Hammers
- a nd Size f
o Worh

For m ak ing an occasion al fo rg ing of a g ive n size a ,

s m al le r h amm er m ay be u sed th an if we were m an u fact u r

in g th is sam e p iece in l arg e qu ant it ies I f we h ave a six inch.

-

p iec e to fo rge such as a p in ion or a sho rt shaft a h ammer of

, ,

about pounds capac ity wou ld an swer very n icely Bu t .

should t he gen era l wo r k be as l arg e as th is it wou ld be ve ry ,

much bett er to u se a pound h am m er I f on t he oth er

-
.
,

h and we w ish to fo rge Six inch axl es econom ica l ly it wou ld

,
-
,

be n ecessary to u se a or pound h amm er T he fol .

low ing table w il l be found conven ient for reference for the
 O
D R P EO RG I N G,
- -
DIE S I N KI N G , ETC .

Ru les fi r F inding t he Capa city of Stea m Ha mmers, - a nd t he

H orse Power Requir ed j br Op er ation

Ical l at tent ion t o som e s impl e rule g d ing steam ham s re ar -

m er p ra ct ise wh ich m ay be of v alue to som e of my read ers

,
.

T he fi rst O f th ese ru l es g iv es the ho rse power requ ired to ru n -

a h amm er of an y siz e an d m ay be exp ressed as fol lows :

,

D i v ide t he ra ted cap acity o f ha mmt he

er , in p ou nds, by 1 00, a n d
the qu otient will be the horsepower required t o run t he hammer
-

Th is rul e is al so appl icabl e in cases where t he h amm er is

not ru n con stantly by est im at ing t he amou nt of t ime t he
,

hamm er is idl e each hou r an d m ak ing allowance th erefor .

Bu t it w i l l be n oted th at in case t he hamm er is not ru n con

st an t ly or n ear ly so an d t he ho rse power is co rrespond i ngly
, ,
-

reduced su fli cien t stea m sto ra ge space mu st be p rov id ed in

,
-

t he bo i l er to p revent t he steam p ressu re being d rawn down -

much faster th an it is m ad e du ring the wo rk ing period .

T he second ru l e d eal s w ith the est im ate of t he p rope r size

of h amm er to be u sed in wo rk in g iron an d steel O f an y de
sired c ro ss sect ion a l area
-
T he ru l e is as fol lows :
.

M u ltiply t he gr eat est cr ss section

o -
desired to be w or ked in the
ha mmer by 80, if of st eel, or , 6 0, if o f i r on ,
a nd t he r odu ct will
p
be t he r a ted v a lu e of the ha mmer requir ed in p oun ds .

Th is ru l e w il l g iv e a h amm er for saf ely wo rk ing

material
of t he S iz e sp ec ifi ed at on e h eat N o doubt m any of my
, .

read ers are do ing wh at we f requ ently do th at is wo r k b i ll ets , ,

wh ich exceed in Siz e th at wh ic h would be al lowabl e if the rul e ,

was a lway s fol low ed .

D ev elopment
f o Steam D r op -Ha mmers

Witho u t raisin g t he qu est ion of who was t he p ion eer in

steam d rop h amm ers M r
-
F B M il es who l ater becam e a
, . . .
,

m ember of t he fi rm O f Bem en t M il es 8: CO d esign ed in , .

,

1 87 2 wh at seem s to be t he fi rst steam d rop h amm er m ade by -

his company an d wh ich was sold to t he Ba ldw i n L ocomot ive

,
 DRO P H AM M E Rs z
- IR
TH E O
D EV EL PMEN T, ET C . 1 85

Works . Since that t im e th is cl ass of m ach in ery has grown to

be a l arg acto r in t he p roduct of Bem ent M i les 8c Co n ow
e
f
,

the N i l es Bem ent Pond Company

- - .

Since t he fi rst h amm ers were m ade by M r M i l es th ere .

,

has b een l ittl e ch ange in t he i m po rtant po ints O f con struct ion ,

such mod ificat ion s as h av e b een m ad e be ing si mply aug m enta

t ion w ith t he v ital or wo rk ing parts as he conceived th em

,
.

As a p roof of t he good design M r M il es p roduced I hav e to

.
,

po int out that most if not all steam h amm ers m anufactu red
, ,
-

in th is count ry to day are con st ructed on t he same l in es an d

-
,

t he i l lu st ra t ion s of th em po i nt very st rongly to d irect cop ies

“
of wh at has becom e known th roughout t he t ra d e as Bem ent
”
hammers wh ich shows a growth of t he same m echan ism p ro
,

du ced ov er th irt y y ears ago by p ract ical ly the sam e com pany ,

an d w ith no rad ica l d iff erences in p ri nc iples .

 CH APT E R V I

ST EEL AN D O
IR N: T WI S I I N G,
’ ‘
R ED U CI N G AN D FO RGI N G
, .

T REAT M EN T FO R WO RKI N G I N M ACH I N E FORGI N G

Action of Steel a nd I ron Under D rf er en t Degr ees f
o Heat

A years ago som e o rn am ental fo rg ings were bei ng

FEW

m ad e by stu dents in t he bl acksm ith shop of t he Al abam a -

Polytechn ic I n st itute T he desig n s i nclud ed som e p ieces of

.

i nch sq u are wh ich w ere to be tw isted an d t he stud ents

, ,

were h av ing d iffi cu lty in gett ing a u n ifo rm p itch to t he tw ist .

T he iron wou ld be h eat ed for sev era l inch es cl amp ed in a ,

v ise an d tw isted w ith a pair of to n gs As would n at u rally

,
.

occu r the p iece of iron was cl amped in t he v ise an d cl asped

,

by t he tongs near t he end s of t he hot part wh ere t he h eat

m erged from red to bl ack I n almost ev ery case when the .

tw ist wou ld be made it wou ld appear greater at t he ends near

t he v ise an d tongs .

The fi rst conclu sion was that t he fasten i ngs m u st exert

som e influ enc e to p roduc e t he e ffect A p iec e was t ried w ith.

t he fast en i ngs attach ed d i rectly to t he b r ight p art s I n th is .

case t he tw ist cam e out v ery u n ifo rm A lo n g p iece was then .

h eated in t he m iddl e an d cl amped at t he ends wh ere t he irons

were cold O n m ak in g t he tw ist t he sam e effect was obse rved
.

as at fi rst t he g reat er tw ist occ u rr in g i n t he d ark red h eat

,
-
.

Sampl es O f inch rou n d iro n w ere th en t r ied to see if the

-

fo rm O f cross sect ion had an y influ en ce SO far as could be Ob

- .

serv ed t he c fl ect was t he sam e as t he squ are iron

,
T he fo rge .

i n wh ich t he spec im en s w ere h eat ed was tho roughly cl ean ed

an d sampl es of inch rou nd i ron w ere th en t r ied to see if
-

t he fo r m O f c ro ss sect ion had an y i nflu enc e

- So far as could .

be ob serv ed t he effect was t he sam e as t he squ are iron

,
T he .

fo rge in wh ich t he spec im en s were h eated was tho roughly

1 86
1 88 DR O P FO RGI N G
-
,
I KI N G
D I E-S N , ET C .

t l
s ee , a m ed iu m g ra de of Am er ican tool steel m ach in ery -
,

steel , N o rway iron ch arcoal iron an d common or ston e coal

, ,
-

I ron .

T he fo rge for h eat ing t he spec im ens was fixed w ith fi re

b rick to l im it t he l en gth of t he heat on each spec im en an d
al so to i n su re a u n ifo r m l en gth for al l Spec ial care was taken .

to keep t he fi re cl ean an d in good cond it ion A good g rade .

of bl acksm ith coal was u sed T he apparatu s for tw ist ing con
-
.

sisted of a l ath e fitt ed w ith a v ise an d an ext ra sp i ndl e w ith a

l arge sock et in on e en d an d a c ra nk fitted on t he oth er After .

t he sp ec im en had b een h eat ed on e en d was put in t he socket ,

FI G . 1 88 — Sam p l es of J
essop st ee l .

an d t he oth er en d fasten ed in t he V ise in l in e w ith t he sp indl e .

A few tu rn s on t he c ra n k would do t he wo rk .

As m all t est i n g m a ch i n e w a s u sed f or m a k i n g t h e t en s ion

tests After a l ittl e p ra ct ise t he boy s w ere abl e to put t he
.

p
s e c i m e n i n t h e cl amp s a n d p u ll it o u t to b re a k i ng b efo re an
y
m ark ed ch ange of t he colo r du e to cool in g could be observed .

N O c fl o rt w a s m a d e to m e a s u re t h e pull e x er t e d by t h e m a ch i n e .

F or t h e b e nd i n g t es t s a s l id
,
i n g block op -e ra t e d , by a l ev e r ,

was m ad e to p re ss o n o n e e n d t h e oth ,
er e n d b e i n g s uppo r ted
by a fixed block T he spec im en s for th is test had t he end s
.

m ade h em isph erical .

I n an oth er t est a sm all h amm er h ead was fitt ed w ith a -

pu n ch g rou nd to an angl e of 6 0 deg rees an d attach ed to a long

 ST EEL AN D I RO N : THE IR T R EATM EN T , ET C .

h andl e p ivoted at t he en d Arrangem en ts were m ade to fix

.

t he d istanc e th rough wh ich t he h amm er was al low ed to d rop .

T he spec im en was h eated as i n t he oth er t ests ; l aid on t he

,

anv i l und er t he pu n ch an d t he l att er ra ised an d d ropped

.
,

rap idly as t he spec im en was mov ed a lo n g m ak i ng t he m arks ,

about h alf an i n ch apart .

T he sp ec im en s w ere cut f rom t he bar an d w ere m ad e of

‘

conv en ient l ength for t he difl eren t tests For t he tw ist ing .

tests th ey were about 1 2 i n ch es lo n g an d th ree p ieces of each

k i nd of m eta l were t ried T he il lu strat io n s Show t he resu lts
.

v ery cl early ( Figs 1 88 to . T he h igh carbon steel shows

FI G . 1 89
.
— Sam p les of ordi n ary Am er ic an l
t oo -st ee l .

t he greatest tw ist at t he po int of h igh est temperatu re T he .

m ach in ery steel gav e ind efin ite results O n e spec im en seem ed
-
.

weaker in t he hottest part anot h er tw ist most at t he red heat

, ,

an d t he th ird seem ed to h av e two or th ree w eak po in t s .

T he spec im en s O f w ro u ght iro n gav e u n m istakabl e ev i

de n ce O f b ein g weak er at t he red h eat a n d t he pu rer t he iro n ,

t he mo re m ar k ed t he efl ect T he N o rway iro n seem ed to

.

tw ist all at on e pl ace in t he dark red h eat t he part at the -

,

wh ite h eat show in g v ery l ittl e tw ist T he ch arcoal an d com .

mon iro n s showed l ess difl eren ce in st ren gth b etween t he

two temperatu res thoug h t he d ifferenc es are st il l v ery ev i
,

d en t
T he ten sio n spec im en s show sim il ar bu t if po ssibl e mo re , ,
 D RO P-FO RGI N G , DI E-
S N I KI N G , ET C .

u n ifo r m results T he h igh carbon steel s S how t he redu ced

.

cross sect ion at t he po in t of t he h igh est tempera t u re wh il e t he

-
,

m ach in ery tool an d t he difl eren t g rades of iro n h av e t he po in t s

, ,

of reduced c ross sect io n on e on each sid e of t he wh ite hot part

-
,
-
.

A numb er of th ese spec im en s pul l ed apart w ith v ery much l ess

reduct ion of area th an t he m ater ial wou ld h av e shown if t ested

in t he o rd in ary way an d at t he u su al t emp era t u re ;

T he b end ing t ests w ere v ery i nconclu siv e Som et im es t he .

b end wou ld occu r at t he wh ite hot part an d som et im es in on e

-

of t he red parts but n ev er in a way to g iv e defin ite info rm a

,

t ion eith er to co rrobo rate or co n t rad ict th at O btain ed f rom t he

.

FI G . 1 90 — Sam p l es of m ac hi n ery st ee l .

preced in g tests T he spec im en s shown in t he i ll u st rat ion were

.

bent w ith tongs over t he ho r n of an an v il i n t he m an n er su g

gested by M r Spau ld ing i n t he art icl e p rev iou s ly referred to
. .

T he punch i ng t ests cou ld be seen by t he eye to co rrobo rate

t he tw ist in g an d ten sion t est s but t he m arks were too sm all
-
,

to S how in photograph an d were u n sat isfacto ry to m easu re

,

for tabul at ion .

Fu el Used in Tests

A c arefu l n alysis of t he coal u sed in th ese tests showed

a

l ess th an on e h alf of on e per cent of sulfu r Care was taken

-
. .

to keep t he fi re cl ea n an d a su fli cien t th ickn ess of bed was

carried to in su re th at t he m etal would not be st ruck by cu r
1 92 DR O P- FO RG I N G, -
D E S N
I I KI N G , ETC .

Pr actica l Resu lts

f o Exp eri ments

F ig 1 88 rep resen t s th ree sampl es O f J essop st eel

. The .

m iddl e on e was tw ist ed mo re th an twenty revolut ion s an d did

not b reak .

F ig 1 89 rep resents o rd in ary Am erican tool steel

.
-
.

F ig 1 90 rep resents sampl es of m ach i n ery st eel

. O ne .

seem ed to tw ist mo st i n t he hottest p art on e most i n t he cool ,

est p arts an d t he th ird or m iddl e spec im en tw ist ed v ery

,

irregu lar lv .

FI G . 1 92 —
Sam p l es of st on e- oa l c i ron .

Fig 1 9 1 rep resents sampl es of a good g ra de of ch arcoal

.

iron I t w i l l be noted th at two of th ese b roke O ff at t he dark

.

red part of h eat t he .

F ig 1 92 rep resents spec im en s of common or ston e coal

.
-

iron . T wo of th ese are f ractu red but not ent irely b roken O ff ,

in t he dar k red part of t he h eat

-
.

F ig 1 93 rep resent s sp ec im en s of N o rway iron Th ese were

. .

t he fi rst sp ec im en s t ried an d th ere was a sl ight irregu l arity in

,

t he l ength of t he h eat ed part Al so on e of t he spec im en s

.

cool ed dow n to a red h eat befo re b eing tw isted an d it sh ows a ,

v ery u n ifo rm p itch .

F ig 1 94 rep resents t he resu lt s of t he t en sion tests

. Be - .

g in n ing at t he l eft th ere is J essop steel Am erican tool ,

steel m ach in ery steel ch arco al iron an d N o rway iron

, ,
T he ,
.
 STEEL AN D I RO N : T HE IR T R EAT M EN T , ET C . 1 93

m ach i n ery s ee t l ll t he ten sion

in a - tests show ed t he sa m e char
act erist ic as t he w rought iron .

F ig 1 9 5 rep resents t wo sampl es of w rought iron an d one

.

O f t he m ach i n ery st eel T h ese w ere bent ov er t he ho r n O f an

.

anv i l w ith tongs T he m ach i n ery steel in th is case fai l s to

.

S how t he ch aract erist ic s ref erred to u nd er F ig 1 94 . .

Working St ock in Dr op Dies -

A considera bl e part of xpen se incu rred in t he pro

t he e
duct ion O f d rop -fo rg in gs is t he cost of t he d ies in wh ich t he
work is shaped T he p ropo rt ion wh ich th is expense bears to
.
“

FI G 1 9 3 .
—
Sam p l es of N orway iron .

t he cost of a cert ain n u mber of fo rg ings depen ds u pon t he

du rab il ity of t he d ies Wh en t he m ak ing of t he fo rg ings is a
.

perm an ent bu si n ess an d th ey are in con stant d em and in such

n umb ers as to requ ire t he re n ew al O f t he d ies f rom i to
tm e .

t im e t he p ropo rt io n ate cost of m ain ten ance of t he d ies in good

cond it ion is som et im es in sign ificant an d som et im es impo rta nt .

T h ere are c ircum stanc es under wh ich t he cost of d ies mu st

be not ic ed . I t is O ften exped ient to m ake d rop fo rg ings in -

order to O btain t he advantage of t he un ifo rm ity wh ich t he d ies

g iv e th em although t he number of fo rg ings requ ired m ay be
,

so sm al l th at t he d ies n eed n ot be much wo r n wh en t he ent ire

amou n t O f fo rg ings has been m ad e but i n t his i n stanc e as i n , ,

ev er y oth er it is for obv iou s reason s v ery d esirabl e to have

,
 D RO P F0 RGI N G ,
-
DI E S I N KI N G , ET C.

t he d ies retain th eir o rig in al perf ect ion s so far as po ssibl e I n .

such cases t he co st of t he d ies is a l arg e f acto r i n t he co st of

t he wo r k . I t is b est to keep th em for th ere is alway s a pos

,

sibil it y th at th ey m ay be n eed ed aga i n .

Fa cilities f or Repr odu ction o f D rop Dies -

Wh en it b ecom es ev id ent th at a l arge n mb er of p ieces have u

to be m ad e , an d th at t he tool s for m ak in g th em w ill qu ire

re

FIG . 1 94 — Resu l t s of t e n si o n t est s .

frequ en t ren ewal it becom es a m atter O f eco n omy to p rov id e

,

reaso n abl e fac i l it ies for t he rep rod u ct ion of th ese tool s an d al so ,

to fix t he m ethods wh ich shou ld be adapted for t he u se O f t he

tool s so as to in su re th eir utmost effect iv en ess an d du ra b il ity ,

an d rest r ict w ith in t he n ar row est l i m its t he expen ses of p rofi t

l ess m an u factu re O n d rop work for in stan c e it is to be

.
-
, ,

determ in ed what siz ed d rop sh all be u sed an d how m an y ,

blows sh all be st ruck at each operat ion D rop d ies th erefo re .

-

com e wel l w ith in t he scope of t he ru l e T h ey are qu ite ex .

en siv e in bot h m at erial an d wo rkm an sh ip a n d are oft en su b

p ,
1 96 D RO P PO RGI N G
-
, D I E-e x I N G, ET C .

th eir tempe r ; but it is qu ite a difl eren t th ing wh en t he hot

iron has al ready been st ruck w ith such fo rc e as to b r ing it into
mo re int im ate contact w ith t he steel of t he die th an it s own
grain s h av e w ith each oth er for t he steel has t he heat abso
,

l u t ely fo rc ed into it wh en an add it ion al blow is g iv en I f th is .

w il l not d ra w t he temper noth ing w i l l an d if t he co rn er of t he

, ,

imp ression is al ready almost red hot th en t he add it io nal blow

-
, ,

d riv ing down on almost cold fin w i ll d riv e down t he co rn er

, ,

an d m ak e it ov er h ang an d hug t he wo rk so th at it w i ll be h ard

to d isen gage if f rom t he die T h en t he good hamm er m an

.
-
,

if he is not unm in dfu l of t he futu re w ill hav e t he die fix ed ,

efo re it get s an y wo rse; but if his temper r ises w ith th at of

b
t he die unt il his wo rk st icks so bad th at in r emov in g it it , ,

gets ou t of shape so m uch as to dam age it th en he w il l h av e ,

t he die repaired .

A drop m an says it is mo re exaspera t ing to have t he wo rk

st ick in t he upp er die th an in t he low er on e esp ec ially i f t he ,

d rop is wo rk in g on a h igh stroke H is wo rk is pu ll ed off his

.

g rasp in sp ite of his most en erget ic efl ort s to r etain it H e .

rel ates th at he was amu sed a sho rt t i m e ago to h ear a fellow ,

who was thu s both ered vent his feel in gs by excl aim in g to his
,

bew itch ed Wo rk as it went upward O h you re go ing to be

“
, ,
’

”
an angel ai n t ye St ick in g i n t he u p pe r die is SO t roubl e
’
?
,

som e th at it is gen era l ly rel iev ed as soon as po ssibl e .

The D ies a nd t he D r op

As gen eral rul e it is better for t he d ies to h av e t he blow

a

O f t he d rop st ruck on t he hot m ater ial w ith fo rce enough to

fill th em at t he fi rst st roke w ithout al low ing it to rem ain in

th em for a repet it ion O f t he blow T h is would often requ ire
.

a h eav ier d rop h amm er th an is av ai l abl e

-
T h ere are som e .

O bj ect ion s i n u si n g h eavy d rops among wh ich t he v ery ,

palpabl e on e of fi rst cost is gen era lly effectu al .

T h ere is anoth er wh ich d em and s con sid era t io n an d th at is ,

t he efl ect wh ich t he sudd en appl icat io n of pow er to ra ise a

h eavy weight has upon t he sh aft in g an d carries back in som e
m easu re toward t he p rim e moto r d iffu sing itself an d be i ng
,
 STEEL AN D I RO N : I
T H E R T REAT M EN T, ET C . 1 97

b o bed partly among t he revolv ing pu l l eys an d shafts an d

a s r , ,

ru nn i ng belts unt i l it s l ast v ib rat ion is taken up by t he fly

wh eel .

T he re are som e oth er O bj ect ion s al so an d it th erefo re be ,

com es a qu est ion wh eth er it is better when all th ings are taken ,

into con sid era t ion to d rop h eavy enough to m ake t he p iece
,

at on e blow or st r ik e it t wo or mo re
, .

I n th is con sid erat ion t he fact mu st not be negl ect ed th at

wh eth er a h eavy d rop is l ifted on e foot to st rike a l ight blow ,

or fi v e f eet to st r ike a heavy blow the appl icat ion of pow er, ,

requ ired to g iv e it it s fi rs t i mpu l se u pward is as g reat in on e ,

case as in t he oth er an d th erefo re t he effect of shock upon t he

,

mot ive po wer an d it s appl iances is l ess wh en l ight blows are

st ruck w ith l ight d rops th an whe n l ight blow s are stru ck w ith

h eavy d rops .

Leav ing out of t he qu est ion , howev er, ev eryth ing bu t the
espec ial economy of t he d ies, it is b ett er to fin ish at on e blow

all t he wo rk t he d ies h av e to perfo rm at each i n sert ion of t he

hot p iec e T he d ies w il l l ast longer wh en thu s t reated an d

.
,

t he co r n ers of t he i mp ression s w i ll retai n th eir o ri g in a l fo rm

longer th an wh en t he p ieces are subm itted to mo re blows
befo re remov ing them f rom t he d ies .

T he effect u pon t he wo rk of st ri k ing on e blow or mo re is

’

a d ifferent qu est ion f rom th at re l at i ng to t he eff ect u pon

t he d ies an d to th is quest ion it mu st be repl ied th at in a

,

m ajo rity of in stances the stock is better by being St ruck mo re

than on e blow Act ion an d react ion are equ al howev er much
.
,

t he attacked m ay ret ire b efo re t he advanc e T he fall ing die .

del ivers it s fo rce an d t he stock is driv en into every recess

,

open to it but th ere is react ion enough to stop t he blow

, ,

an d resil iency st i l l in t he st ruck m ass ev en if it has ,

been st ra in ed beyond t he bo u nd s of compl ete recov ery an d ,

—
in stantly b efo re t he w eight is l ifted t he part icl es h av e re
cov ered to som e extent th eir lost posit ion s or hav e mov ed ,

back toward th em an d th is repu l sion l eav es th em w ith an

1 98 D RO PFO RGI N G
-
,
-
DIE e x I N G, ETC .

open g rain an d it is only by st rik ing th em blow after blow

, , ,

th at t he part icl es can be p ressed into a close un ion wh ich th ey

w il l retain each blow l eav ing th em n earer unt il t he stock is
,

got into th at cond it ion when t he fo rce of t he blow no longer

st rai n s them b eyond t he l im it of el ast ic recov ery .

Pra cti ca l Efi
f Working I r on ct o

“
Th is is t he p ra ct ica l effect of wo rk ing iron an d it s ,

ben efits are mo re or l ess d ispl ay ed on d rop fo rg ing in p ropo r -

t ion to t he number of blows wh ich are affected up to t he

po int of full effi c iency A greater blow than on e th at is
.

effi c ient p rod u c es no mo re u sefu l eff ect th an on e wh ich is

sim ply su ffi c ient A number of d istu rbances from wh ich t he

.
,

fo rg in gs recov er in d ifferen t degrees is n ecessary to produce ,

close textu re an d t he g reatest amount of cohesion ; in sho rt ,

t he best m ate r ia l .

Efi ct of D rops on St ock

Pract ically l ittl e r egard is paid , as th ings go in shops wh ere

d rops are u sed, to t he effect wh ich t he work ing of t he drops
has u po n t he stock I n t he old en t im e, wh en t he bl ack
.

sm ith s so u l was in his wo r k t he art of wo rk in g upon t he anv i l

’

was not ga ged by t he amount of wo rk th rown upon t he floo r ,

bu t som ewh at, al so , by t he q u al it ies w hich t he m ann er in

wo rk in g t he m aterial conferred u pon it T h is is l ittl e con .

s idered now for t he reason th at , as it is o rd i n ar ily wo rk ed

, ,

t he m ater ia l is ab u n d antly good for all pu rpo ses for wh ich it

is u sed . I f upon t rial on e b ra nd of stock is found to be

defect iv e wh en wo rked in a cert ain m ann er t he wo rk ing ,

p ract ise is not ch an ged , bu t another b rand of stock is secu red

wh ich w il l y ield good res ults wh en wo rked in the m ann er
adopted .

Working in D r op an d Bending M a chin e

-

T he i nc reasi n g mploym en t of ben d ing m ach in es has ex

e -

tended an d rend ered mo re imperat iv e t he n ecessity of secu r

i n g stock wh ich w i ll stan d t he p ecul iar u sage to wh ich it is
2 00 D RO P- F O RGI N G ,
-
D I E SI N x I N G, ET C.

p iece an d the die wh ich affords t he b ridge for the qu ic k

,

passage of t he h eat to t he edges O f t he impression wh ich it ,

soften s an d m akes su sc ept i bl e to i nju ry I t does not requ ire .

a w id e separat ion to greatly weak en the conduct i n g capac ity

of actu al co n tact .

Wh en it is found th at t he d rop fo rg ings do not have the -

st ren gt h wh ich th ey w ere c alcu l ated to possess som e rev ision ,

S hou ld be mad e of t he p roc esses an d such co rrect ion s appl ied,

as m ay h av e a favo rabl e effect I f t he d ies are p roperly d ev ised

.

an d t he wo r k is carefully m an ipu l at ed t he m aterial i n t he ,

d rop fo rg ing can be b rought to the h igh est d egree of excel

-

l ence wh ich Such stock is capabl e of possessing T he stock

. .

can be w rought i n t he d rop d ies to it s g reat est p erfect ion with

-

out much inju ry to t he dies Stock allowed to cool f rom a .

weld ing h eat w ith no wo rk don e upon it below that heat is

, ,

very far from be ing in t he best cond it ion .

I mp rov ed An v il Block
Th ere is noth ing m k wh ich
fo rge o m so u nt idy in
a es a -ro

it s appeara nce as a nv i l s carel essly pl ac ed on the wooden blocks .

Ev en tho se secu red fi rm ly to t he blocks by m ean s of stra ps O f

iron bolt s or stapl es in t im e wo rk loose sh ift about an d
, , , ,

f requ ently fai l altogeth er To hold t he anv i l fi rmly to have

.
,

it look n eat an d at t he sam e t im e to m ake it as no isel ess as

,

possibl e wh en in u se is a p robl em dem and ing much thought

,

an d exp er ienc e .

As it is d esired to u se w rought iron an v i l s in p reference -

to cast iron sev eral experim ents hav e b een m ade T he resu lt
-
, .

is that t wo blocks are now i n u se in t he fo rge room : on e is -

mounted w ith a T renton an d one w ith a H ey 8c Badden anv il ,

both bein g w rought iron anv i l s Th ese are sat isfactory in

-
.

ev ery respect an d t he diffi culty in hold in g t he anv il secu re

,

is solv ed All n Oise an d v ib rat ion wh en t he an v il is st ruck

.

are stopp ed an d it s gen eral appeara n ce is v ery n eat

, T he .

anv i l is m ad e fast to a m ass of conc ret e ( F ig 1 96 ) of b rok en .

ston e an d c em ent encased in a rectan gul ar sh ap ed box 1 8

inch es h igh m ad e of cast iro n

, inch th ick w ith a base 1 4 ,
 ST EEL AN D O
IR N: I
TH E R T REAT M ENT ,
ET C. 2 01

x 1 8 inch es tapering up to 8 x 1 0 in ch es at t he top being ,

1 inch l arger i n s id e m easu rem ent th an t he b ase of t he an v i l

, , .

T he anv il as stated rests upon t he conc rete 2 i nch es b elow

, ,

t he top of t he cast i n g O n each side ( f ront an d b ack ) of t he

.

an v il emb edded in the conc rete to the d epth of about 3 i nch es

, ,

is a bolt an d nut t he nut p roj ect i ng up to n ear ly t he top O f

,

t he c ast i ng an d abo u t 1 i nch abov e t he conc ret e

, O n t he top .

of th is concrete m elted l ead is pou red ( fill ing up th is space

FI G . 1 96 -
I m p rov ed an v i l bl oc k .

between the base of t he anv il an d t he top of t he cast ing about

2 i n ch es ) wh ich flow s all rou n d t he anv il t he nut O f t he bolt , ,

an d i n to t he co r n ers of t he cast ing T he taper of t he cast i n g

.
,

togeth er w ith t he nut holds t he l ead to t he cem ent an d th is

, , ,

it is ev iden t holds t he an v il fi rmly

, .

Sev era l m ethod s h av e b een tho u ght of such as h av i n g t he ,

an v i l rest on a box of san d mou n ted on wo od en an d co n c ret e

,

blocks by m ean s of ban ds of iro n hook bolts stapl es et c ,

-
, ,
.
2 02 O
DR P -
FO RGI N G , Dl E S
- I N KI N G ,
ET C .

All th ese dev ic es fail ed to g iv e t he result d esired I t was .

found th at by pl ac ing 1 in ch or mo re of t he base O f t he anv il

in a tub of wat er it lost it s ring i ng soun d t he V ib rat ion s
, ,

ceased all togeth er an d the sound when st ru ck with a hamm er

, ,

was d ead so to sp eak as much as t he so call ed no isel ess anv il s

, ,
-

m ade of cast iron T he base O f t he anv il rests on t he con

.

c rete an d is gripped by t he l ead T h is arra ngem ent stopped

, .

compl etely j u st as the water did all v ibrat ion s T he cost of

, , .

t his m ethod of mount ing anv il s sho u ld exceed bu t l it tl e t he

cost of t he anv il s mounted in the u su al way on t he wooden
blocks w ith straps of iron et c , .
2 04 DR O P FO RGI N G
-
,
-
DI E S I N KI N G , ETC .

if on efol lows the old way he escapes t he st igm a of experi ,

m ent an d stan ds on t he safe g round of establ ished p ract ise

,
“ ”
an d con serv at ive eng i n eeri n g Con serv at iv e p ra ct ise is a .

fi n e term fi n e to cap ital ists a n d to rout in e follow ers an d wh en

, , ,

some ru l e b reak i ng exp er im en ter find s n ew an d b etter way s

-

of do in g th in gs then co n serv at iv e p ract ise becom es dear in

,

the oth er sen se of t he wo rd Sad to say though som e .

,

t im es t he experim enter does not com e out right an d th en ,

FI G . 1 97 .
— Part s of whee l ready for asse m b l in g .

t he old way advocates can

- be h appy an d sa
y, I told you
”
so w ith compl acent joy .

Op era tions on Wheel

T he parts of
ght spoke m etal wh eelbarrow wh eel are
t he ei -

shown i n Fig 1 97 an d co n s ist of t he co red cast iron hu b t wo

.
,
-
,

hot p ressed steel flanges fo u r bent spoke parts two spokes

-
, ,

each eight r iv et s an d t he w eld ed wh ee l r im

, .

T he cast iron hub cal l s for fi v e or mo re op erat io n s

-

m ak ing t he co re mold in g po u rin g tum bl in g an d spru in g on

, , , ,

t he em ery wh eel T he co r i n g l en gth an d o u tsid e d iam eters

- .
 PO RM I N G OF H EAV Y ST O C K IN I
D ES 2 05

are al close to u n ifo rm ity an d t he hub an d sid e flan ges an d

l ,

spok es m ake a fi rmly u n ited st ruct u re after th ey are assembl ed

in t he p ress befo re riv et i n g ( as shown in F igs 2 08 an d

,
.

as t he ey es of t he hub flan ges are fo rc ed down h ard on t he

-

outside of t he h u b .

—
For t he t ire sev en operat io n s are requ ired to cut it off
,

f rom t he bar stra ighten pu n ch w ith a hol e for each spoke

, ,

en d S ix or eight as m ay be an d two riv et hol es for t he w eld

, ,
-

FI G . 1 98 — Sm a l l r i m -be n di n g ro ll s .

rivet wh ich in su res t he co rrect t ire d iam eter ; in sert t he weld

,

riv et h eat an d w eld an d fi n al ly fo r m a n d t ri m on a ro u n d

, ,

iro n block
-
N o n e of t he op era t ion s on t he wh eelbarrow t ire
.

are show n as l arg er wh eel t ires w ere i n wo rk t he day t he

,

p ictu res were taken .

T he t ires are cut off in t he p ress an d al l t he hol es are ,

—
pu n ch ed at o n ce squ are h ol es for t he spoke en ds an d a ,

rou n d en d for t he w eld i n g r iv et Fig 1 9 8 shows t he l ittl e -

. .

M ol in e t ire ben d er th ree roll s op en at t he right h an d on e

-
, ,

adju stabl e T he l arger t ires are ben t i n a l arger M ol in e

.

m ach in e Fig 1 99 h av in g t he adju stabl e roll carried on a

, .
,
2 06 D RO P F O RGI N G
-
, DI E S N
-
I KI N G . ETC .

re ctan gul ar g ibbed sl ide at t he l eft T he compan y m ake .

wh eel s u p to 54 in ch es d iam eter w ith r im s 6 in ch es w id e an d

, ,

fit them w ith two sets of V Sect io n spok es spread at t he base

-
, ,

an d ext rem ely sub sta n t ial i n co n st ruct io n to c arr y as m u ch as ,

—
pou n ds load per wh eel an en t irely d ifferen t aff air f rom
th is s impl e an d ch eap wh eelbarrow wh eel .

T he r im s are h eat ed for weld i n g in t he n at u ra l gas fi re -

,

S how n i n F ig 2 00
. Th is is a fi re b rick p it not v ery w ide
.
-
, ,

FIG . 1 99 —
Larger r i m - be n di n g ro ll s .

hav in g two loose fi re b rick sl id in g cov ers ra ised up o n b ricks

-
,

2 or 3 i n ch es ab ov e t he h earth su rf ace T he n at u ra l gas p ipe

.
-

is at t he l eft glob e v alv e regu l at io n a n d t he t in air p ip e takes

, ,
-

t he gas at t he t op b en d abov e t he flat air regu l at in g s l id e

,
-
,

fix ed in posit io n w ith t he th in wooden wedge ly in g on top O f

t he s l id e
. T he fl am e was sh u t O ff for t he cam era expo su re ,

bu t t he p it was y et red hot T he t wo fi re b rick cov ers are

.
-

m ad e each of two b r icks p ierced togeth er w ith cl amp pl at es

,
-
2 08 D RO P FO RGI N G
-
,
DI -
E SI N xI NG, ET C.

t ire is th en taken by t he h elper who t rim s t he weld a v ery ,

l ittl e w ith a h and ham m er wh ich compl etes t he weld in g

-
,
.

Weld in g m ak es t he rim ready for t he spokes T he spokes .

are m ad e two i n on e p iec e of ov a l st eel rod cut to l en gth an d

, , ,

sl abb ed o n t he sid es t o fo rm a squ are t en on on each en d to fit

t he sq u are hol e pu n ch es in t he t ire a n d th en fo rm ed V ,

sh aped in t he p ress as show n i n F ig 2 02

,
T h ere are fou r . .

operat io n s on t he spoke V o n ly on e th at of ben d i n g bein g

, , ,

il l u st rated F irst t he spok e bl an k is cu t to l en gth th en

.
-
,

FI G . 2 01 —
. Weldin g wagon - w heel r i m s on Ju st ic e ham m er .

l bbed on on e en d at a t im e for t he sq u are ten o n th en fo rm ed

s a ,

by b eing l aid on t op of t he V ho rn of t he p ress in t he gages

-
,

wh ich are of t he sam e th ickn ess slott ed so th at t he fo rm ing ,

tool i n t he p ress sl ide ca n ben d both en ds down i n to t he com

-

let ed fo r m shown i n F i 1 9 7
p g . .

T he spok es are r iv eted i n to t he t ire by a rap id pn eu m at ic

r iv et er t he p iston bein g c ra n k d r iv en an d t he tool b ei n g a
,
-
,

rep rod u ct ion of t he flat h a n d hamm er p een t u rn in g rou n d a

-
,

l ittl e between blows T he spo ke ten o n s are in serted in t he

.
 O
F RM N I G or H EAV Y ST O C K IN I
D ES 2 09

rim by h an d bein g taken on e at a t im e f rom t he rod on wh ich

,

th ey h an g at t he wo rkm an s l eft an d th en on e spoke is

’

grabbed in t he p ress fixtu re V ise an d h eld hard by a lo n g cam

l ev er all as cl early S hown in F ig 2 03 wh i l e r iv et in g is do n e
,
.
, .

T he hamm er is v ery fast an d t he spoke S l ides down an in ch

,

or so wh i l e t he riv et i ng is don e wh ich m akes no d iff eren c e as

,

t he atmosph er ic h amm er fol low s it down all r ight Riv et i n g .

compl etes t he rim an d spokes ready for assembl in g t he en t ire

,

wh eel by add in g t he hub an d side at t he cen ter of t he bent

FI G 2 02
. .
—
Sp ok e - form in g p ress l
a n d t oo s .

s pokes wh ich are seen i n t he row of wh eel s on t he floo r at t he

l eft in F ig 2 03 an d al so in t he p il e O f l arger d iam et er w heel s
.
,

in F ig 2 04 in wh ich the wheelbarrow wh eel s are show n

.
,

stack ed up at t he r ight .

M a king t he Fla nges

T he flan ges cal l for eight operat io n s for each on e of t he ,

pair bl an k in g an d p ierc in g w ith a sm all cen t ral ho le t hen

, ,

h eat in g th en fo rm in g an d c u tt i n g t he cen t ra l hol e t o fi n is hed

,
2 10 D RO P FO RGI N G
-
,
DI -
E S I N KI N G ,
ET C .

d iam eter an d fi n ally p ierc in g t he flan ge for t he c ight riv ets

,
.

I t w i ll be not ed i n F ig 1 97 th at t he cast iron h u bs hav e a

.
-

sm all t r ian gul ar bo ss o n on e sid e T his to u c hes both flan ges

.

an d serv es to locat e t he fl an g es an d spok es m idway of t he hu b

l en gth T h is sho rt bo ss m ight h av e taken t he fo rm O f a

.

c ircu l ar flan ge bu t t his w ou ld i n c rease t he weight to n o

,

adv a n tag e .

T he fl an ge bl an k s are h eated to dark red i n a m u fli e hav

- -

in g a bottom of b rok en fi re b rick k ept red hot by a n at u ra l

-
,

FI G . 2 03 .
— Riv et i n g k
Sp o es i n w heel s . Air -
p ow er ha m m er .

gas an d p ressu re fi re sam e gen era l arra n gem en t as t he

ai r -
,

w eld in g fi re al l as cl ear ly show n in Fig 2 05 atten d ed by a

, .
,

youth w earin g L o n do n smoke goggl es who pl aces t he bl an ks ,

on t he m u fli e bottom an d p u ll s th em ou t w ith a lo n g sl end er , ,

st eel rod hooked at t he wo rk in g en d

-
a lw ay s k eep in g o n e
-
,

bl ank h eated red hot on t he si ll O f t he m u flI e doo r at t he l eft -

,

ready to be t ak en w ith t o n gs by t he p ressm an who s it s at t he ,

r ight of t he p ress on a c u sh io n ed seat sh ow n i n Fi 2 06

g .
,

wh ich shows t he rel at iv e locat io n s of t he f orm in g p ress an d -

t he h eat i ng m u fli e -
.
2 12 D RO P -
FO RGI N G , DI -
E S I N KI N G , ET C .

punch gang die as shown in Fig 2 08 T h is b r in gs t he job

, . .

to t he assembl er who u ses a press as shown in Fig 209 fi rst

, , .
,

s l ipp i ng a fl an ge on an en d of o n e of t he h u b s seen i n t he box

at t he l eft of F ig 2 09 an d th en st an d in g t he hub u p r ight i n

.
,

t he bol st er die an d n ext l ay i n g t he wh eel spoke in sid e en d s

-
,
-

in t he flan ges h ard on t he hu b ev eryth i n g b ein g adj u sted so ,

that t he descent of t he p ress sl ide fo rc es t he flan ges hard o n

-

t he hub an d closes th em h ard on t he spok es ready for riv et ,

FIG . 2 05 .
— Heat i n g flan ges in m u flI e ,
u s i n g n at u ra l gas
.

i n g, how n in F ig 2 1 0 taken f rom t he p il e of wo rk at the

as s .
,

r ight h an d of t he assembl i n g p ress

- -
.

I do n ot recal l t he pl ac i n g of t he eight fl an ge riv et s but ,

th i n k they are all h ead ed d ow n at on e squ eez e of t he p ress as ,

t he r iv ets are n ot v ery big .

T he wo rk is all v ery close an d good t he fi t s are excell en t , ,

an d t he p ress wo rk gag i n g is v ery ex act as is S how n by t he

-
,

sy mm et ry of t he sp ok e V i n F ig 1 9 7 an d by t he acc u ra t e .
,
 r OR
'

M l NG OF H EAV Y ST O CK IN D ESI 2 13

c ntering
e of wheel spokes in F igs 2 03 an d 2 04 F ig
t he -
. . .

2 1 0 al so bears w itn ess to t he excell en t fitt i ng of t he rough

parts an d F ig 2 04 shows exactly flu sh w ith t he t ire outside
, .

t he spoke tenon riv et T he compl eted wh eel is v ery strong

.

an d v ery du ra bl e an d is really a m iracl e of con st ruct ion

,

wh en on e sto ps to co n sider the number of operat ion s t he pl an t

employ ed an d t he p r ic e e pound t h wo k i old fo
p r e r s s r .

Su ppo sin g th at st eel bars an d gra y i ron cast in gs cost the

- -

Wheel Company cen ts a pound then t he stock in an ,

FI G 2 06
. .
—
Whee l - flan ge m u fll e
, an d form in g p ress
- .

8% pou n d wheel wou ld stan d for p retty n ear ly 1 5 cents l eav

-
,

in g 1 2 c ents out of t he 2 7 c ents sell i ng p rice to cov er all

expen ses of p er fo rm in g t he 2 9 p ri n c ipal operat ion s requ ired

to p roduce t he wh eel m ain tain t he pl ant an d m arket t he

, ,

product .

I th i n k I could easi ly m ake t he pl ant of t he Wh eel Com

p y
an s m ’
a i n floo r co s t mo r e th an it co st at fi rst w ith ,

t he san ct io n of t he m ajo rity of toolm ak ers educ at ed i n N ew

2 14 D RO P FO RGI N G
-
, D E SI N
I -
KI NG , E TC .

E ngl an d don t th in k I could ch eapen t he cost of t he

’
. I
wheelbarrow wh eel s by in c reasin g t he cost of t he pl ant I f I .

could not I Sho u ld c ertainly th row away whatever I put into

t he pl ant betterm ent wh ich would n ot be a betterm en t at
,

all but wo rse th a n a d ead wast e b ecau se t he ear n i n s m u st

, g ,

p y
a i nt erest o n it fo rev er .

FIG . 2 07 .
—
Fl an ge - fo rm i n g t oo ls
.

Th ere are pl en ty of ch an ces to th in k about th ings in t he

27 - cent wh eelbarrow wh eel job .

Pressed Steel Gea rs

An imp rov em en t i n t he m an ufact u re of steel gears has been

d ev ised by M essrs U l rich an d F red L Eberh ardt of N ewark
. .
, ,

N gT he i i d i g d t t v
'

.
J . ears are p m ar r ly es n e fo r s ree -
car ser

ic es b ei n g m ad e i n
, h alv es for ready an d easy cl amp i n g upon
t he axl e or remov al an d re n e wal wh en n ec essary . St eel cast
-
 D RO P-EO RG I N G , -S
DI E I N KI N G , ET C .

in t he jo u rn al s wh ich are t he v eh icl es of m echan ical in t elli

gen c e ; but it s p rogress m erits occas io n al not ice .

A c han g e has taken pl ac e in t he past fifteen y ears in t he

m aterial of wh ich m an y wh eel s are m ad e I t was wood ; it is .

n ow st ee l As t he u t il ity an d av ai l ab il ity of m etal wh eel s

.

becam e mo re w id ely k n ow n t he dem an d for th em in c reased .

L arge m an u facto r ies equ ipp ed w ith t he mo st adv an c ed tool s

,

an d m ethod s h av e b een est abl ish ed i n t he West an d a n n u al ly

, ,

FI G . 2 09 — Assem bl i n g flan ges an d hu b w i t h Sp okes an d r im .

co n sum e for th eir p rod u ct tho u sands of ton s of steel T he .

st ren gth du rab i l ity an d ch eap n ess of m et al wh eel s h av e m ade

, ,

t he m an ufact u re of so m e m ach in es p rofitabl e wh ich wou ld n ot

h av e been on t he m ark et if th ese wh eel s had n ot been av aila

ble . T he wh eel s are m ad e i n comm erc ial qu an t it ies for a
g reat v ariety of m ach in es : bal in g p resses b in der m aster wh eel s , ,

b in d er gra i n wh eel s co rn an d oth er pl an t in g m ach in es co rn

, ,

sh el l ers c u lt iv ators farm t ru cks g rain d ril l s hay rakes t ed

, , ,
-
,
-
,
 FO R M I N G OF H EAV Y ST OCK IN I
D ES 2 17

ders an d loaders ho rse powers plows po rtabl e eng in es road

,
-
, , ,

grad ers th resh ers separato rs an d wh eelbarrows A d rawback

, , , .

to t he p rofi t ablen ess of m an ufactu re would appear to be th is

great variety ; for every d iff erent k in d of wh eel is a separate
art icl e of m an ufactu re E v ery v ariety al so requ ires a ch an ge
.

O f som e k in d in t he m anufactu ring an d ev ery ch an g e takes ,

t im e an d costs mo n ey .

T he d im en s ion s of the t ire v ary all the way f rom 1 5 i nch es

in w idth to 1 % i nch es w ith th ickn ess f rom, i nch to yé

—
FI G 2 1 0
. Ready t o go t o t he r iv et i n g p ress - .

i n ch , ch w idth w ith an y th ick n ess an d each t hick n ess w ith

ea ,

an
y w idth .T h e t ires are not al l flat ; som e v ar iat io n s of fo rm
-

hav e n am es such as half oval chann el ed ribbed concave

,
-
, , , ,

an d som e S h apes are n am el ess T he poss ib il it ies of cutt i ng

.

an
y t i re to an
y l en th ext en d s t he v ar iety
g A n d t he v ar iat io n s .

are not SO mu ch in t he t ire as i n t he s iz e sh ap e l en gth a n d , , ,

number of t he spokes a n d t he m an n er in wh ich th ey are

,
2 18 D RO P FO RGI N G
-
, DI -
E S I N KI N G ,
ET C.

fasten ed an d al so in t he d ifferen t fo rm s sizes an d compl ica

, , ,

t ion s of t he desig n in t he hu b wh ich fo rm er ly sat isfi ed w ith, ,

two parts t he spoke Sh el l an d t he sp indl e box are n ow mo re

,
- -
,

involv ed sin c e rol l er b eari ngs h av e com e i nto u se .

From hu b to t ire t he wh eel is t he p rey of innov at ion It .

is alw ay s l iabl e to hav e som e n ew th ing p u t on it anywh ere ,

ev en outsid e of t he t ire The moto r wh eel of an ag ricu ltu ra l

.

m ach in e mu st t u rn aro u n d for if it s l id es on t he g round t he

,

m ech an ism is in act iv e T h erefo re th ese wh eel s are p rov ided

.

w ith sp u rs w hic h settl e into t he g rou n d an d p revent sl id ing .

T h ese sp u rs ar e attach ed to t he t ire are of m any fo rm s an d ,

FIG . 21 1 .
—
Pressed- St eel gea r .

attach ed i n m any d iff erent ways I n . a Si ngl e m eta l wh eel

-

m an u facto ry th ere are m ad e n o l ess th an 1, 5 00 d iff erent styl es

of wh eel s .

Wheel Ti r e M a king
T he p rinc ipa l fo rm of co rn pl anter wh eel t ire was for som e
-

t im e t hat shown in F ig 2 1 4 I t was 5 inches w ide an d f rom

. .

l
/ é i nch to i nch t hick T he co n c av e was
.
96 i nch d eep .

N ot mo re th an tw enty y ears ago I took a day on p u rpose to

see t hem w eld ed u n d er a t r ip hamm er T hese w ere h eated
-
.

by a h ard coal f u rn ace u n d er t he n arrow cap w hich p roj ected

-

ov er t he S lott ed top th rou gh wh ich t he fl am es were d riv en on

,
220 D RO P- FO GI G
R N , D I E-S N I KI N G , ET C .

One wou ld su ppose su ch an expend it u re of fo rce wou l d

p roduc e q u ite sen sibl e heat but wh en it is felt for w ith t he
,

bare h an d th ere is fou n d so l ittl e h eat th at it req u ires faith to

perceiv e th at th ere is an y N or is an y h eat d eveloped in t he
.

m ach in e although t he operat io n is repeated ev ery two m in

,

utes as it comp resses 3 00 a day T h is is not a case for com

, .

parison between m ach in e wo rk an d th at don e by h and an d no ,

compariso n can be in st ituted I f m ach in ery was not av ail abl e

.

th ese w heel s would not be m ad e T h ese t ires wh ich h ave to .

,

be co mp ressed after w eld i ng are n ow pu n ch ed as the fi rst ,

ope ra t ion upon them .

T he m u lt ipl e pu n ch
d ispl ays it s advantages by
pu n ch in g all t he hol es in
som e t ires at on e st roke .

T h ere are eight hol es in

a c u lt iv ato r t ire an d it ,

pu n ch es t ires a day .

T he t ire S hown i n F ig .

2 1 4 has twen ty hol es ,

th ere bein g two roll s of

spok es w ith t en spok es i n

— each row T h ese hol es

FIG 2 1 3 Press d st e l g ar
. . e -
e e .
.

are p u n ch ed on a com

mon punch p ress t he d ies of wh ic h how ev er are so m ad e

-
, , ,

th at th ey punch fo u r hol es at a st roke an d w ith t his arra nge

m ent upward of 1 5 0 t ires are pu n ch ed dai ly .

Wh en on e m ach in e does a lot of wo rk a lot of wo rk stops

wh en it stops For instan ce : O nc e th ere was a mu lt ipl e
.

p u n ch p u nch ing fi v e hol es

,
i n ch d iam eter th rough steel § é z

i nch t hick .N ow it is easy to v ary t he l en gth of t he

,

punch es a l ittl e so that t he whol e st rain m ay not com e at o n ce

, ,

but it was n ot tho u ght th at t he pu nch n eeded humo ri ng al ,

t hough t he sh ear st ra in was about equ al to punch in g a hol e 3

i nch es d iam et er Th ere had b een fou l wo rk on t he punch
.

before an d t h ere was k n own to be a sl ight c rack i n on e of t he

,

uprights T h is t im e cam e a bar w hich was as h ard as t hough

.
 FO R M I N G OF H EAV Y ST O CK IN I
D ES 22 1

it had been h arden ed I t was t he fi rst t im e to dec ide t he

.

q u est ion wh eth er t he m ach in e wo u ld stall or b reak an d t he ,

bal an ce wh eel did not stop to g ive t he qu est ion an y con sider
-

at ion . Th ere was qu ite a lo u d repo rt ; no v ery great d isorder .

FIGS . 214 to 22 1 .
—
I) e t a i ls of m et a l w hee ls
.

T he up right simply let go an d t he upper part ra ised up

eno u gh to p erm it t he revolut io n of t he ecc ent ric an d t he ,

m ach in e was tho u ghtf u lly th rown ou t of gear T he bal ance .

wh eel cam e to rest aft er a wh i l e an d wh en t he n ew u p right

,

cam e an d was set u p n o On e wo u ld k n ow an yth in g had ev er

,
222 D RO P F ORGI N G
-
,
I -
D E S N I KI N G , ET C .

h appen ed except for t he p il e of wo rk t hat was beh in d h and t o

,

p rov e th at a m ac hin e t hat can do such wo rk can stay wo rk ing .

Per haps not hing co u ld g iv e a bett er idea O f t he amou n t of

t im e th at is vo id of V isible p roduct tha n t he output of som e ’

m ach in e wh ich m ak es regul ar st rokes an d m akes a p iece at ,

ev ery st roke if t he wo r k is fed to it O f th is k i nd are t he

.

bolt m ach in es u sed for m ak ing t he col lar head en d of t he

,
-

spok e wh ich is to be riv et ed in t he t ire Th ey can h ead a .

spoke at ev ery st rok e an d ru n st rok es a da

y an d 1 7 , ,

000 spok es a day is t he v ery best day s wo rk th at has been

’

don e on on e althou gh wh en everyth i ng is i n good ru n n in g

,

o rd er ev ery stroke is easily caught The fu el is gas t he fi re .

,

con stan t an d u n ifo rm an d a pair of well hard en ed d ies of good

,
-

st eel w i ll l ast h alf a day w itho u t ch an g ing O pen h earth st eel .

is u sed for spokes exclu siv ely aft er y ears of experim ent as
, ,

it s u n ifo rm ity can be d epen ded on .

O n e succ essfu l p rocess of m ak i n g m etal wh eel s is t he p rep

ara t ion of t he t ire by punch i ng t he spok e hol es an d b end i ng -

t he m al l eabl e iro n hub s hot w ith a m ach i n e th at th row s out

-
,

a col l ar outs id e of t he hub at t he sam e t im e th at it ra m s up a

h ead i n arecess on t he inside T hese m ach in es head severa l

.

thou sand spokes in t he h u bs in a day f rom S ix to twenty ,

spok es i n a hub T he r im s or t ires are th en put on an d t he

.
,

spok es are riv eted i n th em cold by riv et in g m ach i n es

, Th ey -
.

can p ass in to t he adj u st er s h and s who t ak es t he k inks out of

’

th em so th at t he lap of t he t ire fi t s for t he w elder T h ey are .

h eated on a gas f u rn ace for weld in g I t has three fi res attach ed .

to a c ent ra l standard aro u nd wh ich th ey are revolv ed as

,

wan ted Wh en a t ire is at a weld ing h eat t he fi re is hold ing

.
,

it wh ere it can be conv en ien tly l ifted ou t an d d ropped on t he

die of t he w eld i ng h amm er -
T he spark shield is in stan tly i n
.

pl ace an d t he q u ick ru n n in g h amm er m ak es t he weld wh il e

,
-
,

t he operato r mov es t he t ire to rec eiv e t he blow s to t he best

adv an tag e . T he wh eel is th en han d ed t o t he t rimm er wh i l e

t he w eld er pl ac es an oth er t ire i n t he fu rn ac e an d sw i n gs it

aw ay b r ing i n g t he t ire th at is hot i n to it s pl ac e

,
Som e of t he .

l ight t ires are welded at t he rate of t wo in a m inute an d som e ,

22 4 D RO PF ORGI N G
-
, DI -
E S I N KI N G , ET C.

hub an d bolted to t ire; spokes 3 x i nch steel A few of

, .

these tract ion eng in es rol l in g along t he path s of i ndu stria l

p rogress would hav e a weighty influ ence in settl ing that
commot ion al isl e .

Steel Wheels
St eel wh eel s for u se und er variou s agricultu ral impl em en ts ,

en g in es , et c
. h av e w ith i n t he past few y ears almost ent irel y
,

FI G 2 2 2 . .
—
Pu n c hi n g hol es for t he sp okes .

s s—
uperseded t he wood wh eel both those w ith wood an d those
w ith iron hub s T h is has been du e to t he d em an d for a wh eel
.

th at would w ith stan d t he h eat of t he su n as wel l as th at of a

st ea m bo i l er
-
.T he i mm en se n umb er of such wh eel s u sed has
m ad e it n ecessary to p rov ide improv ed m ach in ery an d to
adopt sy st e m at ic m eth ods for th eir m an u fact u re An y f act ory .

u s in g s u c h w heel s ca n we ll aff o rd to do t his i f n ot l ess th a n ,

 FOR M I N G OF H EAV Y ST O CK IN I
D ES 22 5

th ree or fou r hund red are wanted per y ear T he m anufactu re .

of such wh eel s m ay not be in t he l in e of m ach in e wo rk but -

,

the const ruct ion of t he n ecessary tool s an d appl iances an d t he

m ann er of u sing th em m ay be u seful an d interest in g to som e
of my readers .

Fig 22 6 show s t he el em ents of a wh eel of wh ich a l arge

.

number have been u sed yet on e wh ich is n ot sat isfact o ry

, .

FI G 22 1
.
-
Ri m an d S p o
k es of w hee l as t hey c om e from m ac hin e .

T he pokes hav ing no coll ar on t he in side of t he rim an d

s , ,

being fasten ed to the hub by nuts as show n are cont inu ally , ,

wo rk ing loose T h is wh eel is al so very expensiv e

. .

F ig 22 2 shows t he outl i n es of a riv et ing an d punc hing

.

m ach in e u sed in th is work Fig 2 2 3 rep resents t he r im an d

. .

spok es O f a wh eel as th ey com e f rom th is m ach i n e .

Fig 2 2 4 shows an enl arged sect ion of t he rim w ith the

.
22 6 D RO F O RGI N G,
P- DI -
E S I N KI N G , ET C .

s pokes in pl ace on e of wh ich is riv eted an d t he oth er t o be

,

riv et ed .

Comm enc ing at t he beg inn ing of the v ariou s ope rat ions ,

we w i ll fol low t he wh eel th rough to a fin ish .

T he t ire or r im as we sh all ca ll it is fi rst cut to l en gth

, , , ,

bent an d welded in the u su al way after wh ich t he v ariou s ,

imp rov ed m ethods an d tool s come i nto u se N o at t ent ion is .

paid in t he fi rst ope rat ion to hav ing t he rim exact as to d iam
eter . I t is pl aced in a hyd raul ic t ire sett ing m ach in e ( bought -

an d u sed p ri m ari ly for sett ing t ires on wood en wh eel s ) wh ere ,

it is fo rced to siz e an d m ad e p ract ica lly a

t ru e c ircl e Th is opera t ion is compl eted in
.

l ess th an fi v e m inutes .

T he n ext op erat ion con sists in punch in g

t he hol es for t he spok es wh ich is don e in ,

t he m ach i n e S hown i n F ig 2 2 2 I t w il l be . .

not iced by F ig 2 2 4 th at t he hol es are t a .

pered T he taper is obtain ed by u sing a die

.

w ith a hol e of t he sam e d iam eter as t he l arge

en d of t he hol e t he punch b eing the sam e ,

as t he sm al l en d of t he hol e; or pe r h aps to , ,

make my m ean in g cl earer we u se a die as ,

much l arger th an t he pu n ch as t he t aper

£
fér 3122 5;
F’
d esired plu s t he cl eara nc e u su a lly u sed w ith

of r i m .
p u n ch es an d d ies .

T he rim is fi rst pl ac ed in t he m ach in e as ,

s how n by dott ed l i n es a t x an d as t he hol es are staggered t he

, ,

space r ( not shown ) is set for on e h alf of t he tota l numb er of -

hol es requ ired an d to compl ete t he operat ion t he rim is

, , ,

tu rn ed ov er to punch t he oth er h alf T he spok es are cut .

t he p roper l ength allowanc e b eing m ad e for m at erial to fo r m

,

t he coll ar show n Th is is don e in an o rd in ary bolt h eader t he

.
-
,

oth er en d b ein g flatten ed by a blow from a sm al l t rip h amm er - .

T he spokes an d r im are now ready to go to t he riv eter .

Th is m ach in e is suppl ied w ith a stand C on wh ich is mou n ted ,

a cast i ng D wh ich is s lott ed as shown at B

, Th is slot re
, .

ceiv es the spok e an d hold s it i n p rop er po sit ion for riv et ing .
22 8 D RO P- FO RGI N G ,
-
DI E S I N KI N G , ET C.

by other m etal rings an d th is was the fi rst m eta l ch ain Ap

, .

p a re n t ly ch ai n s w ere u sed mo re as o r n a m ents th an anyth ing

el se up to abou t on e hund red an d twenty fi v e y ears ago al -
,

thoug h occasional patents have b een issu ed du ring t he past

two hu n d red an d sev enty fi v e y ears The fi rst paten t t he
- .

autho r has knowl edg e of was issu ed in E ngl and i n 1 6 3 4 an d

desc ribed as fol lows :

“
A Way for t he M earing of Sh ipp s w ith I ron Chayn es by
find ing ou t the T ru e H eat in g Ppaein g an d Temp in g of ,

I y ron for th at Pp ose an d t h at he hat h h owe att ayn ed to t he

,

T ru e U se of t he said Chayn es an d th at t he same wi lbe for t he

g reat sav ein g of co rd age an d
Safet y of Sh ipp s an d w il l re ,

dou n d to t he Good of ou r
Common Wea lth .

A N ew M et hod of M a king
Weldless Cha ins
T he weldl ess ch ai n i n ,

t he fo r m of t he common
”
plunger s or safety Ch ain ’
,

is a fam i l iar art icl e I t is said .

to h ave been dev ised o rig i

—
n a lly by t he i nv ento r of t he
FI G 2 2 6 C om p l t d t i l
e e e a
.

fi rs t w atchm an s t im e d et ecto r
’
.

o f o t c ti
n s ru c on .

as t he m ean s of f ast en i n g t he

variou s keys u sed in t he sy stem scattered at d ifferen t po in ts

,
“
about t he p rem ises A ch ain of th is so rt can only be u h
.

”
rav el ed f rom one en d an d if th at en d is seal ed w it h t he
,

im age an d sup ersc ript ion of t he ow n er t he t ask of d ec ept io n ,

is a d iffi cu lt on e .

I ron ch ain s of l arg e siz es h av e b een m ad e on t he sam e

“

princ ipl e but mo re for reason of st ren gt h an d ease of m ak in g

,

th an for safety I t is a po int gain ed wh en t he w eld of t he

.

o rd in ary chain l ink is avo id ed sin ce it s st ren gth can n ever be

-
,

proph esied befo reh an d an d t he whol e ch ain in t he wo rd s of

, ,
“
t he common p rov er b is no st ro n ger than it s weakest l ink
,
.
 FO R M I N G OF H EAV Y ST OCK IN I
D ES 2 29

AS ch ch ain s h av e h ith ert o been m ade howev er it has

su , ,

alway s been n ec essary to m ak e t he open i ng i n t he Outer l ink

lo n g eno u gh to adm it t he n ext l ink to be added to t he chain .

Wh i l e th is elongated l ink does v ery wel l on S heet m etal plum -

ber s ch ain it is a sou rc e of w eakn ess in chain s of w rought

’
,

iron or steel of l arge siz es i nt en d ed to suppo rt l arge loads

, , .

Wh en such a chain passes ov er a sheav e or around a Sp rocket ,

t he b end in g St resses set up i n t he long l in ks qu ickly d efo rm

th em and spo i l t he ch ain T he obj ect of t he inven t ion of a
.

—
H ungarian St efan Kiss v Ecseghy by n am e is to m ake — .
,

FI G . 22 7 .
—
D l
et a i s of n ew shor t S t i ff -l in k c ha i n .

it possibl e to produce chain s of th is k in d w ith very sho rt ,

st iff l i nks .

T he s h ap e of t he ch a in is shown in F ig 22 7 As w i ll be . .

seen each l i nk is do u bl e b eing fo rm ed of two loop s b ei ng

, ,

spl it . T he m ethod of fo rm in g t he ch ain is shown in Fig .

2 2 8 T he sec ret of t he p roc ess is shown in t he fi rst operat ion

. .

F ig 2 2 7 at D s hows a compl ete l i nk an d A t he bl an k f ro m

.
, , ,

wh ich a n ew l ink is to be fo rm ed As w il l be seen th is is .

,

m ade of stock som ewh at l arger th an t he size of t he chain t e ,

du ced in it s c en t ral po rt ion to th at S iz e T h ese bl an k s m ay be .

m ad e by d ro p fo rg ing roll ing or an y oth er comm erc ially su it

-

abl e m ethod O n e of th em is h eat ed in t he fo rge a n d in sert ed

.

in t he en d of t he al ready compl et ed po rt ion of the ch ain as ,

show n T he en d s are th en st ruck up u n d er d ies to t he sh ap e

.
230 DR O P FO RGI N G
-
,
-
DI E S NI KI N G ,
ETC .

show n operat ion 2 wh ere E is t he en d of t he fin ish ed ch ain

in , ,

an d B t he n ew l ink b eing fo rm ed I t w i l l be seen that t he

.

hol e in t he old l ink is but sl ightly l arger th an t he d iam eter of

t he stock compos in g t he n ew on e wh i l e t he n ew ha lf l i nks in
,

t he en d are of co n sid era bly g reater siz e I t wou ld ev id ently

.

be impossibl e to i n sert th em if th ey w ere fo rm ed b efo re in ser

t ion h ence t he proc ess of in sert ing t he bl an k fi rst an d fo rm
,

FI G 2 2 8
. .
-
D ies for form in g chain , Fig 22 7 . .

in g it fterward Th is is t he v ital pri nc iple of t he patent

a . .

As shown in t he th ird operat ion t he ends are n ext bent ,

around to fo r m t he n ew compl et e l i nk wh ich is t hu s made ,

ready for t he in se rt ion of t he n ext bl a nk .

f WDies
eldless Ch
ora in

F ig 2 2 9 show s t he d ies u sed for do i ng th is w ork

. The .

p ress show n is of a type commo n in E u rope tho u gh seldom , ,

if ev er seen in th is co u n t ry
,
T he two frict ion wh eel s on t he
.
-
23 2 DR P O -
F O RGI N G ,
-
DI E S I N KI N G , ET C.

th is ngem ent th ree operat ion s are n ecessary for t he fo rm

arra ,

in g of t he co m pl eted l i nk th ese opera t ion s co rrespond ing t o ,

those Shown in F ig 2 2 7 T he compl et e po rt ion of t he ch ain is

. .

su spend ed ov er a pul l ey f rom t he c ei l ing w ith t he free en d i n

t he easy reach of t he Operato r of t he m ach in e A h eated ban k .

of t he l ink shown in F ig 22 7 operat ion 1 is taken from t he .

, ,

fo rge in serted th rough t he l ink an d pl aced in d ies C C on

, ,

t he bed of t he p ress Ram D show n b est in t he sm all d etai l

.
,

at t he low er l eft h and co r n er is th en b rought do w

-
n on t he ,

l ink flatten in g out t he ends an d cu rv in g t he cent ra l po rt ion

, .

T he plunger is ra ised again t he l i nk is mov ed fo rward to d ies ,

E E an d t he plunger is agai n b rought down

, T he die at E is .

compou n d an d punch F abov e it descen d ing on t he work

, , ,

fo rm s t he rounded half l in ks on t he en d of t he bl ank punch es ,

t he hol e an d t ri m s off t he p er iph ery of t he wo rk

, .

T he ram of t he p ress is raised fo r a th ird t i m e an d t he ,

now compl etely fo rm ed ( bu t st i l l open ) l ink is moved to t he

bend in g d ies at G G Wh en t he ram of t he p ress is b roug ht
-
.

down on the wor k at th is po int after smooth ing the wo rk ,

u n der t he p ressin g act ion of punch H p in s I I are pu sh ed in ,

by t he operato r entering hol es in l inks R R wh ich are th en

, ,

in po sit io n to rec eive t hem O f t he two p art s G t he on e at .

, ,

t he l eft i n t he l eft h and V iew is fast en ed t o t he hold er i nt eg ral

-
,

w ith rin g K wh ile t he oth er on e is suppo rted i n a sim il ar

,

m an ner f rom ring L Th ese two r ings are free to rock about .

eac h oth er an d about t he p ivot M fo rm ed i n t he b racket ,

cast ing N attached to t he bed of t he m ach in e _ A t ie bar O

, .
-
,

key ed on t he base P serv es to suppo rt t he ov erhan g ing p ivot

,

M of b ra cket N A suppo rt not shown in t he cut exten d s

.

out over t he fi n ish ed po rt ion of t he ch ain th rough wh ich t he

n ew l i nk p asses an d suppo rt s it again st t he upward p re ssu re
,

of t he b end ing operat ion wh ich now takes pl ace Wh en t he .

ra m of t he p ress is st art ed upw ard l inks R attach ed to it d ra w , ,

aft er t hem die hold ers Q Q wh ich rock as d esc r ib ed about t he

-
,

ax is of p ivot M By th is m ean s t he l in k is b en t fin al ly i nto

.

it s c ompl et e fo rm as Show n i n operat io n D of Fig 22 7

, . .

T he h alf to n e F ig 2 2 9 show s th ree op erato rs

-
, . Th is is ,
.
 F O RM I N G O F H EAV Y ST O CK IN DI ES 233

n Ot necessary however as on e of t he m en shown is there

, ,

p robably m erely for t he sake of hav ing his p ictu re taken

,
.

A boy to tend t he fi re an d a sm ith to wo rk t he p ress is all , ,

that is requ ired T he mach in e is start ed an d stopped by t he

.

treadl e T he m an at t he ext rem e en d is t he inv ento r

. .

T he writ er has had t he oppo rtun ity O f seeing th is p roc ess

i n O p erat ion T he tool s u sed w ere som ewh at d ifferent f rom
.

these shown an d mo re Ope rat ion s were requ ired although t he

, ,

basic p r inc ipl e involv ed in t he inv ent ion was ident ica l T he .

n ew l i nk of t he ch ai n wh ich was O f h a lf inch s iz e was bent in

,
-
,

t he die C as d esc ribed but in t he die E t he end s w ere m erely

, ,

rou n ded an d t he c ent ral hol e fo rm ed n ear ly th rough w ithout

'

, ,

bei ng actu al ly pu nch ed T he n ew l ink was th en closed up i n

.

a th ird ope rat ion as b efo re Th ese operat ions took pl ace in a
.

press of t he sam e type as shown in Fig 2 2 9 T he unfin ish ed . .

sh ed l i nk was n ext tak en to a sm al l c ra nk p ress stand ing b esid e -

t he l arg er m ach in e wh ere fi rs t t he c ent ra l hol e was punch ed

,

th rough after wh ich for a compl et ing operat ion t he l ink was
, , ,

pu sh ed th rough a trimm ing die to h ave t he fin sh av ed off -

.

Th is resulted in an exceed ingly n eat an d cl ean look ing l ink -

,

w ith t he jo i nt t ightly closed an d smooth ly fin ish ed T he ope r .

at ion O f fo r m ing t he l i nk for a h alf inch ch ai n tak es 2 5 seconds -

.

Besides t he O bv iou s rap id ity of m ak i ng ch ain s by th is m eth

od th ere is t he mo re i mpo rt ant adv antag e O f g reatly inc re ased
,

st rength . T he Br it ish Gov ernm ent requ irem en ts for ch ain s

in sist on a facto r of safety of 5 ow ing to t he unknown qu an ,

t ity of t he st rength of t he w eld A good welded ha lf in ch .

-

ch ain fai l s at about pounds Sampl es of th is imp roved .

weldl ess type were tested at about pounds wh en made of

w rought iron an d th ey ru n w ith remarkabl e un ifo rm it y at
,

about th is lo ad show ing th at a h igh er f acto r of saf ety cou ld eas

,

ily be u sed F u rth ermo re t he u se of st eel is m ade po ssibl e

.
,

by t he fact th at a weld in g h eat is not requ ired A h eat inten se .

enough to weld steel w i ll d ecarbon iz e it so th at it has not t he ,

st rength th at it p rev iou s ly po ssessed Steel is espec ially u se .

ful in cran e serv ic e wh ere du rab i l ity is fully as important as

,

strengt h . A w rought iron ch ain wi ll wear an d st retch unt i l it

-
2 34 DR O -O RGI N G
P F ,
- I KI N G
D E S N
I , ET C .

w ill not fit t he sp rockets long befo re it breaks Steel ch ain s

,
.

m ade by th is n ew p rocess test at about pou n ds for

i nch sid e Fractu red sampl es seen by t he w riter fail ed at the
.

s id es of t he l in k s an d not as m ight be exp ect ed at t he po int

, , ,

wh ere t he two parts of t he sam e l ink com e togeth er An inter .

est ing po int is t he f act th at t he two h alv es of t he spl it l in k

beg in to separate a l ittl e wh i l e befo re t he fi nal ruptu re takes

pl ace thu s serv ing as a so rt of safety ind icato r to app rise t he
,

u ser of t he fact that he is n ear t he danger l i m it .

T h is i nv ent ion is cont roll ed by t he I n tern at ion a l e H an

delsgesellschaft Kl ei n eb erg 8c CO an d is for sal e i n th is
, .
,

country by t he I ntern at ion al I mpo rt an d Expo rt Company of ,

N o 1 M ad ison Av enu e N ew Y o rk City

.
,
.

M odern M ethods of M a nufa ctu ring Welded Cha in

I t is
not perh aps gen era lly k n own th at t he U n ited States is
not only t he l argest p rod u cer but al so t he l argest con sum er of
,

welded chain in t he wo r ld an d th at it s annu al p roduct ion

,

reach ed in t he y ear ju st ended t he

, ton m ark T h is
,
-
.

indu st ry is p robably o n e of t he b est ex ampl es of l arge g rowth

mad e possibl e by t he int roduct ion of t he l atest types of l abo r
sav ing m ach in ery T he i nc reas ing dem an d for th is p roduct
.
,

wh ich was g reatly in exc ess of t he p rod u ct ion in 1 901 2 re —

,

su lt ed i n m any pl an ts b ein g start ed i n t he fol low ing y ear ,

an d 1 904 found t he p roduct ion S l ightly i n exc ess of t he co rr

sumpt ion T he p resent era of p ro sp erity an d t he gen era l

.

resu mpt ion of al l m anuf act u ri ng bu si n ess find s t he p roduct ion

O f w eld ed ch ain g reat er th an ev er befo re an d t he p ro sp ects ,

for a most sat isfacto ry y ear are of t he b right est .

T h is i ndu st ry is wh at on e m ight c al l a t ra n spl anted indu s

t ry as i n fo rm er y ears E n gl an d suppl ied u s w ith all ou r ch ai n
, ,

but ou r con sumpt ion reach ed such p ropo rt io n s th at it was

found n ecessary for u s to ent er th is fi eld as m anufactu rers As .

an accompan i m ent of t he t ra n spl ant i ng t he p roc esses a n d t he

,

p roduct h av e been co rrected imp rov ed an d dev eloped u nt i l

, ,

to day Am erican ch ain is recogn ized as a standard

-
.

T he m anufactu re of ch ain requ ires essent ial ly sk i ll ed l abor

236 D RO P-FO RGI N O , DI -
E S I N KI N G , ET C .

t he l ink was tu rn ed over an d back so that every po rt io n of ,

t he part of t he l ink bein g weld ed S ho u ld rec ei v e t he p rope r

wo rk ing that was n ecessary to secu re a perfect weld By th is .

p rocess t he sm ith could not w eld over 2 5 0 pou n ds of in ch -

common ch ain per day th is bein g equ ival ent to 3 1 feet or 1 5 6

, ,

li nks as a day s wo rk an d wh i l e t he qu al ity of t he Ch ain p ro

’

du ced i n th is m ann er was of t he best it was f ou n d th at by ,

p e rfo rm i ng part of t he l abo r by m ach i n ery t he p ro d uct i o n

cou ld be qu ad rupl ed an d t he q u al ity bettered .

Pr esen t M et hod of M a king Welded Cha in

U nd er t he p resent p roc ess of m an ufactu re, we fi n d th at the

lo n g bar is now wound into a sp ira l of l in ks on a l ink -w ind
in g m ach in e an d th en cut up into l in ks on t he l in k cutt ing
,
-

m ach in e t he cutt ing p roc ess fo rm ing t he scrafs O I I t he ends of

,

t he l inks a n d do ing away w ith two beat in gs of t he iron th at

,

were n ecessary und er t he fo rm er p rocess as t he w ind i ng an d ,

cutt in g are don e w ith t he iron cold .

The L in k Winder
T he l in k w ind ing m ach in e F ig 2 3 0 con sists of a ho r i
-
, .
,

z on t al sh aft about 4 f eet long wh ich is operat ed by a b elt an d

,

pul l ey geared to on e en d wh i l e on t he oth er en d is attach ed

,

t he w ind ing m a nd rel or l ink fo rm er T h is m and rel ca n be

-
.

ch an ged acco rd in g to t he l in ks th at are to be wo u nd an d has ,

outsid e d im en s ion s confo rm i n g to t he i n sid e d im en s io n s of

t he req u ired l i nk O n e en d of t he bar of iron is fasten ed

.

ov er th is m an d rel by a m ovabl e attachm en t an d a grooved ,

gu ide wh eel is lowered t o m eet t he bar an d p ress it fi rmly o n

-

t he m a n d rel b y m ean s O f a pow erf u l sp r ing As t he m ach i n e .

is start ed t he shaft S lowly revolv es an d t he iron is wou n d

,

t ightly arou n d t he m a nd rel i n t he fo rm of a sp iral of t ight

sp r ing t he p ressu re o f t he g roov ed gu id e wh eel fo rc ing t he
,
-

iro n to co n fo r m exactly t o t he d esired sh ape \V h en t he bar .

has b een en t irely w ou nd up t he resu lt is a sp ira l l ink abo u t

6 f eet l o n g ready t o be cu t in t o l in ks
,
By m ean s of th is .
 F OR M I N G OF H EAV Y ST O CK IN I
D ES 23 7

m ach in e pou n ds of bar iron can be wound into sp iral s in

on e day equ a l to about
, l inks I n som e roll i ng m ill s
.

wh ich su pply ch ain m anufactu rers w ith rods th ey h av e l ink

,

w ind in g m ach in es pl ac ed so th at t he bar of iron can be wound

hot into sp iral s as it com es f rom t he rol l s as by so do in g t he

,

l ink w ind er can be ru n at a h igh er rate of speed resu lt in g in

-
,

greater da i ly p rodu ct ion an d w ith l ess waste th an by cold

w ind in g
.
 The Link-Cutter

T he l ink cutt ing m ach in e con sists of on e fixed lower cut

-

t ing bl ade an d on e S l id ing uppe r cutt ing bl ade wh ich sl ides

- -
,

in a g roov e an d is operated by belt an d pu ll ey gears T he .

sp ira ls are fed i nto t he cutt i ng b lad es f rom t he l eft sid e of t he

-

cutter an d h eld in such a m ann er th at t he iron is cut at an

an gl e of 6 0 d eg rees w ith t he d iam ete r of t he rod each cut ,

rel easi n g on e l i n k wo u nd an d scrafed ready for w eld i ng an d

, ,

at the rate of on e cut ev ery second or l in ks per day

, .

The Welding M a chine

The powe h mm er on wh ich the ch ain is n ow welded is
r- a

shown in F ig 2 3 1 an d rep resents t he results of y ears of ex peri

.

enc e an d t rial Wh en t he idea of weld ing t he l inks of a ch ain

.

by m ean s of d ies in stead of by blows of h and h amm ers was -

fi rst conc eiv ed a foot power h amm er was attach ed to the anv i l
,
-
,

t he h amm er b ei ng h in g ed on t he opposite S id e O f t he anv i l

from t he sm ith an d so arranged that by k icks on a foot treadle -

t he sm ith cou ld sw ing t he h amm er arm down to m eet the face-

of t he anv il I n t he lower face of the h amm er arm was at

.
-

t ached the upp er die an d on t he fac e of t he anv i l

, I n the .

—
lower face of t he ham m er arm was at tach ed t he upper die an d
'

on t he face of the anv i l was att ach ed t he lower die t he resu lt ,

being a smooth fin ish superio r to that of a h amm er welded -

l ink Th is was a big step in t he right d irect ion but it was

. ,

soon found th at on lai ge siz es of ch ai n t he l abo r of operat i ng

'

t he h amme r arm by foot pow er was too g reat an d t he p resent

- -

w el l known type of p ow er opera ted h amm er was dev ised to

- -

obv iate th is difli cu lt y T he power for operat ing th is type is

.

convey ed to a pull ey on t he h amm er base by m ean s of a belt -

f rom t he shaft ing of t he shop arranged to g ive t he h amm er a

,

speed of about 1 2 0 st rok es per m i nut e T he w eight of the .

h amm er arm is i n it s h ead an d t he fo rce Of it s blow is due

-
,

both to grav ity an d to t he pu l l ing power exerted by a power -

ful spring The m ach i n e is SO arra nged th at wh en not in u se

.

t he arm is raised about a foot f rom the f ace of t he anv i l an d held

2 40 O
DR P F-
ORGI G N , D I E-S N I KI N G , ET C
.

of i nch
- chain
welded in on e day equ ivalent t o
can be ,

1 2 4 feet or 6 2 6 l i n ks bei ng fou r t i m es t he dai ly p rod u c

, ,

t ion u nd er t he old hand p roc ess .

The Die

In g d to t he d ies u sed t he lower die con sists of a bloc k

re ar ,

of steel cut away unt i l a sm all rounded p roj ect ion is l eft wh ic h
w il l j u st fit in side t he en d of t he l ink wh il e t he uppe r die is a ,

block of steel hollowed out SO th at it w ill j u st fit over t he out

sid e of t he en d of t he l ink t he sp ac e betw een t he two d ies be
,

i n g j u st t he siz e O f t he en d of t he l ink wh ich is to be welded .

Th ese d ies are fitt ed in spaces l eft in t he fac e of t he ham

m er h ead an d t he fac e of t he anv il so th at d iff erent Siz e d ies
-
, ,

can be u sed on t he sam e pow er h amm er acco rd i ng to the size -

,

chai n that is to be welded .

The Pr ocess o f Welding

T he m ith sel ects f rom t he severa l l inks in t he glow in g

s

bed O f coke i n the f u rn ace on e th at has reach ed t he w eld ing

h eat an d hook ing it th rough t he l ink l ast welded pl aces
, ,

t he open en d of t he l ink ov er t he low er di e Pressu re on .

t he foot t readle rel eases t he h amm er ar m an d t he i mpact of t he

- -

b low fo rces t he scrafed ends closely togeth er an d welds the

l in k t he d ies reduc ing t he body of t he w eld to t he sam e size
,

as t he rest of the l ink an d g iv i ng t he w eld a s mooth fin ish ed ,

app earanc e sup erio r to a h amm er w eld ed ch ai n

, About t en - .

blows of t he h amm er arm are requ ired to m ake an d fin ish the

-

w eld t he interval between t he blows O f the arm being ut il ized

,

by t he sm ith to tu rn t he l ink ov er an d back on t he lower die

an d to l ightly t ap t he w eld w ith his h and h amm er thu s g iv ing -
,

t he p rop er wo rk ing n ecessary to secu re a perf ect weld .

T he u se of th ese th ree impo rtant m ach i n es has compl etely

rev o lut io n iz ed t he p roc ess of ch ai n m anufactu re t he resu lt not ,

o n ly b ei ng in c reased p roduct ion but al so a much b ett e r g rade

,

of ch ain at a greatly reduced co st .

 CH APT E R V I I I

PO RGI N G I
M AC H N E, ST E M H AM M E
A - R , B U LLDO Z E R , AN D S WAGI N G
I
M ACH N E M ET H O DS AN D P O CESS ES R
Ha ndy Bu lldozer App u rtena n ces
T HE bulldoz er or bend ing m ach in e is at p resent found in
,
-
,

almost ev ery car ra i l ro ad b r idg e an d ag ricultu ra l shop in t he

, , ,

country an d as a t im e saver an d all around tool for w rought

,
- -

iro n wo rk it stands p reem i n ent Lo n g experienc e w ith th is .

mach i n e an d w ith t he varied m ethods u sed in d iff eren t shops

h av e g iven oppo rtun it y to judge of t he easiest an d best m eth
ods for do i ng wo rk on it .

A back pl ate ( F ig 1 of whol e F ig 2 3 2 ) is d ispen sed

.
, .

w ith in many shops u sing th is m ach in e but why u n less it is , ,

igno ranc e of it s ut i l ity is u n know n as it is ind ispen sabl e

, , .

H av in g int roduced it in sev era l sh ops it has alway s been ,

retai ned an d t he wond er has been how th ey got a long w ithout

,

it b efo re I t keeps t he wo rk st ra ight sav es a g reat dea l of

.
,

gray iron an d it is much easier to fasten t he fo rm s to th an

,

t he bed of t he m ach in e .

By m ak i ng a d iv ided ap ron or flat part as in F ig 2 an d , , .

,

cast i ng a lug on t he bottom see Fig 3 it s u sef u l n ess is in , .

,

c reased an d t he pl ate is l ighten ed for easier h an dl ing T he .

pl at e Should be m ade pl en ty w ide en ough to take in t he

longest wo rk don e on t he mach in e an d t he face an d ap ron
sho u ld be pl an ed perf ectly t r u e A d ep ressed fil l et at A .
,

F ig 2 allows a fo rm er to always go snug agai n st t he back

.
, .

Two bolt slots in t he back are better th an h av in g to d ril l n ew

hol es to fasten t he form s T he hol es in t he fo rm s can be .

cored to su it or dr ill ed as d esired

, .

T he pl ate on t he ram h ead is shown in F ig 4 I t sho u ld . .

have to n gu es cast to fit t he c rossh ead fi rm ly so th at th ere w il l ,

2 41
2 42 O
DR PFORGI N G,
-
I KI N G
D I E-S N ETC.
,
2 44 DR O P- FORGI N G , DI -
E S I N KI N G , ET C .

oth er angle or siz e of iron by back ing off or runn ing t he back
pl ate up th at it an swers for rounds as wel l as for flats
, .

A simpl e dev ice for U bolts l in ks stapl es an d hange rs is -

, , ,

show n in d etai l in F igs 1 2 t he arm s ; 1 3 rol l ers ; 1 4 stud s

.
, , ,

an d 1 5 t he plu nger for U bolts

, The sockets shown in F ig -
. .

1 0 is u sed w ith th is d ev ice a l so an d com es i n ext em ely h andy ,

for oth er fo rm s as wel l an d l ike a few doll ars in o n e s pock et

’
, , ,

is a handy th i ng to h av e .

F l ats can be b ent as wel l as round s by m ak ing rol l ers w ith

out concaves The adj u st m ent for d iff erent sizes is made by
.

t he eye bolt on wh ich the rol l ers t u r n

-
F i 1 6 d 1 7 how
s g s an S . .

t he id ea O f cou rse a plunger has to be m ade for eac h shape

.
,

an d it can be m ade of g ray or w rought I ron u nl ess con st antly ,

i n u se . Th en t he work ing po i nts shou ld be m ade of stee l if

u sed on cold bend ing .

Rol l er arm s for t he c ro ss h ead are t he n ext essent ial for th is

m achin e Th ere are m any S h apes bent wh ere t he wo rk is
.

”
don e by what are term ed w ing fo rm s w ith much better ,

resu lts th an f rom plung er fo rm s The p iece shown in F ig . .

1 8 wou l d tear t he iron an d redu ce t he s id es so w ith a plunger

fo rm t h at it would be imp ract icabl e bu t by subst itut ing t he ,

w ings t he wo rk is don e perfectly F ig 1 9 shows a rol l er arm . .

-

for t he c rosshead I t is m ade r ight an d l eft T he sa m e flat

. .

rol l ers eye bolts an d th read ed rod for adj u stm ent can be u sed
,
-
,

as b efo re Th ese arm s shou ld be fo rg ings an d m ade qu ite

.
,

h eavy as they have somet im es to stand a v er h eavy st rain

,
y
.

At l east two -in ch bolts shou ld be u sed to faste n them to

t he c ro sshead .

With th is outfit on h and a great m any cast form s are dis

en sed w ith I n som e shop s th ese b ecom e a posit iv e nu isanc e
p .
,

bei ng so num erou s an d rep resent ing qu ite a valu e in u sel ess
,

m aterial .

Ta ck a nd Ta ck Dies
-

Although p roduced by wh at looks to be t he c rudest of

d ies an d wh ich are m ade an d kept in o rd er by t he u se of t he
,

g r ind ston e or em ery wh eel a lo n e t he m a nuf actu re of tack s is

-
,

at tend ed w ith t he l east wast e of m at er ial an d t he sm all est ,

 M ACH N E I -
F O RG I N G M ET H DS AN D PR CESSES
O O 2 45

pe c nt g of bad work of an y bu siness In t he sheet metal l ine

r e a e ,
‘

that I k now of .

Som e years ago I was i nt erested m ech an ica lly in the, ,

— T m ak in g t oo ls an d t heir act ion

FI G . 23 3 . ac k - .

m ak i ng of both tacks and tack m ach in ery -

, an dwh i le thus en
gag ed I accumul at ed a lot of i n fo rm at ion on the su bject t hat
m ay interest my readers .
2 46 DR O P- F O RGI N G, -
DI E SI N KI N G , ET C .

Tacks w ere fi rs t ( I was go ing to say inv ented but I h ardly ,

th ink I cou ld back th at cl aim up ) m ade in t he seven teenth

centu ry an d i n 1 7 7 5 on e J erem iah Wi lk i n son of Cumber l and
, , ,

R I st arted the m anufactu re of tacks cut f rom sh eet iron

. .
,
-

w ith h and shears an d h eaded w ith a h and hamm er in a bench -

V ise I n 1 7 86 Ezek iel Reed of Bridgewater Mass in v ented

.
, , , ,

a m ach i n e th at wou ld part ial ly m ake a tack an d i n 1 7 9 8 he ,

took out a patent on a m ach in e for cutt ing O ff an d h ead ing

th em in one operat ion Th is m ach ine was fed by hand ; but
.

w ith th at except ion it was p ract ical ly the sam e as t he Reed

n ai l m ach i n e in u se to da I 1 7 2 7 Thom B
-l nch d of
y n as a. ar , ,

FIG — Com p l et e ck l
. 234 . set of t a m ak i n g
- t oo s .

Ab ingto n M ass
, , i nv ent ed a m a ch i n e i nt end ed espec ially for

tacks Th is m ach in e is wh at is known to th is day as the

.

Bl anch ard tack m ach in e, an d is the only successfu l m ach ine

-

in u se for cutt ing t acks f rom sh eet metal th at I am acqu ainted

-

w ith As fi rst m ade, it was a h and fed mach in e, wh ereas n ow

.
-

it is autom at ic ; but w ith th at exc ept ion the m ach i n e was p re

cisely the same as bu ilt to day - T he tack is cut off by the.

contact of the two upper kn iv es ( see F igs 2 3 3 an d 2 3 4) an d .

t he bed kn ife b elow I n t he act ion O f cutt ing, t he t wo u ppe r

.

kn iv es wo rk as one ; an d as soon as t he bl ank for t he tack is cut

“ ”
off an d the l eft hand kn ife known as the
,
- loggy stops an d
, , ,
“
t he righ t h and one cal l ed t he l eader hold ing the bl an k by
, ,
2 50 DR O P- FO RGI N G ,
-
DI E S NI KI NG , ETC.

Op er ation
f o Process

The operat ion of the m ech an ism can pe rh aps best be d e

sc ribed by fol low in g t he mov em ents of t he opera to r i n m ak i n g

a sin gl e wo rk in g st rok e on a fo rg i n g start in g w ith t he ram i n

-
,

t he posit ion shown in F ig 2 3 5 w ith t he d ies togeth er

.
, T he .

movem ents of t he p ress are co n t rol l ed by lev er L T he ope r .

ato r fi rst d esires to raise t he ram B for t he pu rpo se O f i n sert i n g

t he wo rk. H andl e L is pul l ed ov er toward t he right th is open s ,

FI G . 23 6 .
—
Rap id ac t i on l
hy drau ic forg in g p ress .

valv e R fi rst allow in g t he stem to enter u n der t he p isto n s

,

in l ift in g t he cyl in d ers D Ram B is thu s raised fo rc i n g

.
,

t he w at er contai n ed in cyl in d er C b ack th ro u gh p ipe I i nto

t he w ater en d of t he i n t en sifi er at G When t he in ten sifi er.

ra m has b een fo rc ed dow n ward an d t he spac e above it has

been compl etely fi l l ed w ith t he retu rn ing water t he upward ,

mov em en t of ram B wou ld hav e to cease did not t he ope rato r ,

cont in u e to pu l l l ev er L farth er toward t he right Th is .

act io n opera tes a rel ay v alv e at M wh ich adm itt in g steam

, ,
 M ACH I NE- FO RGI N G O
M ET H DS AN D PR CESSES O 251

u n der an aux i l iary p iston I V open s v alve E thu s allow ing t he

, ,

water in p ipe I to escape into t he water spac e of reservo ir F -

.

Th is reserv o ir has a lower compartm ent co n tain ing air under

moderate p ressu re but t he steam in t he cyl in der fu rn ish es su fli
,

c ient force to ret u rn t he wate r to t he reservo ir again st t he air

p ressu re contain ed in it T he ram bein g th u s raised for t he
.

in sert ion of the wo rk t he opera to r retu rn s l ev er L to it s

,

centra l position wh en all valv es are closed an d t he parts are

,

in equ i l ib rium .

T he wo rk b eing p roper ly p resented to t he d ies t he oper ,

ato r pu sh es t he cont ro ll i ng l ev er toward t he l eft Th is mov e .

m ent fi rst sh ifts p iston valv e R an d conn ects cyl ind er D w ith
t he exh au st T he we ight of the ram an d die I s thu s l eft u n
.

suppo rted an d the de scend at t he rat e of about 2 f eet per

, y
second b eing h elp ed along by t he wate r under p ressu re i n
,

reserv o ir F enter i ng th rough v alv e E wh ich is arranged as a

, ,

ch eck valv e an d freely perm its movem ent in th is d irect ion

-
.

AS t he die reach es t he wo rk a f u rth er mov em ent of h andl e L

,
-

to t he right th rough t he con n ect ing mech an ism shown open s

, ,

t he b al anc ed popp et v alv e S S adm itt in g steam to t he u nd er

,

sid e of t he p iston i n t he st ea m cyl ind er H of t he inten sifi er -

.

T he upward mov em ent of t he ram result i ng f rom th is fo rces

t he w at er u n d er t rem endou s p ressu re i nto cyl i nd er C of t he

p ress g iv ing t he movem ent an d p ressu re requ ired for the

,

wo rk ing of t he m etal .

Th is m ovem ent is under st rict contro l t he len gth of t he ,

st rok e of t he in t en sifi er p iston b ei ng l i m ited by the amou n t by

wh ich l ev er L has been pu sh ed ov er toward the l eft Th is .

govern in g act io n is O btain ed th ro u gh a float ing lever m ech an

ism sim i l ar to that u sed for wate r whee l governo rs st eering
,
-
,

eng in es et c A bar K set on an an gle is en ga ged by a roll er

, .
, ,

P at ta ch ed to t he i nt en sifi er p iston rod The p u sh ing of l ev er -

.

L to t he l eft mov es bar K toward t he rol l As t he roll t ra v el s .

up K it pu sh es it back again an d t he pu sh ing back of th is bar

,

is t ra n sm itted th rough t he float ing l ev er to in let v alv e S an d

exh au st v al v e 0 opera t i n g th em i n su ch a fash ion as to stop
,

t he m ovement of t he i n t en sifi er at t he desired poin t .

2 52 DR O PF O RGI N G
-
, DI -
E S I N KI N G , ET C.

Prov ision is m ad e for Sho rt ra p id st rokes und er ful l pres

su re for such wo rk as rou n d ing
, swagein g cogg i ng dow n , , ,

etc By m ean s of a l ev er show n in F ig 2 3 5 at t he ope rato r s

. .
’

l eft hand t he conn ect ion between lever L an d valve R m ay be

,

sev ered Th is cond it ion is shown in F ig 2 3 5 by the dott ed

. .

l in es show ing t he l ink attach ed to t he bel l c ranks raised

, .

Weight Q u n de r these cond it ion s d rops valve R keep ing t he

, , ,

l ift ing cyl ind ers in con stan t commun icat ion w it h t he steam
pressu re N ow t he handl e L being worked back an d fo rth
.
,

f rom l eft h and to t he cent ra l posit ion steam is alter nately ,

fo rc ing t he ram down an d allow ing t he steam p ressu re at D -

to b ring it back U nder th ese c ircum sta nces t he water und er

.
,

p ressu re in reserv oir F is not u sed at all si nce h andl e L is ,

not moved to t he right far enough to separa te rel ayv alve M .

Th is rap id act ion b rings t he p ress in to t he same cl ass w ith t he

steam h amm er for opera t ion s of t he k i nd ref erred to
-
.

Work Pressu re for Small

For sm al le r wo rk th at requ ir in g a p ressu re of f rom 1 50 to
,

3 00 ton s t he singl e column type of m ach i n e il lu st rat ed in

, ,

Fig 2 3 7 is u sed
. I n th is t he whol e m ech an ism is self con
, .
-

t ain ed as shown t he i nten sifi er be i ng mou n ted at t he rear of

, ,

t he f rame wh ich is ho l lo w an d serv es as a rese rvo ir for t he

,

wate r supply und er pressu re The m ethod of operat ion an d

-
.

t he p ri nc ipl e of t he m ech an ism are howeve r id en t ica l w it h , ,

th at of t he l arger p resses T he 1 50 an d 2 00 t on m ach ines .

w il l wo rk 6 an d 8 inch d iam eter in gots successfu l ly For t he .

l arge S izes w ith the o rd in ary steam p ressu re of 1 5 0 pounds

,
-

er squ are i nch an d wate r p ressu re of 2 % ton s per squ are i nch
-
p , ,

t he size of i ngots wh ich can be wo rked v ar ies f rom 1 0 i nch es

for t he 3 00 ton siz e an d 3 6 inch es for t he
-
ton size to -
,

7 2 inch es for t he ton size T he sm al lest Of th ese

-
.

m ach ines wo rk i n g on short stroke w i l l m ake 80 strokes per

, ,

m inute w ith the reservo ir F cut ou t an d steam pressu re on -

the raisin g cyl in d ers as d esc ribed ; an d w ith a m ach ine as

l arge as ton s as m any as 6 0 effect ive st rokes per
,

m inute m ay be obtained Th is g reat rap id ity O f act ion

.
2 54 O
DR P- FORGI N G ,
-
D E S N
I I KI N G , ET C .

b rings t he hyd ra u l ic p ress well w ith in t he field of t he sm al l

-

an d m ed ium s iz ed st eam h amm er Such p resses are som e

-
.

what mo re expen siv e than h amm ers of equ iv al ent power but ,

t he add it io n al co st of t he fou n d at ion s for t he l atte r app roxi

m ately counterbal ance th is co n d it ion so th at t he fi rst cost is ,

real ly about equ al O n ly about h alf t he steam is requ ired

.

for t he p ress an d it is much less l iabl e to wast e th rough

,
.

wear a n d n egl ect I t has al so t he great adv an tages that t he

'

b reakage O f t he wo rk ing parts is v ery sm al l an d t he tool s can ,

be m ade l ighter an d ch eaper an d l ast longer , .

Hot-Pressed N u t-M a chine

T he l in e eng rav ings Fig 2 3 8 h erew ith il lu stra te the
, .
,

Bu rdict hot pressed nut m ach in e bu ilt by t he H oward I ron

- -

Wo rks of Bu ff alo N Y Th is m ach ine is O f heav y design

, , . .
,

as i nd icat ed i n t he i l lu st rat ion an d w i ll fo rm f rom t he bar hex

,

agon or squ are nut s of an s iz e f rom to 1 % i nch es

y .

Ref erri n g to F ig 2 3 8 wh ich g iv es a clear id ea of t he con

.
,

st ruct io n an d opera t ion of t he m ach in e it w i ll be seen th at t he ,

sl id e AA wh ich carries t he cut off for severing t he stock is -

,

actu at ed by a cam B wh ich is mount ed on the d r iv ing shaft

,
-
,

togeth er w ith fou r eccent ric s C an d two fly wh eel s ; t he con -

n ect ion between t he two po rt io n s of t he cut off sl id e are -

adj u stabl e for w ea r by m ean s of j am nut s so th at b ackl as h is ,

avo id ed an d smooth runn in g ass u red T he cut off D is h eld .

-

in a hold er E by a set sc rew E a n d t he hold er is tu rn ed

’
"

bolted to t he S ide th at it Can be adj u st ed to a l im ited exten t .

T he fo u r ecc en t rics are i n two pairs for operat i n g t he sl ides

F an d G wh ich c arry respect iv el y t he c rown er an d p iercer ;
, , ,

t he s l id es an d ecc en t ric s b ein g co n n ected by eight rod s H fo u r ,

on each sid e of t he m ach in e T he p iercer is h eld in it s sl id e

.

by a v ery st rong f r ict ion cl amp I an d is read ily removed

-
, .

T he p ierc er s l id e co n n ect io n s are r ig id t he w ear b eing taken ,

up on t he eccen t r ic st raps .

T he c row n er I is h eld in it s s l id e by cl amp bolts a n d t he ,

conn ect ion s on t his sl id e are so arra n ged t hat wh en t he nut is

bein g p ressed in to sh ape t he p ressu re c om es o n a v ery h eavy
 MACH I NE- F O RGI N G M ET H O DS O
AN D PR CES SES 255

a butm ent K an d does not strain t he eccent rics an d opera te t he

,

S l ide .T he fo u r rod s con n ect ing t he ecc en t r ic s an d t he s l ide

pass f reely th rough the t runn ion conn ect ion s L an d each O f ,

t he rod s is p rov id ed w ith a sp ri ng M wh ich is co n fin ed as , ,

show n b etween t he en d of t he con n ect ion L an d t he col l ar

,

cl amped to t he rod Wh en t he sl id e reaches t he abut m ent

.
,

—
FI G . 23 8 . H o t -p ressed nut m ac h i n e .

t he r ods sl id e on a certain d istance l eav ing t he stat io n ary lo n g

,

en ough fo r t he n u t t o be p ressed or c row n ed t he sp r in gs M ,

o n t he rod s tak i ng u p t he s l ack o n t he retu rn st rok e w ithout

no ise or shock .

I n operat in g th is m ach in e t he h eated stock is fed in f ront

,

of t he fo rm in g d ies N aga in st a back gage O ( an d al so again st

-

a b ack gag e wh ich do es n ot Show ) an d t he cut off adv anc i ng

,
-
2 56 D RO P FO RGI N G
-
, DI E-S I N KI N G , ET C.

’
cuts O ff an d fo rces t he stock for t he n u t into t he d ies b ringing ,

it up to t he c rown er ( wh ich is stat ion ary for t he t ime being )

an d p ressi ng it i nto sh ape Wh ile t he partly fin ish ed nut is
.

h eld rig idly between t he c row n er an d cut off the p iercer ad -

,

v an ces an d compl etes t he n u t As soon as the hol e is p ierced . ,

t he cut O ff wh ich is h eld stat io n ar y du ring t he p ierc i ng opera

-
,

t ion moves back an d t he c row n er fol lows it up but at a slower

, ,

pace so th at wh en t he cut O ff arrives at t he en d of it s stroke

,
-

an d t he w ad e or sc rap is ej ect ed by m ean s of t he stat ion ary rod

P t he nut is shoved outsid e of t he fo rm ing d ies by t he c rown er -

an d d rops u n d er t he m ach i n e Shou ld t he nut h av e an y ten .

den ey to st ick it is removed by a knock off Q wh ich is oper

,
-
,

ated by a cam on t he m ain sh aft ; thu s it is i mposs ibl e for t w o

nuts to get i nto t he fo rm ing d ies at t he sam e t im e under an y -

cond it ion s .

Th is m ach in e can be ch anged f rom on e siz e of nut to an

oth er v ery qu ickly as o n ly t he tool s requ ire chang in g t he
, ,

movem ent of t he v ario us m embers O f the m ach in e being t he

sam e for t he d iff erent siz es O f nuts .

T he speed of t he m ach in e d epend s som ewh at on t he ex

pert n ess of t he opera to r a speed of about 80 tu rn s per m in ute
,

u su ally g iv ing good results T he m akers state that t he output

.

is f rom to nuts per day O f t en hou rs .

T he m ach in e is v ery r ig id a n d w eigh s wh en ready for , ,

wo rk 9 000 pounds I t has fly wh eel s 48 x 7 an d 6 0 x 7

, , .
-

inch es an d m ay be b elted d irect f rom a clutch on t he l in e shaft

,
-
.

A sm all er m ach in e is bu ilt on sim i l ar l i n es for to §é

in ch n uts Th is ru n s at 1 1 0 to 1 2 5 tu rn s per m inute has
.
,

fly wh eel s 3 0 x 6 an d 3 6 x 6 inch es an d w eigh s

- pou n ds , .

A l a rge Hydra ulic Forgi ng M a chine

In
o rd er to redu ce t he cost of wo rk certa in sm th S hop
i -

done by t he Pen nsylv an ia Rail road t he mu lt icyl in d er hy ,

drau lic fo rg i ng an d upsett i ng m ach in e shown in F ig 2 3 7 was ,

.
,

design ed an d bu ilt .

The m ach in e has been in operat ion over a y ear an d has

m ore than m et t he expectat ion s of those respon sible for it s
 D RO P F O RGI N G
-
,
DI E S N
-
I KI N G , ETC .

form er w ith m al l ets Th is was a ted ious an d expen siv e pro

, .

cess requ iring a n u mber of beat in gs for each bucket an d as

, ,

mo re of th em would probably be n eeded for futu re d redges we

dec ided to m ake a pair O f cast iron d ies an d fo rm t he buckets
-

in a singl e op erat ion w ith t he pou nd steam h amm er -

.

We had on h and a sampl e bucket of i n ch steel an d as -

,

t he sm al l reduct ion s i n S ize by sh ri n k age of t he die cast i n gs -

were not obj ect io n abl e I u sed t he sampl e bucket as a pattern

,

f rom wh ich to mold t he cu rved po rt ion of t he two d ies A .

ch eap wooden f ra m e A F ig 2 42 was n ail ed up for a patter n

, .
,

for t he body of t he f em al e d ie t he sampl e bucket B was set in

,

it an d fasten ed w ith wood sc rews S S an d his wood an d iron

, ,

pattern was blocked up in t he d rag Sand was then ramm ed

.

—
FI G 2 3 9
. L ocom ot iv e forg i n gs m ade in hy drau l ic m achi n e .
 O O
M ACH I N E F RG I N G M ETH DS AN D PR CESSES
-
O 2 59

in t he drag arou n d the side an d i n side of the p att ern The .

dovetail st rips, Q , were th en set , the part ing m ade an d the cope
rammed up , the mold n ow appear i ng in sect ion l ike F ig 2 40 . .

I t was the n rol led ove r, the blocks removed , the bucket B
un screwed an d l ifted ou t of the f ra me Part ing sand was th en
.

u t on t he cu rv ed su r face left by t he b racket , an d t he dra g

p
was ramm ed up agai n st th is san d pattern The d rag was l ifted
.

an d t u r ned, t he wood an d sand patte r n remove d f rom t he cope,

an d t he mold clo sed , app eari ng i n sect ion l ike F ig 2 43 The

. .

m ale die was mold ed in a sim il ar m ann er, an d as shown in

Figs 2 44 an d 2 45
. .

T he mold i ng was don e w ith c are an d t he result ing cast i n g

,

was exc el l ent. T he m a l e die was pl an ed to fit t he h amm er

-

~l
l
e —a x "
~ —

. “
L a n

9 4’

FI G 2 40
.
— L oc om ot iv e forg i n gs m ade in hy dra u l ic m ac hin e .
260 DR P O FO RGI N G,
- DI -
E S I N KI N G ,
-
I rrc.

head an d t he femal e to fit t he anv i l b lock T wo l i h gu ide

,
-
.
- nc

p i n s
, w ith th eir out er ends w ell tapered w ere d ri v en t i ghtly ,

in to the lower su rfac e of the m ale die The p l ates for t he .

buckets were cu t to very n ear ly t he co rrect shape an d two ,

holes E Fig 2 41 we re p u nch ed for the gu id e p in s After

, , .
,
-
.

h eat ing in t he fu rn ace the pl ate was h eld up on t he gu ide

,

p in s wh il e the h amme r was b rought carefu lly down not st ri ,

k ing an y blow unt il the pl ate was fo rced n ear ly to sh ape Th is .

gave t he h elpers t ime to take th eir tongs away after t he pl ate

touched the upper edge of the low er die O n e or two blows .

then took out an y w rinkl es an d fo rm ed t he bu ckets n icely .

The ent ire lot of buckets were fo rm ed easily in on e after noon ,

FIG . 2 41 .
— D esign l
of e ev at or bu c k et .

th eir sh ape was more un ifo rm than that of t he h and m ad e -

buckets an d t he l abo r saved on th is on e lot more than paid

,

for t he d ies .

A I ob fi r t he Hea vy wagi ng M achine

S -

T he fi n ished fo rg i n g F ig 2 46 shows wh at can be do n e on

, .
,

a h eavy swag i ng m ach ine sim i l ar to the Ar m strong Wh itwo rth

- -

type an d a desc ript ion of how it is don e an d t he swages u sed

,

m ay be of i nterest .

Th is m ach in e has fou r ram s m ak in g about 6 00 blows of 1

,

i nch st roke per m in ute I t has al so fou r lower ram s wh ich are
.

adj u st abl e to su it t he part icu l ar job an d th ey can a l so be ,

mov ed wh en requ ired wh il e operat ing i n fo rg ing The d iam .

et er an d l ength requ ired are d eter m i n ed by t r ial I t is easier .

to m ake two h eads th an on e at t he sam e t im e as all t he fo rces ,

are bal anc ed an d h enc e th ere i s no j erk i ng of the fo rg i ngs as

,

wou ld h appen when m ak in g on e; for th is reason as well as t he ,

262 DR O P- FO RGI N G , DI -
E SI N KI NG , ETC .

an d w idth on t he other end Of the sam e swages by alternatel y

passin g it t hrou gh fi rst on e way an d the n t he oth er as ca n ,

read i ly be seen All of these op era t io n s are rap idly per

.

fo rm ed the fo rg in gs be i ng th en separated an d th is fin ishes

, ,

t he fi rst h eat .

The second h eat con sists in fo rm ing t he V -sh aped part ,

Fig 6 inten d ed to fit ov er an in ch squ are bar an d in mak i n g

.
,
-
,

FI G . I The Work

The Stock

Resu l t s of First H eat

FI G 2 46
. .
— F orgin g in t he heav y swagin g m ac hin e .

t he qu arter tw ist both as seen in t he fin ished fo rg ing Fig 1

, , . .

T he fo rm i ng swages i llu st rate how the V is set i n the swages ,

be ing show n in t he ope n posit io n T he forgi n gs are located .

between t he strips an d t he lowe r ram is m oved u p qu ickly

,

wh il e the blow from the u pper ram bends t he fo rgi ng into

t he sh ape shown t he st rips wh ich are of t he same th ickness
, ,

as t he fo rg i n gs act i ng as stops
,
.

T he qu art er tw ist is m ad e by a fixtu re wh ich con sists of

 M ACH N EI -F
O RGI N G M ETHODS AN D PR O CESSES 26 3

two m ai n parts t he hold er an d t he key t he co n struct ion of

, , ,

both being ch iefly shown T he face on the fo rgi ng is brought

.

up to t he face of t he hold er ; t he key is moved along t he pin

on wh ich it rests as shown in t he el evat io n an d wh ich also
,

keeps it cen t ral w ith t he socket in t he hold er .

N l n
i i
I II

l l l
—
FI G 2 47
. . Passen ger-car t ru c k sw in g han ger .

T he lev er wh ich opera tes t he gripp ing pl ate by m ean s

of an eccentric p in is th en raised after wh ich t he key is ,

rotat ed u n t i l t he h an dl e st r ikes t he stop tw ist ing t he fo rg in g

,

w ith it to t he requ ired angl e T he fo rg ing is remov ed by

.

s l ipp i ng t he k e b ack on to t he i d th n pu h i ng t h
-
y p n an e s e

l ev er back to t he open po sit ion .

I n a fixt u re wh ich is l ikely to b ecom e hot by co n tact w ith

264 O
DR P- FO RGI N G, -
D I E SI N KI N G , ET C
.

t he m aterial operated upon an d wh ere sca l e gathers gr ipp in g ,

sc rews are obj ect ion abl e ow ing to the d iffi cu lty of retain ing

t he gr ipp i ng pl at e such as F in pl ac e an d al so on accou n t of

lub ricat io n T he reason for u sing t he eccentr ic p in wh ich is

.
,

qu ick in it s act ion an d self lock ing is m ainly to overco m e th is

-
,

t roubl e an d it is a good con st ruct ion I n o rde r to get rid of

,
.

FI G 2 48
. .
—
Bol st er for p ost a l an d baggage cars .

c l wh ich w il l n atu ra lly gath er in t he holder socket a s lot

t he s a e ,

is cut into wh ich all t he sca l e w i l l d rop k eep i ng t he sock et ,

cl ean for t he key to operate in .

Th ese tool s are fo rged f rom steel except t he qu arter tw ist

,
-

fixtu re t he holder bein g a gray iro n cast in g All are ca refu l ly

,
-
.

m ade t he swages requ irin g spec ial care in m ach in in g as w i l l

, ,

be apparen t T he swages are arra n ged in t he ra m s so th at t he

.
,
266 DR O -
P F O RG I N G , DI E-
S N I KI N G , ET C.

th m ch ines daily is su rp rising,

ese a an d no wel l equ ipped S hop
-

shou ld be w ithout th em .

In ch fo rg ing m ach ine we are t u rn ing out t he

ou r 4i
- n -

fol low ing as per Figs 2 47 2 48 an d 2 49 : Sw ing hangers for

, .
, ,

passenger car t rucks bol sters for all baggage an d posta l cars
-
, ,

c rown bars for locomot ive bo il ers d rawbar stra ps for baggage ,

an d f reigh t cars conn ect i n od fo S L sw i tch -st nd s s l id e

g r , s r a . .
,

pl ate sw itch es an d oth er forg in gs too numerou s to m ention

, ,

so me of wh ich are S hown i n F igs 2 5 0 an d 2 52 . .

I n design i ng t he d ies for t he wo r k to be don e on these

m ach in es the fi rs t th ing to do is to figu re out t he n ecessary
,

FI G .
—
2 5 0 \V ork
. of t he form in g m ac hin e - an d bu ll doz er .

a mount of stock to m ake t he p iece requ ired wh ich w i l l g ive

t he el n gt h of d ie to be u se d F ig 2 5 2 .s how s a sw .i n g h a n g er

p
for ass eng e r ca r t ruck
- s w it h the ,
d ie s a n d h ea d er s fo r m a k i ng
it . F r s
o toc k e y
w la the p ar ts tog e th e r
p u t th e m i n a s,m al l
oil fi red f
- u r n ac e a n d i n
, a V e r y sho rt t i m e w e h a ve a w e ld i ng
heat about t en inch es long on them Th ey are then p l aced in .

t he low e r sp ace o f t he d i es a n d the l e v er i s o p e ra t e d T h e .

d ies close an d the h eader en ters th em t he back stop on t he ,

-

m ach in e hold in g t he stoc k f rom sl ipp ing back an d in an ,

 M ACH I NE- FO RGI N G M ET H O DS AN D PRO CESSES 267

in stan t t he
two p ieces are welded t ogether an d the h ead is
fo rm ed The stoc k is then tu rn ed en d for en d an d pl aced in
.

the u pper space of the die an d on operat ing t he lever again

,

the dies close an d the t aper m and rel enters t he die spl its t he ,

t wo p ieces of stoc k apart an d fo rc i ng th em i n t o the die com

, ,

pl etes t he h an ger as shown in the lower righ t h and V iew of

,

F ig 2 5 2 an d al so in Fig 2 5 0 We m ade f rom fifty to sixty

. . .

FI G . 251.
— Work of t he forgin g - c
m a hin e an d bu ll doz er .

of th ese h an gers per day an d it does not take l ong for a m a

,

ch in e of th is k ind to pay for itself .

Care mu st be t aken i n sett ing d ies in t he m ach in e a n d all ,

b o lts m u st be well t ightened befo re starti ng F ig 2 5 2 g ives . .

a ll d im en sion s O f the wo rk t he die an d the h ead ers

,
T he .

die seat is 2 1 in ches lo n g wh en the d ies are closed an d t he ,

h eader block is at the en d of its st roke T he space between .

t he h ead er bl oc k an d d ies is 4% i nch es Wh en sho rter d ies .

are u sed t he punch or h ead er m u st be i nc reased in l ength i n

,

the sam e p ropo rt io n As the l en gth of d ies is dec reased wh en

.

h eaders p u n ches or m an d rel s enter t he d ies t he d istance th ey

, , ,

g o i nt o t he d ies m u st al so be i nc reased .
26 8 O
DR P-
FO RG IN G ,
- I KI N G
D E S N
I , ETC.
270 DR O -
P F O RGI N G ,
- I KI N G
DI E S N , ET C.
’

two p ieces O f x 5 inch bars of an y length requ ired t he

-
,

whol e being we lded an d p ressed into shape by one O pera t io n .

We have a g reat m any target conn ect in g rod s for S P -

. .

sw itch stand s to m ak e i n t he Sac ramento shops an d th is is a

-
,

-
O rbead
v e f rom

FI G . 254 .
-
An e m ergen cy st eam - ham m er .

Simpl e job for th is m ach i n e We take ou r bar of 1 } i nc h

. é
-

rou n d iron on t he requ ired length et wh it e h ea t on bo t

g a , a u

1 1 or 1 2 inch es of it at on e en d pl ac e it in t he lower po rt io n
,
 M ACH
‘

ING FO RGI N G
- O
M ET H DS AN D PR CESSES O 27 1

of t he die an d p ress t he l ev er T he plunger com es up an d

, .

upsets an en d on the bar 2 % x 2 x 4 % i nches long We th en .

take it ou t of t he lower port ion of t he die pl ace it in t he ,

upp er po rt ion i n a v ert ical posit ion when t he die closes an d ,

t he punc h complet es t he j aw We t h en t ake t he rod t o a 3

.

in ch fo rg ing m ach i n e t hat we have c l ose by an d u pset the

-

oth er en d Th is t akes bu t a v ery sh ort t im e an d we h av e a

.
,

target connect i ng rod compl eted withou t a weld T he id ea in

- .

tak in g these rods from on e m ach in e to t he other is to sav e

t ime in changin g an d sett in g d ies .

T he bu l ldoz er as wel l as t he fo rg i ng m ach in e is a m ach i n e

,
-
,

th at shou l d be in every bl acksm ith shop wh ere t here is a large -

qu ant it y of b end ing an d fo rm ing t o be done su c h as d raw bar ,

-

st raps for passeng er or fre igh t cars arch bars for freight or ,
-

tender trucks side si ll steps u ncoupl in g levers carry iron s

, , , ,

co rn er iron s l inks an d a large q u ant ity of other wrou ght iron

,
-

wo rk th at is u sed on cars an d locomot iv es .

The face of t he m ach in e wh ic h is con sta ntly in u se in t he

,

Sac ram ent o bl acksm ith shop is 1 4 i nches h igh 5 feet 4 i nch es
-
, ,

w ide an d has t wo g roov es runn in g the widt h of t he face cut

, ,

ou t t he sam e as t he g roov es in the bed of a pl an e r .

We h ave t wo rol l ers simply con stru cted th at we fasten to

, ,

the face of the m ach in e w ith t he bolts sl ipped in t he groov es .

Co n sequ ently we ca n sh ift th ese rol l ers t o bend st raps from , ,

inc h w idth of open i ng up to 5 feet Wh en an y m aterial .

has to be b en t at right angl es we s l ip on e of the roll ers on , .

The pl at es on the back stop of t he mach ine is const ructed

-

si m i l ar ly t o t he f ace pl at e an d we f asten a ll d ies form ers an d

-
, , ,

m and rel s for th is T he m aterial is h el d in t he form ers or

.

mand rel s b efo re b end i ng by a h i nged cl amp m ad e for t he

, ,

pu rpose T he bu lldozer u sed is a N o 7 an d is l arge enough

. .
,

for all rai l ro ad p u rposes .

A R k D rill Used
oc - as a Steam-Hammer
T he drill m in u s t he t ripod was fasten ed to a v ert ica l
, ,

suppo rt abou t as s hown in t he sk etch F i 2 5 4 wh ich w

g as , .
,

d rawn from memo ry no attempt b ein g m ade to S how an

,
272 DR P O - F O RGI N G, DI E-
S N I KI N G , ET C .

x ct p ict u re but m erely enough to conv ey an idea of t he

e a ,

arrangem ent .An o rd i n ary anv il was fix ed in a posit ion

under the ram an d t he necessary air conn ect ions not shown
, , ,

were made w ith t he cyl i nder Wh en a bl acks m ith has so m e

.

h eavy hamm ering t o do he has some on e as u su al to m an age

, , ,

th is contrivance wh i le the sm ith t akes care to have t he blows

,

st ruck in the p roper pl aces as w ith a steam h amm er except

-
,

that the blows are n ot as h eav y bu t st ill mo re num erou s for ,

FIG . 25 5 .
—
Shear for c u t t i n g O ff ir on .

a g iv en spac e of t im e At t he t im e I saw th is improv ised

.

st ea m h amme r in operat io n the sm ith was work ing dow n,

a p iece of steel or w ro u ght iron about 3 i nches w id e at it s ,

w id est part 1 inc h th ick at it s th ickest part 2 % feet long

, , ,

taperi ng in both w idth an d th ickness an d the h amm er ap ,

red t o be do i ng excel l en t serv ice I t app eared t o m e as

p e a .

b ein g a v ery simp le eff ect ive an d qu ite in expen siv e appa
, ,

rat u s a n d th at i f at an y t i m e it be thought co n v en ient to

,
“ ”
disco n t inue the u se of th is r ig as a st eam h amm er it could ,
274 O
DR PFO RGI
- N G ,
-
DI E S I N KI N G , ETC .

t he base that fi t s loosely on t he bottom die of the ham m er -

,

A being a right side v iew of t he p iece I t is a steel cast i ng . .

B is t he bottom kn if e wh ich fi t s i n t he base an d is h el d in

,

pl ace w ith two i nch t ap bolts m arked F C is t he top k n i f e

-
.
,

wh ich wo rks loosely between bottom kn ife an d Side of base -

,

an d is h eld i n pl ac e by a sp r ing on each s id e a hol e being d r i l l ed,

in t he bottom of t he k n if e an d i n t he bottom of base as p er ,

S ketch l arg e enough to receiv e t he b en t en d s of sp ri ng l oose l y

, .

T he kn iv es are m ad e of sh ear st eel T he sp ri ngs E are

.
, ,

m ad e of 91 in ch round sp ring steel T he gu id e pl ates for

-
.
-

sp r in gs on en d of base m ark ed D are m ad e of 1 ; or 3 in ch

tank steel an d are h eld in pl ace by fou r
, inch t ap bolt s as -
,

shown .N arrow s lot s cut i n th ese two pl ates allow t he sp ri n g

to wo rk up an d down T he cutt ing edges of t he kn iv es
.

sh ou ld be fi l ed back a t r ifl e for cl eara nce to m ake th em cu t

better .
 C H APT E R I X

M AC H I N E - FO RGI N G W I T H
,
EX AM PLES O F M O DE RN P RAC TI SE AN D

TOO LS I N V O LV ED
M a chine Forging -

T HE p rogress in m ach n e fo rg in g,
or i n t he u se O f m ach i n
i -

er for fo rg i ng opera t ion s has: b een v ery g reat i n t he l ast

y ,

th irt y y ears T he g reater part Of t he wo rk for car an d loco

.

mot iv e co n st ruct ion now do n e by m ach in es such as bolt ,

h ead ers bu l ldoz ers steam h amm ers an d oth ers was befo re
, ,
-
,

th at don e by h an d Those tool s th at h av e com e into u se are

.

t he g reat est facto rs i n p roduc i ng fo rg ings for cars O n e for .

g ing m ach i n e an d a good m an to ru n it can p roduce mo re for

-

g ings th an t en fi res can tu rn ou t in t he sam e t im e w ith only

o n e h and at wo rk an d at t he sam e t im e t he wo rk w i ll be mo re
,

u n ifo rm .

You mu st get up t he d ies you rself to su it t he for g in gs you

w ish to p roduce as t he m ach in e is not Of much u se w ithout
,

th em I t is t he sam e way w ith a steam hamm er you ca n do

.
— -

a lmo st a n yth ing if you h av e t he d ies an d fo rm ers to do t he

ob w ith n a l arge shop it w i ll tak e al mo st t he ent ire t im e

j . I
of a fo rem an in study in g up d ies an d fo rm ers to do certain
'

jobs that com e to han d ev ery day N ot o n ly that but t he .

,

tool s for do ing t he wo rk on e y ear w il l be out of dat e t he n ext ,

an d as t i m e p rog resses t he eng in es bu i lt on e y ea r are not t he

,

sam e as t he w i ll be t he n ext ; an d mo re so w ith t he c ars Th y

_ y e .

u sed to be pou n d s capac ity n ow th ey are ,

pou n d s capac ity I t is t he sam e w ith en g in es You take an

. .

en g i n e b u i lt tw en ty y ears a o an d put it b esid e on e th at was

g
b u i lt to day an d see t he d ifferen ce ; an d so w ith all t he wo rk
-

m an sh ip d on e on th em an d t he tool s to prod u ce th eir heavy

,

forg in gs I f you h ave n o u p to d ate tool s you can not bu il d

.
- -
,

27 5
276 D R FO RGI N G
O P- ,
-
DI E S I N KI N G , ET C.

cars o r l comot iv es i
o il road shop an d compete w ith t he
n a ra -

m anufactu rers .

For i n stan ce if al l cars had t o h av e J an n ey c ou pl ers o n a

,

certain dat e an d you r company had a g reat m an y cars to eq u ip ,

an d w ere n ett i ng about d raw bar st em s per mo n th an d -

,

you had n o bolt head er large en ough to m ake -

th em T o weld a coll ar on th em by hand

.

is out of t he qu est io n as w ith on e fi re t he ,

best you can d o is th irty hy e or fo rty per -

day You d ec id e to wo rk th em u n d er t he
.

st eam h amm er T o h andl e t he bottom h ead

- .

in g tool p u t up a po st by t he h amm er ; t he
top h ead er fo rm in g t he h ead a p iece of , ,

ro u n d m ach i n e st eel about 4% in ch es in di -

am et er an d 5 i nch es long w ith t he sh ape of ,

t he h ead c arv ed in t he cent er of it After .

you d rop yo u r stem with w eld ing h eat in , ,

t he bottom to o l you p u t t he top head er on ,

t he iro n ( y o u r bottom h eade r w i l l k eep t he

top in t he c en ter of t he stem ) you hit it two ,

blows w ith t he steam hamm er th en t u rn it -

,

ov er an d d r iv e it out t he sam e way m ak in g ,

a p erf ect h ead i n c en t er of st em By p u t .

t in g fou r or fi v e app rent ic e boy s h eat in g

th em i n hol l ow fi res you can h ead u p 7 00 ,

st em s per day an d punch th em i n t he sa m e

m an n er .

I n sert t he p u nch i n t he top die an d t he , ,

FIG 2 5 1 li
.
—
mot
n
io n bei n g so q u ick you can punch
g i e cno n ec t n
,

i g ro d
n - or
.
st em s b efo re y ou n eed to d ress yo u r

p u n ch .

Aft er g ett in g all th ese tool s up a ch ange is m ade in car ,

bu ild in g : to u se n oth in g but yokes T h en study again t he .

sam e as befo re T he yokes are m ad e out of

. x 4 i nc h or 1 x

4 i nch w ith l ips doubl e ov er t he en d for a sho u ld er l ike t he

, , ,

sk etch You s imply tak e a rou n d c ou pl ing l in k weld a han

.
,

dle on on e en d put a sh arp f u ll er in pl ace wh ere you wan t t o

,
27 8 D R OP- FO RGI N G , DI E S N - I KI N G , ET C
.

a g ricu ltu ra l eng in es T he qu a l ity as wel l as t he cost n ot

.

bein g sat isfacto ry it was determ in ed to m an ufactu re t he rods

,

at hom e an d if possibl e to red uce , , ,

t he co st an d imp rov e t he qu al ity .

F ig 2 5 7 show s t he d esign ad opt

.

ed T he body O f t he rod was smoo th

.

forged an d l eft unfin ish ed , T he .

boxes were of good grad e of b ras s .

T he take u p was accompl ish ed by t he -

wedge as Show n I n d etail t he m an .

u fact u re of t he rod was as fol low s :

T he body of t he rod was fo rged

f rom a bar steel 3 % by 2 §é inc hes -

FI G 2 5 9
.
— M i ll in g t he und er a steam h amm er an d in o rd er
.
-
,
sides of rods
to qu ickly b r ing t he p iece to a
.

smooth fin ish an d to u n ifo r m S iz e d ies w ere m ad e as show n ,

by F ig 2 5 8 t he su n ken die bein g key ed an d bolted to t he

.
,

anv i l block
-
an d t he m a l e h a lf t o t he h ead of a d rop ham
,
-

m er . T he bar of stee l b ein g of t he p rop er siz e for t he c rank

en d of t he p iec e w itho u t f o rg in g th at en d of t he d ies was

m ad e l arge enough to receiv e t he bar

wh en hot T he body of t he rod an d t he
.

c ross h ead en d was fo rged sl ightly sm all er

th an t he die t he wid e way an d sl ightl y ,

l arger t he oth er way Aft er fo rg ing t he .

,

p iece was b rought to a b right red h eat an d

pl aced in t he die an d t he h amm er d ropped
on it fo rc ing t he su rpl u s t hick n ess of
,

m etal to fi ll t he die th u s m ak in g a smooth

,

p iece of wo rk an d an y s u rpl u s b ein g fo rced

ou t at t he bar en d T he work was don e
.

befo re cutt in g off f rom t he o rig in al bar ,

t h u s av o id i n g a ll wast e Th is p iec e of .

forg in g w eigh ed 3 2 po u n d s ; t he m aterial

at th at t i m e co st c en ts per po u n d ,
Fx z
fig fig : nz s g
ll
thu s m ak in g 6 0 cen ts A bl ac ksm ith an d .

e j
helper to geth er receiv in g p er da
y c o n n ec t i n g rods
- .
 M AC H I N E FO RGI N G
- ExAM PLEs OF I
PRACT S E 279

fo rged 2 0 rod s about 2 2 c en ts per rod Add ing to th is 2 5

,
.

pe r c en t for fu el an d repairs we h av e a co st of
.
,
each for

th is p ric e.

T he st raps were m ad e O f 2 56 by inch steel weigh ing

2 8 pound s an d co st ing 5 2 cents Th ese were cut from t he
.

bar in p roper l ength s h eat ed i n a h eat i ng fu rn ace an d bent to

,

— Ben din g
FI G 2 6 1
. . t he S t rap s.

h p
s a e in a bu l ldoz er Wh en even ly h eated they we re placed
.

in t he die as S hown in F ig 2 5 9 on e eird rest ing again st

, .
,

the stop D F ig 2 59 shows t he die an d plunger, a sect ion ,

. .

F F bein g a gu ard ext end ing ov er t he plunger to p revent

,

the p iece wh ich was being opera ted u pon f rom gett in g out
of pl ace O n e revolut ion of t he m ach in e fo rc ed t he plunger
.

fo rward an d back aga n to t he start ing po int, each rev olu

i -

t ion b end ing a st rap in to Sh ape T wo m en u sing a sh ear

.

an d th is m ach in e could cu t off h eat an d b end 400 st raps

, ,
2 80 D RO P Fo RGI N G
-
,
I KI N G
D I E-S N , ET C .

per dayof t en hou rs cost ing a l itt l e ov er on e c ent each i n

,

l abor Add ing to th is an al lowance for fu el an d d ies

.

an d t he cost of m aterial we h av e t he two stra p s compl eted a t

,

a tota l cost O f 6 1 c ents T he m ethod u sed in bend i ng th es e

.

stra p s was to cut off su fli c ien t bl ank s of v ariou s siz es to keep

the m ach in e wo rk in g a day of two at a t im e I n two days .

,

i nclud i ng ch ang i ng of d ies su ffi c ient st ra p s could be bent t o

,

keep t he wo rks suppl ied for severa l month s .

N o doubt th ere are m any readers who n ever saw or

h eard of a bu l ldozer Th is .

m ach in e is now exte n siv el y

u sed by bu i lders of agricu l
tu ra l mach in ery for fo rm
i n g all var iet ies of sh apes .

I t wo u ld not p ro bably pay

eng in e bu i ld ers to put in
th is m ach in e u nl ess requ ir
in g m an y fo rm s of bent
wo rk as su ch a m ach in e ,

woul d ben d f rom eight to

twelve th ou san d st raps per
mo n th if wo rk i ng on th em ,

al o n e .

We n ow h av e t he for
g in gs compl ete for a 1 0 by
1 2 i n ch c o nn ect i ng rod at a -

cost of T he end s of
t he rod s w ere fin ish ed on

FI G 26 2.
-
Pla i n g t h
n n ds
a
e e
"fou r S d es in a m i ll i ng
i
of rods .
m ach i n e s ix a t on e t i m e , .

T h ese could be m i ll ed com

p let e i n two hou rs at a c ost of 40 c en t s A dd i ng to th i
.s a

p ercentage for k eep in g u p t he c u tters et c we have a cost , .

,

of 8 % c ents per rod .

T he n ext operat io n was fi n ishi n g t he en d s of t he rod s .

Th is was do n e in a h eavy d raw cut sh aper A chuck ( see - .

Fig 2 6 2 ) b ei n g bo lt ed again st t he h ead of t he sh aper an d

.
2 82 D RO P- FO RGI N G ,
-
DI E S N I KI N G , ET C .

s l itt ing saw T h ese were m ade in l arge l ots at a l abo r c ost
.

of 3 cents each .

T he b rass boxes for each en d w ere cast in on e p iece T he .

weight of th ese per set was 8 pounds Bra ss cast ing at that .

t im e cost 1 5 cents per pound m ak ing t he cost per set

,

T h ey w ere bo red an d f ac ed in a tu rret l ath e th en pl ac ed in a ,

i
j g i n a doubl e sp i ndl e m i l l i n g m ach i n e a -
n d m i l l ed on a ll
,

fou r sides to fit t he stra ps Th ey were afte rward cut in two

.

w ith a sl id ing saw These boxes were m ach in ed in lots of

.

f rom 50 to 1 00 t he l abo r cost being 2 0 cents per set

, .

Each conn ect ing rod requ ired fou r bolts for bolt i ng t he
-

stra ps to t he body of t he rod an d two bolts for t he adj u st i ng

,

wedges Th ese were m ade in a tu rret m ach in e f rom h exagon

.
-

stock co st ing i n l abo r 2 5 c ent s an d i n m at er ia l 1 7 c ent s

, J igs .

were m ad e for d r ill in g t he st raps t he body of t he rod an d t he

,

adj u st i ng w edg es . D ril l in g th ese c ost 3 0 c ents .

T he assembl ing of t he v ar iou s part s was don e by t he p iece ,

for wh ich 7 5 c ents per rod was p aid T h is wo rk inclu ded

.

smooth i ng up t he sh arp co r n ers t app in g t he hol es i n t he,

wedges an d fitt ing t he boxes to t he straps T he variou s item s

,
.

of cost were
Forgin gs, i nclud ing m aterial for t he adj u st in g wedges . .
$l 6 9
.

M ach in ing rod body 13

M ach in ing st raps 30
M ach in ing w edges 03
Bra ss boxes
M ach i n i n g box es 20
M aterial for bolts 25
M ak ing bolts 17
D ri ll i ng 30
Assembl ing 75

Add in g 2 5 p er c en t . fo r t he s hop expense we h av e tota l

cost
Inth is ch apter I hav e d esc r ibed t he tool s an d m ethods
u sed i n t he m an ufactu re of som e part s of a 1 0 by 1 2 i nch
 M AC H I N E FO RGI N G
- ExAM PLEs OF R
P ACT I S E 2 83

eng in e by m ean s of wh ich t he pl ant was b rought up f ro m a

,

n on pay i ng cond it ion to a v ery p rofit abl e on e

- .

The sm al l er parts of wh ich th ere has b een no m ent ion

,

m ad e were all m ach in ed in t he u su al way the wo r k on th em

, ,

be ing don e by the p iece .

D ie fbr Ta m ing Ey Bolts e-

T he accompan y ing ketch es ( F igs 2 6 5 2 6 6 ) S how an eye

s .
,

bol t bend er for t he bu lldozer or h ead er We fou n d ou rselv es .

in a posit ion wh ere we had to b en d about i

H nch ~

eyes of yé inch stock p er season ,

an d the d ies shown do es the wo rk

w ith an i nc reased outpu t O f about

3 00 per c ent .

At a is t he body of t he die ,

an d at b an d c are p roj ect io n s

f ro m it s face t heir in n er edges ,

an d top s b eing pl an ed as was t he ,

spac e between th em A p late d .

b ridges ov er b an d c an d a tool ,

st eel S l id e c sh ap ed on on e en d to
,

fit on e side of the eye an d on t he

oth er l eft st raight except the beV pm 2 6 4
, M ac hin i g in . . n

el i ng of on e co rn er as shown s i d s r f c e of rods , e u a .

fi t s t he spac e betw een b c an d , ,

d . At f an d g are t wo add it iona l p roj ect ion s an d at h is a ,

aw fitted w ith a h ard en ed steel f ac e h eld down w ith two

j V
inch cap sc rew s a n d fitted w ith two adj u st i ng sc rews as shown
-
, .

T he p in i arou n d wh ich t he eye is fo rm ed is arra nged to be

, ,

w ithd rawn du rin g t he back stroke O f t he bu lldoz er I t is-

.

m ad e of tool steel an d is h arden ed as is t he bu sh ing in t he

-
,

pl ate d T o t u rn d iff eren t siz es O f ey es su itable sl ides p in s

.
, ,

an d bu sh ing s are m ad e .

T he stock is en tered at r ight O f t he p in i to t he gage an d ,

t he ram j en t ers betw een t he aw h an d s l id e e an d of co u rse

j , ,

forces ghe l atter toward t he p in an d part ly fo rm s t he eye leav ,

in g t he su rplu s stock st ick in g out in a ho rizo n ta l p osit ion ,

2 84 D RO P- FO RGI N G, -
DI E S I N KI N G ,
ET C .

wh en t he tool teel ra m k compl etes t he t u rn ing by en gag ing

-s

w ith t he incl in e on p iece I .

About 1 in ch eyes of "

-
p in ch st ock ar e bent cold
p er da y of n i ne hou rs .

Wh i l e the repair S hops of the L eh igh V al ley Rail road

in
Compan y at Sout h Eas ton some i nterest ing m ethod s an d
, ,

tool s were observ ed wh ich as t ime , ,

sav ers d eserve to be not iced h ere

, .

I n a bl acksm ith shop a 200 -

pound Bradly h amm er was kep t in

co n stant u se d ies of d ifferent fo rm s
,

being em p loyed on a variety of

wo rk These d ies were n ot of ex
.

pen sive d rop -die o rder steel p rofil ed ,

—
to sh ape an d h arden ed but w ere
pl ai n cast iron blocks w ith the de
-
,

sired sh ap e cast i n th eir f ac es .

O n e p air of d ies w ere do ing

som e v ery c red itabl e wo r k fo rging

S tra ight peen hamm ers of wh ich -

,

sev eral hund red r y ear are u sed

p e

aro u n d the shops an d on the en

'

g in es of th is road The stock for .

.

th ese were an inch an d a qu arte r an d ,

cut lo n g enough for two h amm ers ,

wh ich w ere rough ed out an d the ,

eye fo rm ed at the rate of t en or

twelv e per hou r Figs 2 6 1 to 2 6 3 . .

show t he d ies an d successive op

FI G 2 6 5 — B en din g y e e
era t ion s u nd er the h amm er T h
. .

e
bol t s in b ll doz er
u .
.

p u n ch P for t he eye is of h ard en ed

st e e l an d is sc rew ed i n to t he upp er die
, as S hown in F ig , .

26 1 . T he co rn ers of t he st ock are fi rst b roken down in

rec ess 1 l eav ing t he p iec e as shown at b F ig 2 6 3, th en
, , .

t he p een is fo rm ed in recess 2 t he piec es b ein g tu rn ed ov er

,
2 86 D OP R -
FO RG I N G , I KI N G
D I E- S N , ET C .

p la i n flat su rfa e c . As lo n g faces a re para l lel t he

as t he t wo
work w i l l be para ll el but if o n e en d of t he wo rk be lo wered
,

t he loose bl ock wi l l be o n it s seat th u s p rod uc i ng t he a n gl e

,

w ith t he upper face as s ho w n i n Fi 2 7 0 w h p i of

, g ere a ec e .

wo rk is be in g draw n taper AS t his an g l e is u n der t he co n tro l

.

of t he wo rkm a n it w i l l be seen th at t he v ar in g a n gl es a n d
, y ,

FIGS . 2 07 to 271 -
F o gin g st ra ight
r p ee n l ham m ers.

thu s vary ing tapers can be prod u ced at wil l w ithout separa te
,

d ies T he loose block cann ot be fo rced out of it as t he m eta l

.
,

in f ro n t of t he block in lower die acts as a stop when t he

wo rk is h eld t oo low .

T he w riter was show n a pair of brakes wh ich had bee n

fo rged w ith th ese d ies t he two en d s b ein g d rawn out to a dif
,

feren t taper as sh own i n F ig 2 7 0 an d th ey were most sat rsfac

,
.
,

—
to ry t he su rf ace b eing smooth an d f ree f rom hamme r m ark s -
.
 MACH I N E FO RGI N G
- ExAM PLES o r PRACT SE I 2 87

The Adv a ntage of Sp ecia l Tools in Forging

T he ketch es in whol e F ig 2 7 2 numbered F igs 1 to 9
s .
,
.
,

i llu st ra te how w ith sp ec ial tool s wo rk can be don e i n t he

, ,

forge by so cal l ed un sk il l ed l abo r an d al so how sk il l ed l abo r

-
, ,

"0 6 .

n o .
3

FI G 2 7 2 — F orgin g w it h sp ec ial l ll ed l
. t oo s an d u n sk i a bor
.

w ithout spec ial tool s even although the wo rk p roduced w il l

,

o n ly occupy the same t i m e c annot comp ete i n co st w ith t he

,

comb inat ion of tool s an d u n sk il l ed l abo r .

F ig 4 is a t ie rod wh ich is a part of t he West inghou se

.
-

air b ra ke g ear
-
as suppl ied to the N ew Z ea l and ra i lway s
, .

T h is p art was fo r m er ly m ad e i n t he O ld way T he end s or .

ey es w ere fo rged an d th en w e ld ed to a in ch rod to t he re -

 2 88 DR O P-
FORGI N G ,
D -
IE SI N KI N G , ET C.

q u i re d l e n gth T h is i n.v ol v ed t w o s e p ara t e f o rg gi n s a n d t w o

weld s a n d t he s m ith had h ard wo rk to m ak e th is job t
,
p y
a a

6 % p ence or 1 3 c ents a p iec e

, L ater on an oth er fi rm took .
,

u p th is cl ass of wo rk a n d it was th en ru n th rou h i n t he

”

g
foll ow in g m an n er
A set of cup d ies t o fit a bolt head in g m ac hin e was m ade
-
,
-
,

an d fitted as sho w n in F i 1 s f m i l i to mo t of T h
g a a ar . s , u s e .

block a is in t wo part s an d th ese are 3 in ch es apart wh en t he

,

m ach in e is at rest T he h eated ron is in sert ed again st t he face

.

o f fix ed bl ock b an d up a a i n st a stop not sho wn wh ich d et er

g , ,

m in es the l ength requ ired to fo rm

t he h ead The cam is e n gaged .
,

t he die bl ock clo ses on t he rod au -

t om at ically hold i n g it t ight an d , ,

t he mov ing head comes fo rward

an d p resses the rod i nt o t he die s

fo rm ing a compl ete bal l

,

These .

d ies are m ade of too l steel an d -

h arde n ed t he gripp ing su rfaces be ,

in g rou gh Wh en t he fu rn ace was .

properly go ing t he fuel u sed be ing ,

o i l 6 0 h ead s per hou r or 3 0 rods , ,

co u ld he fi gu red on The rods .

FI G 2 7 3
.
— T im
. df w ere h eated IO I abou t
e-c a r or
Six inch es
’

t he forg i g sh p n - along the end

o . an d t he op erato r , ,

who was a sm ith s h elpe r assisted

’
,

by a boy m ad e th em to a l ength gage the greatest allowabl e

, ,

erro r of wh ich was 1 ; in c h e ith er way t he l en gth of t he rods

1
,

u sed b ei ng caref u l ly d et er m ined b efo reh and by exp eri m en t .

Th ese h ead ed rods were n ext h andled by the 3 00 pound -

d rop stamp an d F ig 2 shows t he dies for stamp in g t he eye

-
, .
,

an d al so how the lowe r half die is h eld on t he h amm er base -

.

T he co rn ers of t he gray iron h ol de r are cu t away at an angl e

-

of 6 0 deg rees so as to pe rm it of a sl ight rotat ive adj u stment

, ,

t he sid es al so h ave a slop e upward so t h at t he holder is held

.

again st it s seat by the adj u st i ng sc rews Th is is v ery con v e .

n ien t for t he ope rato r in adju st in g his d ies an d help s t o lessen ,

2 90 DRO P-FO RG I NC, m -
a s m x l xc , ET C.

FI G . 27 5 —.T e n -t h l
ou sa n d-t o n hy drau ic p ress .
 MAC H I N E FO RG I N G
- EX AM PLES o r PRACT I SE 29 1

show n at e, wh ic h did away w it h the d ri ll ing j ig

F ig . 2,
an d as t he d r i l l fol lowed the st amp ed hol e as i nd ica t ed at ,

f; g F i 4
. t he
'

err
,
o r i f an y app eared i n
,
the cent er to ce ,
n

t er di st ance an d not in the eye O w ing to the sav ing of .

materia l by th is m ethod the head ing d ies w ere reduced f rom

,
-

1 334 to HA i n ch es an d t he rods w ere cu t U4 inch e

,
s sho rt er ,

wh ich o n a l arge qu ant ity m eant a con s id erabl e sav ing .

Parging H ithout Specia l Tools

’

T he tool s shown in F igs 6 , 7 , an d 8 an d al so t he numb ered

.

operat ions i l lu strate the v ery best m ethod of m ak ing a sim il ar

t ie rod of sho rt len gth und er a steam h amm er by a sk i l l ed
- -

sm ith . T he rod is m ade in on e h eat T he m aterial is h eated .

in t he bar fo rm an d cut off ; th en , by m ean s of swages, F ig .

6 , it is ough ed ou t as shown in operat ion 1 N ext on e eye is

r .
,

fo rm ed an d th en t he oth er by t he repeated appl icat ion of

, ,

swages F ig 7 an d t he h amm er itself

, .
, Th en the fin ish ing .

swag es F ig 8 are u sed to b ring t he rod to co rrect l ength t he

, .
, ,

tail s g g being cut off at an anv i l I h av e watch ed t he p iece .

m ade in th is mann er m any t im es an d h ave seen a fo rg ing l aid ,

down compl ete b efo re t he colo r had l eft it I h av e also .

watch ed th is p iece being m ade by t he fo rm er m ethod as de

sc r ibed an d t he resu lts w ere a reduct ion of 80 per cent on t he .

cost of p roduct ion by t he l atter m ethod T here were no .

spec ia l tool s in t he l atter case as t he swages u sed are in ev ery ,

day u se for gen era l wo rk in t he fo rge .

T he sk i ll of the sm ith has th u s b een repl ac ed by m ean s of

tool s wh ich el im inate all in accu racy t he n ecessary handl ing ,

be ing do n e by t he operato rs who are boys an d sm ith s h elpers ’

.

F igs 2 7 3 an d 2 7 4 i llu strat e a t im e card for t he fo rg in g

.
-

shop .

Ten Thou sa nd Ton Press at t he Dusseldorf Exhibition

T he i ll u st rat io n ( F ig 2 7 5 ) show s a steam an d hyd rau l ic
.

p ress, a model of wh ic h is exh ib ited in D u sseldo rf , an d t he

o rig in al of wh ich ex erts t he t rifl in g p ressu re of
k ilog ram s, or pou n ds T h ese p resses, wh ich are .
2 92 D RO P F R- O G I N G, m a—sm x m c , ETC .

m ade by t he Kalker Werkzeu gm asch in en fab rik are p rin ci

.
,

pal ly for fo rg ing an d bend ing armo r pl ates Th ere are th ree .

separate comp resso rs an d th ree separate ram cyl inders ; an d -

they are so conn ected t hat all th ree comp ressors act on all
th ree p ress cyl in ders or an y on e or t wo th ereof on al l th ree
-
,

cyl ind ers Th is en abl es t he employment of t he en t ire p ressu re

.

of ton s or of two th irds or of on e th ird th ereof

,
- -
,

acco rd ing to the n eed T he st roke is al so w idely adj u stabl e

.

at w i l l . To g ive a sl ight idea of t he d im en sion s of these

p resses ( two su ch are at wo rk in Eu ropean shops) it m ay be
said th at the rear column s wh ich are each 1 7 m eters in
,

l en gth weighs 1 50 gross ton s an d t he t h ree hy draul ic

, ,

cyl inders th at togeth er w ith t he steel plate b et ween th em

,
-

make up t he upper pl aten as much mo re T he lower pl aten

, .
,

wh ich is bu il t up weighs about 400 gross tons T he p la

, .
'

ten s are h eld to t he colum n s by sixteen nuts eac h o f ,

mm ( 47 inch es ) d iam eter an d who se un ited weight i s about

.
,

50 g ro ss ton s .
2 94 D RO -
P F0 G G
R IN ,
- i xK N
u ra s
r I G ,
ET C .

soon to be as impo rt an t I refer t o th at b ranch k n own as

.

hyd rau l ic fo rg in g wh ere w ith t he aid of d ies a p iece of h eated

-
, ,

st eel or iro n is p ressed or m ad e to flow i nto t he d es ired sh ape .

D escr iption f
o Hydr a u lic Pr ess
For t he ben efit
of those who are n ot fam il iar w ith a for
g ing mach in e or p ress a d esc ript io n of on e w ill be g iv en h ere
-
, .

We w i l l desc ribe a l arge p ress M ost forg ings m ade by p res .

sing in sh ap ed d ies can be p rod u c ed o n a s m a l l p ress T he .

s m al l er t he p ress u sed for accompl ish

in g yo u r wo rk t he g reater t he eco n
om y .

Em bod ied in
p oper is t he p ress- r

an op erat i ng pl u nger T h is is pu ll ed .

back after perfo rm ing it s st roke by a

plunger A pl aten is m ade mov abl e .

to fac i l itate t he h an dl ing of heavy

d ies T he d ies are secu red to t he
.

plunger an d pl aten by m ean s of bolts

in t ee s lots T he p ress is u su al ly op .

erated by 5 00 po u n d s w ater p ressu re -

.

W h en g reat er p ressu re is requ ired an

FIG 2 7 6 F o g i g
—
r n
i n t en sifi er on t he l eft of t he p ress is
. .

p rac t ise .

u sed .

I t d iffers from t he d rop fo rg in g m ethod in that t he fo rce is

-

compara t iv ely s lowly an d stead i ly appl ied O n e st roke u su al ly .

su ffi c es wh i l e in t he d rop fo rg ing m ethod bars oft en rec eiv e

,
-

d ozen s of blows an d f requ en tly are reh eated severa l t im es .

T he act ion or mot ion of t he h eated steel i n t he d ies is t he

sec ret of b ett er m et al in t he fo rg i n g s I n F ig 2 7 7 is shown a . .

heated p iece of rou n d bar bet ween two d ies As t he top .

p iece is fo rced do wn ward t he m etal flo ws as shown by t he ,

dotted l in es T he reaso n it assu m es th is sh ape in stead of

.
,

th at of a perfect cyl i n d er is on accou n t of t he f rict ion between

,

t he fac es of t he d ies an d t he m eta l wh ich som et im es rest r ict s ,

t he flow of t he m eta l n ex t t o t he fac es of t he d ies .

By m ak ing an imp ress ion i n t he d ies as shown in Fig , .

 Eon c m o, W ELD I N G , AN D G EN ERAL SH OP PRACT SE I 295

2 7 8, we get d ifferent resu lt T he ends inc rease in d iam eter

a .

on account of t he imp ress ion in t he d ies an d thu s t he flow is ,

ent irely confin ed to t he c ent er As t he die cont i nu es to de .

sc end t he c ent ra l po rt io n in c reases in d iam et er but d ec reases

in th ickn ess an d is gradu ally fo rm ed into a fl ange as shown

, ,

by t he dotted l in es .

N ext let u s d eepen t he imp ression in t he bottom die an d

u se a pl a i n cyl i nd r ic al top die as shown i n F ig 2 7 9 ,As t he . .

top die d escen d s t he m etal has a tend ency to flow in t he sam e

,

m ann er as i n t he p reced ing exampl es bu t is rest ricted by t he ,

sid e w a ll s of t he bottom d ie I t is compell ed therefo re; to

.
,

FI GS — Hy drau l ic forg in g
. 277 to 2 79 “

p rac t ise .

flow th rough t he open space arou n d t he top die an d m akes a

cup shaped fo rg i ng
-
.

By sh ap ing t he bottom die an d po in t ing t he top die or ,

punc h as shown in F ig 2 80 you h ave t he shape u sed for

, .
,

m ak in g p roj ect il es T he top p u n ch m u st not n ecessarily be

.

c irc u l ar in fo rm bu t m ay be squ are t rian gu l ar or an y odd

, , ,

sh ape t hat do es n ot w eak en it or d est roy it s st ren gth .

A good exampl e of th is is fo u nd in a paten t ed p roj ect il e .

I n stead of t he cav ity being smooth it is ribbed as shown in ,

t he c ro ss sect io n in F ig 2 8 1 t he id ea b ein g th at on account

- .
, ,

of th ese intern al ribs t he sh el l w il l be b roken into a l arger

numb er of sm all p iec es an d th u s in c rease it s effi c iency as an
,

ofi en siv e w eapo n T hese r ibs are obta in ed by s imply cor

.

ru gat i n g t he pu n c h wh ich of cou rse l eaves co rrespond ing

, , ,

imp ress ion s i n t he m eta l .

I n F ig 2 82 is an oth er exampl e of simpl e fo rg i n g

. Hun .
2 96 D RO P- FO RGI N G , D I E-S N I KI N G , ET C.

d d of h ft
re s s a s w ith
l i n ch col l ars are n eed ed
- I n stead .

of mach in ing all th at m eta l or d ra w ing it out un der a ham

m er you simply h eat on e en d of t he bar wh ere t he co l l ar is
,

wan ted an d w ith on e st roke of t he p ress squ eeze it ou t as

, ,

show n by t he dotted l in es .

Exa mp les f
o Production

These simpl e i l lu st rat ion s are m erely su ggest io n s show in g

the u sefu lness of th is art in t he comm erc ial wo rld By a co rn .

b inat ion of d ifferent d ies an d sev eral opera t io n s d iffi cult for ,

g in gs of t he most int ricate sh ape can be eco n om ical ly p ro

du ced an d w ith such accu ra cy an d smoot hn ess th at on ly those
,

pa r ts i n cont act w i th th e ir wo r k i ng part s n eed m ach i n i ng .

FIGS . 2 80 to 2 82 -
Hy drau l ic forgi n g p rac t ise .

T he hap es shown in F ig 2 83 are a few of t he fo rg in gs

s .

that can be p roduced by th is m ethod T he o n ly l im it to t he .

siz e of t he fo rg in g is t he ca pac ity of t he p ress u sed an d t he

fac il it ies for handl ing th em .

F rom t he sk etch es you w i ll n ot ic e th at t he d ies for fo m i

in g t he va riou s sh apes are n ot expen siv e as t hey gen era lly ,

con sist of shapes th at can be p roduced by eith er a l ath e or

so m e oth er m ach i n e tool H an d wo rk seldom en ters into
-
.
-

th eir con st ru ct ion For p ract ically all shap es t he bottom die
.

can be m ad e of a go od g ra d e of iron cast app rox im at ely to

siz e fin ish in g o n ly t he base an d t he imp ression

,
.

D ies of t he k in d show n i n F igs 2 7 9 an d 2 80 m u st h av e a

.

sl ight taper to f ac il it at e t he rem ov a l o f t he fo rg in g T h is .

,

howeve r, n eed s t o be v ery smal l as t he st eel im mediat elv com

,
2 98 D RO P FORGI G
-
N , D E
I I KI N G
-S N
, ET C .

an coo l i ng of t he punch as water is tu rn ed i n to t he d ies after

d ,

each op erat ion to k eep th em b elow a d est ruct iv e t empera t u re .

Pr oper Practise f or Hydr a u lic Forgi ugs

E ng i n eers
who d esign fo rg ings for p roduct io n by t his
m ethod w il l be w ise to careful ly not e t he fol low ing :
Make you r punch es p ract ica lly st raight w ith a n ice ro u nd ,

in g at t he bottom as shown i n Fig 2 84

, At fi rst gl anc e t he
. .

pu nch i n F ig 2 85 would seem to requ ire l ess p ressu re an d

.
,

h ence for a g iv en p ressu re wou ld g iv e t he m eta l a d eeper

FI GS — Sha in
. 2 84 an d 2 85 .
p g of fo rg i n g p u n c hes .

pu n ch T he rev erse however is t he case an d t he reason is

.
, , ,

th is : Wh en punch N o 1 0 en ters t he m eta l it d ispl aces a cer

.

tain amount an d th is m u st flow upward along t he sid e of t he

pu n ch As t he pu n c h co n t in u es to d esc end t he area of t he
.
,

open in g at t he top of t he die is g ra du ally g row in g small er ,

du e to t he tap er h enc e t he m etal m u st flow u pward fas ter than

,

t he pu n ch d esc en d s to c o mp en sat e for t he d ifi eren ce between

t he area of the open in g an d t he m eta l d ispl ac ed Th is would .

m ak e l ittl e difi eren ce w ith a p erfect l iq u id bu t c reates t rem en ,

do u s f rict ion w ith st eel an d g reatly reduc es t he pen etra t in g

power of a g iv en fo rce .

Again assum ing th at t he p ressu re appl ied to t he punch is

,

downward l ay in g out a paral l elogra m of fo rc es we fi n d that

, ,
 O
F RG I N G W ELD I N G
, , AN D G EN E RAL sn op PRAC T S E I 2 99

t h e res u lta nt is d iv id e d i nto two fo r c es o n e act ing a lo n g t he ,

face of t he p u n ch an d t he oth er at right angl es to it T he

,
.

on e at r ight angl es to t he fac e of t he punch is of no v a lu e in

d is plac in g t he m eta l as it s power is expen ded in j amm in g t he

,

m etal again st t he sid es t end ing to tear t he die apart N o

, .

such cond it io n s ex ist w ith a punch si m i l ar to F ig 2 84 H ere . .

t he area of t he open ing around t he p u n ch rem ain s t he sa m e

du ring t he p ressing an d t he m etal flows at a un ifo rm ra t e of
,

sp eed as t he pu n ch d esc end s T he fo rc e t en d ing to t ear t he

.

die apart is sm a ll compared to a g reatly t ap ered punch .

I n th is c lass of fo rg ing it is not ab so lutely n ec essary th at

the d ies be of on e sol id p iece M any fo rg ings requ ire th em .

to be spl it an d th ere are cases wh ere fi v e an d six parts were

,

requ ired to compl ete on e d ia m eter I n such i n stances t he .

d ies are suppo rted by an outer cas ing .

T he v ar iety of m etal s th at can be fo rged by th is m eth od

is p ract ica lly t he sam e as for d rop fo rg ing or h and fo rg ing - -
.

Wrought iron or steel low in carbon say f rom to , ,

p e r c ent is fo rg ed w ith t he g reat est fac i l ity

.
,
T h e g ra d e of .

st eel commo n ly known as m ach in ery steel rang ing f rom ,

to p e r c e nt ca r bo n is read i ly sh ap ed wh i le steel s rang

.
, ,

in g f rom 0 7 0 to .
p e r c ent ca rbon are fo rged d ai ly i n t he
.

m anufactu re of p roj ect i l es Al loy steel s contain ing eith er .

n ickel ch rom e or vanad ium or all th ree are al so fo rged in

, , , ,

the m an ufactu re of armo r p ierc in g p roj ect il es automob il e -

,

parts cutt in g tool s et c T he h igh er t he g rad e of steel u sed

, , .

t he closer t he att ent ion requ ired in t he h eat in g p rio r to for

i
g ng . S t e el s h igh i n ca r bo n a n d ch r om e c annot be m ade to
flow qu ite so read ily an d requ ire g reat p ressu re .

Some Welding
App lica tions of Au togen ous
T he oxy acet y l en e autogen ou s weld ing p rocess found a
-

l arge fi eld in a number of m anufactu ri ng establ ishm ents I t .

is mo st comm erc ia l in shop s w here th ere is a l arge v ariety of

wo rk I t can not compete w ith m u lt ip le m ach ine rivet in g or
.

w ith expen siv e coke an d gas w eld in g in stall at ion s .

T he obj ect ion to a coke weld in g i n stall at ion is t he h igh -

3 00 DR P O FO RGI
- N G , DI -
E e e G, ET C .

fi rs t cost an d the inj u riou s ox id iz ing effect du e to t he lon g

, ,

exposu re of the hot m eta l to t he atmo sphe re .

O n the othe r sid e a gas w eld ing i n stal l at ion is on ly su ita

,
-

ble for ve ry l arge shops du e to the h igh cost of t he gas ,

gen era to rs gas holder power hamme rs an d p resses

,
-
,
-
, .

T he p roblem i n al l weld ing operat ion s is to wo rk t he hot

m etal s rap idly or to heat only a smal l sect ion at one t ime
, .

FI GS .
—
2 86 t o 2 88 App l ica t ion s of au t ogen ou s
. l
w e din g .

T he oxy ace t ylene p roc ess w i ll fu rn ish the right

- tempe rat u re
for fu sin g t he m etal s, w ithout ox id iz ing t he jo in t .

Heating M eta l Before Welding

The troubl e th at m ight arise in th is weld in g p rocess is , ,

that t he m etal is too ra p idly ch il l ed wh ich wou ld tend to ,

weaken t he jo int .

T h is d iffi culty can be ov ercom e by heat ing the m etal be .

fo re weld ing ; in wh ic h case we gain both better efli ciency of

t he jo int an d h igh er sp eed in weld i ng
, I t is ad v isa ble to .

cover t he h eated m etal as much as possibl e t o prev en t exces ,

siv e ra d iat ion an d to p rot ect the w elde r f rom the high t em
,

pera t u re .

In som e cases wh ere a h igh e ffi c iency of t he jo int is

,

exp ect ed it is adv isabl e to an n ea l the w eld ed p iece in a s l ow

,

cool i ng f u rn ac e for sev eral hou rs .

I t is w el l known th at in all rapid w el din g su ch as else

, ,
3 02 D RO P F0 R -
GI N G , D I E-S N I KI N G , ETC .

. hows weld in g a dom e in a cy l in d er a flan ge a t

F ig 2 93 s ,

t he bottom a n d an outl et at t he s id e ; a ll for h igh p ress u re s

, .

T he p rocess of autogen ou s weld in g is w ell adaptable in

an y m eta l wo rk shop an d w il l pay good ret u rn s for t he s m a l l
-
,

fi rst cost an d operat in g ex pen ses

, .

T he w eld ing opera t io n is n ot d ifli cu lt but req u ires severa l ,

'

month s of p ract ise to tu rn o u t rel iab le work fo r high p ress u re

, .

T he p roc ess does n ot req u ire an v exp en s iv e m achi n ery ,

such as pow er hamm ers an d p resses

-
.

O ver i n stal l at io n s are in da ilv u se in E u rope a n d ,

bri ng good ret u rn s on t he i n v es tm en t .

We bel ieve that in t he n ext few y ears a n ew fi eld w il l be

2 92

FIGS 2 9 1
. to 2 93 .
-
\V e ldi n g c ast - i ro n l
n oz z e a n d fla n ge on c y l in der .

open for t he autogen ou s w eld ing p rocess ,

in bo i l er shops ,

automob i l e w o rk s t an k an d pl ate wo rk s
,
.

Bu ilt up or Wclded up Die Work- -

A qu est io n th at is often ask ed m e by those abo u t to m ake

“
a lot of s h ee t m e t a l wo rk i n g d ie s is th is : Sh a l l we m ak e

th em of sol id st eel ; an d if so w hat k in d an d how ( a n we get

, , ,
”
?
t hem fo rged so as to sav e stock an d l abo r
My exp e r ie n c e h a s b ee n th is : I f y o u h a v e got a s m ith w ho

know s his b u sin ess an d can do a good job w eld th em up ; but ,

 FO RC I N G ,
W ELD I N G ,
AN D G EN ERAL su o p R
P ACT S E I 3 03

a ware th at th ere are two or th ree fi rms in t he bu sin ess who can
take say a 1 2 inch round die an d w eld up t he steel ring an d
,
-
, ,

weld t he sam e on to a wrought iron pl ate an d be su re of good -

,

results b efo re it l eav es the sm ith s h and s an d th ey can do th is

’

, ,

ev ery day in t he week I f I had a m an l ike that I would n ev er

.
,

m ake anoth er bu ilt u p die l ike F ig 2 94; but on e doesn t find

- .
’

such a m an o n t he co rn er w ait i ng for a job ; he has on e a l ready .

At on e t im e I had a lot of d ies six I th ink to m ake all , , , ,

squ are o n es ; an d fai l ing to get good resu lts f rom t he sm ith I
, ,

o rd ered six blocks f rom t he m i l l Th ey were 1 2 x 1 4 x 2 in ch e

. s

th ick on e half steel an d on e h alf iron Th ey cam e in cou rse

,
- - .

of t im e ( about sixty days I bel iev e) an d th ey looked n ice I

, , .

start ed th ree of th em ; cut out t he d ies an d h ard en ed two of

th em all right ; but t he th ird on e parted i n t he weld so it was ,

u sel ess Wel l I fitted t he punch es to t he oth er two an d

.
,

start ed th em to wo rk By t he way did you ev er th ink it was

.
,

a g reat d ea l b ett er to m ak e a die for you r own u se th an for

som ebody el se to u se I t seem s to wo rk better an d a com

?
,

pl ain t from t he boss of t he p ress room doesn t sound so big as -

’

—
on e th at com es in a l ett er e spec ial ly if it is a typ ew ritt en on e .

Wel l t he d ies worked v ery well unt il th ey were wo rn

,
“ ”
down to inch of steel th en on e of th em began to p eel
, ,

as t he p ress boy ca ll ed - it T he v ib rat ion s cau sed by t he

.

punch es started t he weld at on e en d of t he die an d it kept ,

”
peel in g u nt il it was two th ird s of t he way ac ross an d th en
-

we had to sc ra p it T he rest of t he bl anks I had pl an ed up

.

an d let t he boy s h av e th em for bench block s Th ey were a - .

l ittl e expen siv e bu t t hey w ere good on es

, .

T h ere was on e fau lt w ith th ese d ies th at is common to al l

weld ed d ies except rou n d o n es ; th at is t he impossib il ity of
, ,

mak in g a perfectly squ are bl an k an d t he enl arg ing of t he ,

bl ank cau sed by t he cl earance g iven t he die T o overcom e .

th is we fi n al ly m ade a die l ike F ig 2 94 t he sides an d ends

,
.
,

of separa te p iec es an d t he co rn er dovetail ed in All t he

, .

p ieces were got out on t he shap er d ril l ed an d tapered for t he ,

hold in g dow n bolts ( not show n ) th en h ard en ed an d g round

-
,

to an exact fit th en set in t he cast iro n bed an d h eld in pl ace

,
-
,
3 04 D RO P -
FO RG I N G , D I E- I KI N G
S N ,
ET C .

by t he c ws shown T he co st of t he d ie was about t he

set s re .

same as for a sol id d ie an d as I co u ld u se c heaper l abo r for

,

most of t he wo rk bu t as it did about doubl e t he amount of

,

wo rk do n e by a sol id on e an d t he wo rk was far better I

, ,

cal l ed it a ch eap die an d we m ad e t he rest in t he sam e

,

m an n er .

N ow I take t his v iew of t he m att er : I f I had a sm ith that

,

co u ld weld u p a 1 2 o r 2 4 in ch r ing on a w ro u ght iron pl ate -

,

an d be su re of his w ork I th in k it w o u ld be ch eaper an d bett er

t o do so bu t rath er th an tak e ch an c es of a seco n d cl ass m an

,
-
,

I bu ild t hem of steel ri ngs set in cast iron blocks O f co u rse -

.
,

in som e cases t he co st of steel shoul d be t aken in to accou n t ;

,

FI G 2 9 4 . .
—
B u il t -
up die .

bu t wh en t he wo rk in t he sm ithy costs eighty c ents per h ou r ,

an d t he st eel sev ent een c en t s er pou n d it d oes n t see m t o m e

’

p ,

th at t he co st of t he steel cu t s muc h ice an yway .

All t he p u n ch es were m ad e so l id an d l eft soft wh ic h I ,

thin k is t he best wav for th in stoc k .

Gen er a l Pr a ctise for H a rdening D r op -D ies f

o Var iou s Steels

I t was for m er ly c on s i c
m ake a ll fo rg in g
dered y
'

n e essar to

d ies req u irin g t o be hard en ed f ro m c ru c ibl e t ool steel but ex -

,

i n ce has p rov ed th at fo r c ert ai n c lasses of w o r k a good

p er e

g rad e of open h earth steel of t he p rop er carbo n g ives results

-

wh ich j u st ify it s u se I n som e sh ops th is steel is u sed alto

.

geth er bu t t he resu lts are n ot v ery sat isfacto ry for d ies w it h

,

sm al l p roj ect io n s or fo r shap es th at weak en t he die .

3 06 DR O P- FO RGI N G , D I E-S N I KI N G , ET C.

Wh en t ng has cool ed so th at no red can be seen t he

t he a ,

die sho u ld be i nv ert ed an d t he w at er allowed to pl ay on t he

'

face At t he sam e t i m e water shou ld be pou red on t he tank

.

u n t il t he red has d isapp eared f rom t he fac e wh en we should ,

c ease cool ing t he tang an d allow the h eat in the center of t he

,

die to ru n out th rough th is po rt ion .

T he ov erflow in t he tan k shou ld be so regu l ated th at t he

water w i ll on ly com e up on t he face of t he die about an inch .

O f co u rse it w i l l be fo rc ed up t he sid es of t he die by t he flow

,

of t he wat er in t he supply p ipe .

T he p ip e del iv eri ng t he wate r to t he die shou ld d ist rib u t e

it d irectly again st t he whole f ace ra th er th an in a sol id ,

st ream st r ik ing al l i n on e pl ace

, M ake t he top of t he p ip e .

—
FIGS . 29 5 an d 2 96 Pip in g for drop -die harden in g .

in t he fo rm shown in Fig 2 9 5 ; or a p erfo rated top to t he

.

supply p ipe as shown in F ig 2 96 is e

, xcel l ent .
, .

I n wint er som e mean s shou ld be p rov id ed for remov i n g

t he ch i l l Th is can be don e by ent er ing a steam p ip e in to
.
-

t he su pply wh en an y d esired d eg ree of h eat m ay be obt ain ed

, .

T o el i m inate so far as poss ible t he t en d ency of t he steel t o

, ,

c rack f rom intern al st ra in s set up by t he p rocess of cool ing ,

t he die shou ld be so h eat ed as to p romot e th is resu lt Som e .

h ard en ers th ink it adv isabl e to do th is by d raw ing the temper .

Th is seem s to wo rk all r ight if t he h eat ing is don e slowl y

eno u gh for the h eat to p en et rat e to t he c ent er of the block ;

bu t if t he h eat ing is rap id th is resu lt is not accompl ished t he

, ,

st ra in s are st i l l in t he st eel an d m ay m an if est them selves a t

,

an y t im e T he die m ay c rack afte r b eing pl aced on the sh el f

.
,

or it m ay not unt i l som e t i m e aft er .

Know in g t he tend ency of l arge p ieces of h arden ed ste el t o

 FO RGI N G ,
W ELD I N G ,
AN D G EN E R AL S HO P P RAC TI SE 3 07

c rack f rom t he cau se m en t ion ed it is best t o tak e every pre ,

caut ion to p rev en t th is A v ery in exp en s iv e m et hod co n sists

.

in pl ac ing t he h ard en ed d ie in a w at er tan k wh ich has a steam -

p ipe con n ect ed w ith it St eam is let in an d t he water is .

grad u ally h eated to t he bo i l ing po int an d kept th ere for sev -

,

era l hou rs wh en t he d ie m ay be remov ed an d t he t emper

,

d raw n I f it is n ot tho u ght adv isabl e to u se th is m ethod

.
,

pl ace t he die wh ere to in su re u n ifo r m ity of heat in g it w il l

, ,

h eat sl ow ly an d co n t in u e t he h ea t u n t il wh en to u ch ed w ith
, ,

a mo ist en ed fing er a sn app in g so und is h eard

, I n o rd er to .

efl ect iv ely avo id t he t en d en cy to c rack f ro m i n t ern a l st ra in s ,

t he h eat i n g m u st be slow eno u gh to i n su re t he p en et ra t ion of

t he h eat to t he p iec e .

I t is oft en d es ira bl e to d ra w t he t emper imm ed iat ely aft er

t he h ard en in g ; wh en th is is t he c ase t he g rea t est po ssi bl e c are

sho u ld be ex erc ised A die h av ing s l en der p roj ect io n s or

.

l ight i rreg u l ar po rt io n s if h eated fast er th an t he steel can

, ,

abso rb t he h eat u n ifo rm ly w ill of cou rse b ecom e hott est at t he

,

l ighter po rt io n s an d th ese expan d in g faster th an t he sol id

,

po rt io n s adj acen t w il l tear th em selv es away Wh ere th ere

, .

are such l ight p roj ect i ng po rt io n s it is oft en adv isabl e to fi l l ,

t he su rrou n d in g d ep ress io n s w ith o il ; th is w i ll p rev ent a too

“
ra p id h eat i n g of t he part s an d stop th eir sn ipp i n g off .

Som et im es an d for c ert ai n wo rk it is not n ec essary to

, ,

hard en t he d ies bu t it is st il l oft en adv isabl e to st iffen t he

,

st eel som ewh at u n d er such co n d it io n s T he die m ay be .

h eat ed an d th en cool ed in o il A bath of gen ero u s p ropo r .

t io n s sh ou ld be u sed h av in g a j et of oil c om in g u p f rom t he

bottom th is st rik ing t he face m ateria lly aid s in p rod u c ing t he
,

d esired cfi ect .

Wh en open h earth st eel wh ich contain s a su ffi c ient amount

’

of carbo n wo rks w el l on m an y d ies it s u se is not advoc at ed ,

for d ies t hat mu st be v ery st rong or th at sho u ld retain th eir

s iz es as cold d rop d ies
,
-
A good g rad e of c ru c ibl e die steel
.
-
,

co n tain in g a h igh er p erc en tag e of carbon can be u sed wh ic h

w il l h arden much d eeper an d h ard er th an t he op en h eart h of -

lower carbo n .
3 08 DR O P FO R
- GI N G , DI E SI N
- KI NG ,
ETC
.

T he c ruc ibl e steel being lower in p ercen tage of har mf u l

,

i mpu rit ies can saf ely h av e a much h igh er p erc entage of
,

carbon an d yet be l ess l iabl e to c rack th an t he op en h earth -

m aterial .

After all t he rea l essen t ial for su ccessfu l ly do ing wo rk of

,

th is k in d is b rain s ; it is n ecessary to d isc rim in ate b etween t he

d ies of d ifferen t sizes an d sh apes a l so to j u dge co rrectly of
,

ot her cond it io n s an d t h en act acco rd in gly

, .
3 10 DR O -
P EO RG I N G, DI E S N -
I KI N G ,
ET C .

equ ipm ent of m ach in es an d tool s wh ich w i l l al low of his m e

chan ics p roduc i n g good wo r k rap idly .

Higit -Speed Steel an d Tool Holders

An impo rtant it em in m ach i hop o rgan izat io n an d m an

-
ne s

agem en t is the sp eed of cutt i n g tool s an d t he u se of c u t t i n g

tool hold ers T he speed of t he tool is l i m ited by t he f ric

-
.

t ion al h eat i ng of t he tool an d it s co n sequ ent soften in g by

,

d raw ing it s temp er so th at for w rought iro n an d m ild steel

,
-

t he l im its w ere f rom 1 0 to 3 0 f eet p er m i n u t e Som e in c rease .

was m ad e on t he int roduct io n of a self h ard en in g st eel in wh ic h -

h igh er speeds w ere attain ed Bu t th ese tool s were ra p idl y

.

broken down i n wear or were ab ra ided ou t of sh ape With in .

’

the past t en y ears th ere h av e been in t rod u ced v ario u s b ran ds

of h igh speed steel cutt ing th ree fou r an d in som e cases ev en
-
, , ,

six t i m es f ast er th an t he b est tool steel s of t he rec ent p ast a n d

-
,

al so po ssessing a rem arkabl e du ra b i l ity I n som e cases t he .

tool s are h eated to a d u l l red i n t he o perat io n of cu tt ing wh il e ,

t he Ch ips are n ear ly as hot T h is steel w il l stan d lo n g sev ere

.
, ,

an d co n t i n u o u s u sag e w ithout reg r i n d in g an d th is togeth er , ,

w ith t he in c reased st ren gth effects a g reat sav in g in t im e an d

,

l abo r oth erw ise wasted in rem ov in g g r in d in g an d repl ac i n g

, , , .

t he tool D eep er an d w id er c u ts can a l so be taken w ith th is

.

steel an d th is tog eth er w ith t he h igh sp eed resu lt s i n rem ov

, ,
-

i n g a far g reat er w eight of m et al per m in u te w ith a con sequ en t

con siderabl e ch eapen in g i n t he cost of p roduct io n .

Speed s of f rom 7 5 t o 1 00 f eet per m in u t e upo n m ed iu m

h ard steel h av e been attain ed in o rd in ary wo rk wh i l e rough
-
,

in g c u t s h av e b een m ad e at t he rat e of 1 40 f eet per m i n ut e on

cast iro n w ith yé in ch feed an d in ch d eep .

T h ough t he c ost of high speed steel is co n s id era bly g reater

-

than th at of com m on tool steel s t he d ifference in cost is mo re

-
,

th an cov ered by it s l abo r sav in g q u al it ies an d rel iab il ity T he

-
.

best steel I k n ow of fo r high speed c u tt in g costs about sev en

-

t y fi v e c en t s per p ou n d an d
- — for m ach in e c u tt in g tool p u r
,
-

—
poses at l east is n ot forged i n to so l id tool s as in t he old ,

fash ion ed way bu t t he cu tt i n g po rt ion s are fo rg ed an d ground

, ,
H IG H -
S PEED ST EEL EO RG I N G R
AN D H A D EN IN G R
P ACT S E I 311

FI G 2 9 7
. .
—
Shan k in g dies w i t h hi gh- speed c u t t i n g t oo l .
3 12 D R OP- FO RGI N G ,
DI E SI
- N x I NG, ETC.

th en in sert ed in
tool hold er an d h eld by a simpl e pl u n ger
a -

an d l ock i ng st u d as i llu st rat ed an d d esc r ib ed f art h er on i n

,

th is ch apter .

Combina tion Tool -H olders an d Their Use

T heh igh cost per pou n d of t he h igh speed steel s an d t he -

l arge waste of th is val u abl e m aterial by ind iv idu al u sers an d

fo rgers of bar stock wh ere cutt ing tool s are fo rged f rom t he
,
- .

bar has b ro u ght about a t ruly wo n d erful d em and for an effi

,

ie —
c n t su bst itute for expen siv e fo rged tool s a subst itute wh ich
sh all possess all t he b est q u al it ies of t he bar fo rged tool s w ith -

ou t th eir w aste uncert ain h eat t reatm en t m ethods an d pro

, ,

hi bit iv e expen se —
Th is subst itute I b el ieve a fter carefu l per
.

so n al i nv est igat io n an d u se of v ar iou s tool hold ers— is secu red -

i n t he comb in at ion tool hold er m anufactu red by t he O K - . .

T ool H olde r Company of Sh elton Conn as it is t he only , , .

,

o n e I h av e ev er seen an d u sed wh ich comp ares i n effi c iency

an d st rength w ith t he best h igh sp eed tool s fo rg ed compl et e -

f rom bar stock .

T hough exper im en ts h av e b een conduct ed by al m ost all

u sers of h igh sp eed st eel to d et erm i n e t he b est shop p ra ct ise for
- -

t reat in g it t he resu lts of th ese experim en ts as a whol e seem

,

to h av e g iv en u s a gen eral shop ru l e for t reat i ng a h igh speed -

“ ”
steel tool :
-
H eat it to a wh ite h eat an d qu ench it Bu t th is .
,

i n my op i n ion has it s sho rtcom ings becau se a v ar iat ion of 5 0

, ,

d eg rees Fah ren h eit can not be d eterm in ed by t he eye but Such ,

v ariat ion is v ery impo rt ant especial ly in t he temperi ng of ,

th ese steel s .

T he resu lts of poo r ly t reat ed tool s are : A d ec rease in shop

p rod u ct ion for t he m anufactu rer who allow s it in sid e his es ,
'

t abl ishm en t ; d issat isf act io n an d poo r wo rk on t he part of t he .

m ach in ist who u ses it ; an in c rease in t he b il l to t he buy er of

t he shop s p rod u ct s an d t he en t ire result a w aste of en ergy
’

an d c ap it al .

Th erefo re I arg u e t he fact th at perfectly fin ish ed u n i

, , ,

fo rml y t reated a nd gau ra n t eed effi c ien t h igh speed cu t t ing

,
-

tool s can be p u rc hased d irect f rom spec ial ist m akers m akes ,
3 14 D RO PFO RGI N G
-
, DI E-S I e N G, ET C.

th is waste of en ergy an d cap ital on t he part of u se rs of suc h

tool s inexcu sabl e .

E con omy in Use o

f Tool H olders -

O n m any opera t ion s of die wo rk a tool capabl e of rem ov

-

i n g stock at hig h spe ed w ith co rrespo n d ing h eav y cuts is very

-

—
FI G . 2 99 C om p l et e set o f high-Speed l
c u t t in g t oo s an d t heir
hol ders .

des i ra
bl e. Form erly
so l id fo rg ed t ool s w ere n ec essary
-
but ,

modern pract ise d em and s t he mo re econom ical tool hold er - .

A v ery effi c ient type is shown in F igs 2 97 an d 2 9 8 As wil l . .

be seen th is holder is a radical departu re from the old st yle

,
 H IG -
H S PEE D ST EEL EO RG I N G AN D H A DEN R ING PRACT SE I 315

hold er T he hold er itself is m ad e f ro m a tough g rad e of steel

.

design ed to stand t he shock an l st ra in s of h eavy cuts T he . .

cutt ing po in ts are hyd ra u l ic an d d rop fo rged f rom h igh speed

- - -

st eel an d are m d
,
a e ex ct dupl c t of the sol id fo rged too l
a i a es -

cutt ing ends ha v ing a la rge body of metal to soak up the fric
,

tiou dl
hea t gener a ted by t he chip .

Each tool is p rov id ed w ith ound shank fitt ing t he re a r

ceiv in g en d of t he hold er an d is p rev en t ed f rom tu rn i ng by

-

contact of t he plunger at t he flat back of t he tool wh ich i n ,

tu rn is fo rced ah ead by the tapered face of t he lockin g stu d -

.

Th is m ethod of lock ing g iv es p ract ica lly sol id back ing to t he

3 00 —
l
P an of t r im m i n g di e sho w i n g u t i l it y of high p ee d
-s S t ee l
c u t t in g p o in t s
.

tool th ere bein g n o possibl e c han c e o f t he po int sl ipp in g

,

aw ay f rom t he w o rk .

O n e comm en d abl e f eatu re o f th is hold er is t he ent ire ah

senc e of set sc rew s t he lock c o n s ist in g as it do es of a loose
, ,

plunger st u d an d n u t can be in stantly removed if occasion

, , ,

requ ires F ig 2 9 7 shows t he m eth od of sh ank i ng die blocks

. .
-

w ith th is tool T he h ead of t he pl an er is fi rst set over to t he

.

requ ired an gl e o n t he s id e o f t he s h an k an d w ith t he c ro ss ,

h ead feed s u ccessiv e cuts are tak en downward to t he re

q u ired d e th t hu s l eav ing no a n gu l ar co r n er to remov e with
p ,

sho rt l ight c u t s At t he right is show n the t ool u sed to

.

u nd ercut the side an d b ase of s han k By th is m et hod ve ry .

3 16 D RO P I D RG I N G
-
'

.
-
D I E s rx x rx G , E TC .

cl ose est imates o n t im e m a v be m ade by ascert a in i n g t he

n u m ber of po u nds of st oc k to be re mo v ed as t he n u m ber of ,

—
c u t s m a v be fi gu red to a cert a in ty half an in ch in w idth bei n g
t he av erage c u t .

I n F ig 2 9 8 is
. s ho w n
too l u sed for fi n ish i n g side a n d
a

base c u ts on a bl oc k for a head i ng d ie th is bl oc k be i n g -

,

e n t ire l v fin ished wit h a st an dard shaper set of t hese too l

p o i n ts
.

Fig 2 99 sh ows a t ri mm i n g d ie an d well i ll u st rat es t he

.
-
,

u t il it o f o m of th ese s hapes t he N o 2 7 too l be i n g su it a bl e

y s e , .

fo r fi n ish ing t he en t ire fac e both right a n d l eft ,

For rough .

— K l hol der
FI G . 3 01 Se t
. of O . . t oo s an d .

in g wo rk t he N os 9 1 2 5 6 I I R M L 1 04 an d 1 01 are
.
, , , , , , , .

s u itabl e All h av e been fo u n d exc el l en t for t heir part icul ar

.

u r ose o r operat ion I t is to be not ed th at t here are n o sid e

p p .

p roj ect io n s to th is h older wh ich m akes it espec ially good for

,

t r imm ing die work I n F ig 3 0 1 is shown a n asso rtm ent of

- . .

too l s an d h old ers m ad e in sev era l sizes \Vith an asso rtm ent of .

th ese standard S h apes t he m ac hin ist die m ak er or too l m aker ,

-
,
-

is en abl ed t o do his wo rk rap idly an d accu rat ely I n v isit ing .

o n e l arge die sin k i n g est abl ishm ent rec ently

-
n ea rly 1 00 of ,

t hese h old ers w ere see n i n u se on v ario u s parts of d ie wo rk -

a n d i n m ain t ain in g t oo l s fo r s u c h w o rk h av in g m ad e a pl ac e ,

for t h em selv es by th eir great adapt abil it v t o al l cond it io ns an d

3 18 D R O P EG RG I N G ,
-
II I E -s
rx x rx c , ET C .

t he s hea r, o r w he re t he l ev e ra ge is su ffi c ien t t
t o s a rt be n d in g
t he c hip .

T hird : t he to ol m u st corre ct a n gl es o f c leara n ce

ha v e t he

an d top ra k e T he t o p ra ke m u st be s u c h as w i l l sepa ra te t he
.

c hip f ro m t he body of m eta l in a m a n n er to gen era te t he l east

poss ibl e h eat i n p ropo rt io n t o t he m et a l re m o v ed .

Last l y : t he too l m u st be fo rged harden ed an d t em pered i n , ,

t he bes t poss ibl e m an n er a t hi n g w hic h o n l y l o n g ex per ien c e

,

a n d Co n t i n u o u s s e c ia l iza t io n i n rf ect i n g t his p rod u ct ca n

p pe

acc o m p l is h .

T he fo rg i n g p rocess u sed i n m ak in g t he t oo l ho ld er an d -

o i n ts d esc r ibed a n d i ll u st ra t ed here is t he res u lt o f l o n g an d

p

FIG .
—
l l y dra u l ic fo rg i n g -die fo r fi rst o p e ra t io n .

p a t ien t exper im en tat ion an d a l so w ide ex perien ce in t he ha n d

,

l in g of h igh sp eed steel s ; a n d t he appl icat io n s an d d etai l s o f

-

t his p rocess i n terested m e v erv m u ch w hen I v isited t he

O K pl an t l ate l ast year
. . .

I w il l d ig ress here t o st at e t hat th ese peopl e h av e spec ial

ized so m u ch in t he c u tt in g tool b u sin ess th at th ey m ainta i n
-

I n ex er im en ta l dep artm en t fo r t he s ol e pu rpo se of b ei n g in

p
a pos it ion to know at a l l t im es t he b est g ra d es of h igh speed

st eel o btai n a bl e T he resu lt is th at t hey are obtai n i n g a gra de

. .

of st eel f ro m Sh effi eld E n gl an d w hich th eir exp er im en t s l ead

, ,

th em to bel iev e is t he best th ere is an d wh ich th ey are reco m ,

 H I G H -S PEED ST EE L m RG I N G AN D H AR D EN I N G PRAC T SE I 3 19

m end in g an d gu ara n teein g t o t heir cu stom ers for u se in m i ll ,

in g c u tt ers a n d ot her u ses wh ere hi g h s peed st eel is requ ired ,

on t he resu lt s obtain ed by th em in t heir experim en tal d epart

m ent in fair an d sq u are tests w ith ot her steel s .

Start i ng w it h t he comm erc ial bar of h igh speed steel t he -

p ieces are cut off i n a p ress g reat care being tak en to hav e
,

each p iec e of u n i f or m w eight inst ea d o T secu re th is

f size o .

an accu ra t e b al an c e is pl ac ed o n t he ben ch beh i n d t he operat or ,

a st an d ard fo rg in g bei n g i n t he pan fo r a w eight T he fi rst .

p iec e f rom each n ew bar is tested ; an d sh ou ld t he weight v ary ,

ow i n g to a s l ig ht d iff eren ce i n t he s iz e of t he bar t he stop i n ,

t he c u tt i n g p ress is adj u st ed u n t i l t he w eight is ab solutely

co rrect T h is n ot o n ly sav es stock wh ich is qu ite an

.
,

FI G . 3 03 .
—
A w o r m -c u t t e r an d it s c hip .

item w ith h igh speed steel bu t al so i n su res a u n ifo rm ity in

-
,

t he t ext u re of t he f o rg i n g as t he sam e p ressu re is ex ert ed i n

,

each c ase .

After t he c u tt i n g D E w h ich is do n e hot t he p iec es go to

-
, ,

t he f org i n g fu rn ac e T he squ are p iec e of steel is th en h eat ed

.

i w —
n a spec ial fu rn ace of t he r o n m an ufactu re to t he p roper
forg in g h eat an d d ropped in to a hard en ed st eel retai n ing d ie
- -
,

u on a h ard en ed st eel p u n ch t hat fi t s t he p rofil e of t he die

p ,

both of wh ich are shown i n F ig 3 02 . .

T he t op p u nch is th en en tered i nto t he die an d u n d er a ,

5 0 ton p ressu re t he squ are b i llet is bl anked squ eez ed an d

-
, ,

fo rged to t he shape of t he p ieces shown on t he l eft h and sid e -

of t he die i n F ig 3 02 . T he t op p u n ch is t hen withd rawn

.
 3 20 D RO P I O RG I N G ,
-
D I E S I N KI N G ,
- we .

an d t he bl an k d by t he bottom p u n c h to a p roper posit ion

ra ise

o n t he t o
p o f t he re t a in i n g d ie wh e-
re ,
it m a
y h e g ra bb ed bv

t he to n gs an d rem ov ed to t he f u rn ac e to be reh eat ed .

T he f org ed bl an k is n ext passed to an oth er p ress an d

d ropped edgew ise in to an oth er retai n in g die hav in g t he p rofil e -

of t he fi n ish ed fo rg i n g a n d t he opera t io n o f refo rg in g is per

,

fo rm ed u n d er 7 5 t on p ress u re F ig 3 04 s hows t he sec o n d

-
. .

ret a i n i n g d ie i n it s c ast i ro n
-
l t w ith t h bl an k a n d fi n is hed
p a e e
-

fo rg i n g ly in g o n it At t he l eft is t he t op p u n ch an d h o lder
. ,

FI G 3 04
. .
—
Hy drau l ic forg in g-dies for last op era t io n .

t he sa m e t y pe of hol der being u sed on both bl an k in g an d fi n

ishi n g op erat io n s .

T h is m et hod of fo rg in g can n ot help bu t imp rov e t he g ra i n

o f t he st eel .I n a ll c u tt i n g po in t s t he st eel is u sed w ith t he
-

c u tt i n g edge o n t he en d of t he g ra in Whi l e t his seem s a

-
.

s m a ll m att er it has b een m ad e t he su bj ect of c aref u l st u d y an d

,

has p rov ed an adv an tage of g reat impo rt anc e .

An oth er c o mm en d abl e f eat u re of th is f org i n g sy stem is t he -

hig h p ressu re ex ert ed o n t he m et al w hen fo rm i n g t he tool f rom

t he sq u are t o t he fi n is hed s hap e in two bl ow s wh i l e t he m et a l ,

is c o n fi n ed w it hi n t he wa ll s o f t he ret ai n in g d ies T h is com -

.

resses t he gra i n o f t he st ee l an d is adm itt ed by m n u fact u

p a ,

rers of hi g h s p eed s t eel an d t he m o st adv a n c ed st eel expert s

-
,

t o be a n id ea l m et hod o f f o r g i n g c u tt i n g po i n t s fo r st eel a n d
-

I ro n .
3 22 D RO P EO RG I N G , D I E-SI N KI N G , m

t he base . Ll an y m et hods
have been tried w ith v aried su ccess .

T he o ld m et h od of plac in g a l arge log of w ood en d w ise u n der

t he base of t he d ro p an d grout in g aro u n d it t o hold it fi rm l y , ,

an sw ers t he p u r pose fo r a sho rt t im e bu t i n m ost so i l s t he ,

wood soon deca y s an d t he log becom es u sel ess ; wh ere th is

m et h od is cont in u ed it becom es u n sa t isfact o ry an n o y in g an d , ,

ex pen siv e T he wri ter has t ried sev era l m et h ods of set t in g
.

d rop fou n dat io n s an d has co m e t o t he bel ief that fo econ o m y

,
r
,

st abi l ity an d good res ults ou r p resen t m eth od is t he best for

, ,

flat wa re d rops O u r m et hod co n sist s of excav at i n g do w n f ro m

-
.

lev el abo ut eight feet an d w id e a n d lo n g en o u gh to g iv e good

, ,

so l id g ro u t fo u n dat ion u s i n g s m a l l cobbl es to n es an d Po rt l an d

,

cem en t Th is we bu ild up in t he bo ttom of t he ex cavat ion

.

abo u t fou r feet then we put on about t wo feet of c ru shed

,

ston e m ix ed tho roughl y w it h Port l an d cem en t

,
“E th en p ro .

cu re a large stone abo ut t wo feet th ick an d at l eas t s ix i nches

larger th an t he base of t he d rop at all po i n t s Th is sto ne .

we pl ace on top of t he c ru sh ed ston e t hen fil l all arou n d th is ,

fou n dat io n sto n e w ith a c ru sh ed sto n e gro u t in g n ear ly to top

- '

of t he fou n dat io n Aft er t he cem en t work has become har

.

den ed cu t out t he top of th is fo u ndat ion about on e h a lf inch

,
-

in depth an d t he sa m e sh ape as t he base of t he d rop bei ng ,

su re th at t he cutt i ng out is per fect lv l ev el an d t ru e

-
.

u su ally c u t th is rec eiv i n g spac e abou t on e h a lf i nch l arg er at -

a ll poi nts to a llow for l ead in g aro und t he base N ow pl ace .

t he iron base i n t he cav ity bei n g su re it is l ev el an d t r u e a n d

, ,

p roceed to l ead t he sam e When t he hot l ead is pou red i nto

Y
.

t he spac e around t he base it m ak es a ll sec u re w ithou t d ang er

,

of mov ing fro m posit io n as long as t he fou n dat io n st an d s fi rm .

Such a fou n d at io n if p roper ly m ad e i n su res t he best poss i bl e

, ,

res ista nc e to t he blows of t he h a mm er an d g iv es bes t res ults

-

in b ring i ng up eith er pl ain or fig u red pattern s i n t he d ies .

H old ng D es in D r op Pr esses
i i -

Sev era l m ethods for hold in g t he d ies in d rop p resses a re -

u sed an d al l m ay h ave som e good featu res but we fi n d t his to

, ,

be t he most p ra ct ica l o n e for spoo n d ies I t co n sists of w ha t .

 H IG H -
S PEED ST EEL F ORGI N G AN D H A DEN R I NG R
P AC T S E I 323

we c ll d
a ie be
ad k ey d in to the top of t he d rop anv il
e - - Th is .

die bed has a cav it y long enough an d w ide enough

-
an d of

p roper d epth to receive t he die I n t he center of t he depth

.
.

of t he receiv ing space we pl ace six sc rews two on each sid e

-
,

of t he l ength of space an d one each on t he back an d f ront of

,

t he sa m e .Th ese sc rews are of su ita bl e d iameter an d l ength

to hold t he die fi rmly in pl ace With t he six sc rews abov e .

m ent ion ed we can adj u st the die sid ew ise an d endw ise to al ign
p roperly with it s m ate wh ich is h eld in the h amm er by m ean s
,

of a k ey We find th is m ethod of hold ing the d ies for t he

.

st r i k in g up of flat ware t he su rest sa f est an d most p ra ct ical of

-
, ,

an y so far d ev ised T he d ies u sed for st rik ing flat ware are of
.
-

varied sh apes F l at cu rv ed h alf cu rv ed et c to best su it t he

.
-
, , , .
,

wo rk desired .

D ies f or M a king Flat -Wa r e

T he d ies for m ak ing flat ware are expen siv e Th erefo re

-
.
,

qu ite an item to be figu red in t he co st of p roduc ing t he good s .

Th ey mu st be m ad e of t he best steel su itabl e for t he pu rpose

that w il l stand t he hard u sage requ ired of th em Whol e pages .

m ight be w ritten of experim ents wh ich have been m ad e w ith

d ifferent steel s manufactu red t o find a m ake or b rand ent irely
sat isfacto ry i n ev ery way I f t he cost of t he st eel on ly was
.

con sidered we m ight all be sat isfi ed bu t t he expense of cut ,

t in g a pair of figu red spoon or fo rk d ies is another p roposi

t ion an d m any t im es g reater th an t he cost of t he steel
, .

Trea tment a nd Use o f D ies f or F la t Wa re

T he t reatm ent of steel in t he ann ea l ing an d h arden ing pro
cess has a g reat d eal to do with t he w earing qu al ity of t he d ies .

T he w r it er has seen som e costly d ies ent ire ly ru i n ed th rough

.

n egl ect of si mpl e p rinc ipl es i n t he h andl in g an d lon g ago ,

concl u ded that som eth ing mo re than water an d fi re was n eces
sary to ha rd en spoon or fo r k d ies t o get the best serv ic e f rom

th em I n t he st rik ing up of flat ware we h av e m any diffi cu l

.
-

t ies to overcom e F irst we m u st be su re ou r d ies are set

.
,

co rrectly in t he h amm er an d die bed an d th ey m u st be exactly -

,

m itered on e w ith t he oth er or ou r patter n on back an d f ront of

,
324 D RO P-
F
O RGI N G
, DI E -
w k I N G, ET C .

t he bl ank wh en st ruck w il l n ot be t ru e t o each other a n d be ,

thu s m ad e u nfit for t he fin ish ed p iece of work Second t he .

,

operato r m u st k ee t h d i cl n as if a n fo i gn u b t c
p e es ea
y re s , s a n e

ad heres to t he d ies or bl an k it p rev en t s t he fi gu re s f ro m com i ng

up ful l an d cl ear an d al so sho ws bad pl aces i n t he art icl e To

, .

S how how c arefu l t he opera to r mu st be to h av e his wo rk e

p r

fect wh en st ruck u p as a n i llu st rat io n we w il l t ak e t he fi n est

,

h u m an hair an d pl ace it o n som e pl ain part of t he d ie an d th en

pl ace ou r bl ank to be st ruck over t he h air an d let t he h am m er
fal l \V e fi n d when we l ook at ou r bl an k that we h av e a cav
.

it y or i nd en tat io n m any t im es l arger than t he d iam eter of t he

h air tho u gh p ract ica lly t he sam e sh ape T he requ irem en ts
,
.

of a good d rop p ress operato r are act iv ity good j u d gm ent

-
, ,

good eyesight an d posit ive watchfu lness an d carefu l ness to

,

det ect i rregu l ar it ies i n die or bl an k .

Corr ect a nd Relia ble M et hod f or Ha r den ing D r op H a mmer

Dies bVit hou t Loss

T w en ty years at h ard en i ng d ies, employm en t i n fi fteen

Stat es at t he sam e t rade should g iv e a m echan ic an ex pert
k n owl edge of his c raft Th is is t he ex perience of t he fellow
.

m echan ic f rom whom t he m ethods an d p rocesses giv en in t hese

l ast pages of th is book was secu red by t he autho r D u ring .

t his m an s t rav el s he was d et erm i ned to find a way that d ies

’

cou ld be harden ed with perfect sa fet y an d he found it Re , .

ferring to his reco rd of on e y ear an d six month s wo rk I found ,

he had hard en ed d rop h amm er d ies w ithout t he loss of

-

on e die Th ese d ies were all su bj ect to in spect io n by t he fo re

.

m an of t he bl acksm ith s an d die departm en ts as wel l as t he m an

-

who u sed th em Bu t not a die ret u rn ed to be rehardened an d

.
,

du ring th is t ime n ot a die left t he h arden ing shop that cou ld -

be touch ed w ith a fi le Th is shop bel ieved that it s d ies did

.

best wh en d raw n ju st t o a light st ra w colo r .

Th ese dies ranged in siz e f rom 1 6 to 500 pounds an d were ,

—
ju st such d ies as would be seen in an y u p to date forge shop - - .

Th ey had th eir b reakdow n an d fi n ish in g po rt ion s all in t he

sam e die wh ere it was po ss ibl e to do so
,
So it can be seen t hey .
326 D -
O RG I N G,
RO P E DI E-
srx ru x c , ET C .

harden in g heat at t he sa m e t im e As t o t he p roper ha rden i n g

- .

ha t I wou ld p refer t o lea v e t hat t o t he harden er bu t fo r fear ,

of bei n g t old t hat I did n ot n am e t he heat I w i ll sa y t ha t if

o u ha ve st eel t ha t ru n s i n ca rbo n fro m 6 0 t o 7 5 po i n ts heat

y ,

t o a du ll cherry red ; bu t if y ou ha ve st ee l t hat ru n s f ro m 7 5

-

t o 90 poin t s t hen heat t o a l itt le m ore t han so m ber red

, .

Allow t h d i b 2 ho h
’

e es a o u t 3 u rs t o eat
4 .

TW f Cooling II
’
e mtu r e o a t er

Af t er you have t he fi re so
y ou ca n heat t he d ies as de
scr i b ed , x
t he n e t st ep t o get r ght
tem perat u re of t he
i on is t he
wat er t o be used i n t he cooli n g Th ere arem any wa y s of do .

in g th is an d m u ch depends on t he amo u n t of t he p ressu re of

bot h t he water an d st ea m as t o where t he stea m s hou l d be ap
plied Sho u ld t he steam press u re ex ceed t he wat er p ressu re
.
- -
,

p lace t he st eam ahead of t he water valves on t he harden in g -

tan k Th is w i l l g ive comp lete cont rol of t he tem pe ra t u re of

.

t he w ater an d i n f act be bett er th a n h av in g it go d irectly to t he

,

supply tan k - T he n ext m ov e is to h av e t he water i n t he coo l

.

i n g ta n k so that it is abso l u tely u n der co n trol or so you can

-
,

hav e yo u r die in in ch or 2 in ch es of water j u st as t he ,

s hape of t he die w i l l ca l l for T h is ca n be acco m pl ish ed i n

.

sev eral difl eren t way s T he best tan k ever bu ilt was on e
.

with a 4 i nch w ast e p ipe d irect ly i n t he bottom of t he ta nk

- -
,

with a v alv e below an d o u ts ide of t he t a n k u n der t he gro u nd ,

l in e w ith an exten sion h andl e or wh eel where it could be

,
-
,

reach ed wh i l e h an dl i n g t he d ie th u s regul at i ng the depth of ,

t he w at er for cool i n g by t he v a lv e of t he 4 i nch w aste p ipe - -

.

Wh ere water would do dam age in case of t he tan k overflow in g ,

t h ere sho u ld al so be an overflo w waste p ipe thu s confi n i ng t he -

,

w ater ent irely to t he tank .

Ha ve Plenty
f

f
o Supply Pipes -
f or Wa ter
\V hereth ree or fo u r 400 pou n d d ies are t o be harden ed-

dai ly th ere sho u ld be severa l su pply p ipes w ith not l ess th an

,
-

3 0 pounds p ressu re f ro m a 52; i n c h p ipe ent erin g t he ta nk at a

-
,

pl ace on t he sid e or en d wh ere it can ru n to t he botto m an d

 H IG H -
S PEED ST EEL FO RG I N G AN D H AR DEN I N G PRAC TI SE 327

ce nter of t he tank th en u p an d d irectly under an d w ith in 6

,
-

inches of wh ere t he face of t he die w i ll rest wh en h ard en ing .

I n some ca ses it w i l l requ ire mo re t h an on e stream of water

on a die th is of cou rse depend i ng on the ou tl ine of t he face
,

of t he die Th ere are oth er th in gs to consider ev en befo re

.
,

t he die is h eat ed .

Sho u ld t he die h av e a hol e for a pl u g or p in th ese hol es ,

shou ld be closed w it h I ron p i n s tu r n ed to fi t t he hol e al low i ng ,

alway s for sh r i nkage wh ich s houl d not be l ess th an 3 ; i nch

1
,

wh ere t he hol e 1 3 l arge being su re to h ave th em so th ey can

,

not drop out R iv et ing is b est wh ere possibl e Then th read

. .

on e en d of t he pl u g an d put a nut on an d t ight en the sam e

,

as a bolt
. I k now som e w i l l say u se fi re cl ay or putty F ire
.
,
-
.

cl ay is not safe; pu t ty is ca lc iu m carbonate an d wh en t he wo rk ,

is h eat ed w ith putty in t he hol es t he ca lc iu m carbo n ate b ecomes

j u st l ike an y l im e ready to h eat t he mom ent water st rikes it
, ,

con sequ ently it is n ot safe .

Ha rden ing t he D ie
After it is h eated
dy to h ard en take say t he l 6 -pou nd
rea , , ,

die f rom t he fi re an d pl ac e i n f rom on e to two in ch es of w ater

,

face u p Let it stay u nt i l t he b ack gets moderately bl ack or

.

cool ed j u st enough so that wh en t he die is tu rn ed t he back

,

can be cool ed as qu ickly as t he fac e Befo re tu r n ing it on t he .

fac e ov er t he st ream of water to h ard en take a p iece of coarse ,

cloth w rapped fi r mly on a h andl e so as to m ake a swab

, , .

H av e th is in wat er at a ll t im es Take t he swab or w ipe st ick

.
-

f rom t he wat er wipe t he face an d h igh po ints of t he die so as

,

to d riv e an y excessiv e h eat f rom th em b eing su re not to u se ,

it so f reely as to p rev ent h ard en in g T h en pl ac e t he die ov er .

t he st ream fac e d ow n co o l t he back s lowly by l ett i ng t he w at er

,

on an d ofl t he back th u s allow ing t he h eat to be d riv en ou t

’
,

t he back rath er th a n t he fac e or sid es

"
.

T he d epth t he f ac e of t he die sho u ld be i n t he w ater de l -'

pends on t he o u tl in e of t he wo rk in g face bu t not mo re th an -

,

i nch on a die th at has a m od era tely st ra ight fac e When .

t he die becom es bl ack o n al l sid es shut ofl t he w ater an d re

’
,
328 D RO P F0 RGI N G ,
-
D I E SI N KI N G , ET C.

move to a pl ace i n the tank w here it can be placed in the water

face down an d j u st su ffi c ient water to cov er t he i mp ressions ,

p rov id ing th ey are on e inch d eep T he die should sit in at

.

least on e inch of water rega rd l ess of t he shallow n ess of it s

,

imp ression after be i ng taken f rom the st ream bu t do not

, ,

co n t in u e t he st ream after t he die is bl ack L eav e it in t he st i ll .

wat er unt i l tho ro u gh ly cool th en d ra w t he t empe r

, .

D ra wing t he Temper

T h ere man y ways of temper in g th em but th is shou ld

are ,

be don e i n a fu r n ace con st ru ct ed for th at pu rpo se nev er pl ac i ng ,

t he d ies to be drawn i n a fi re w ith mo re th an 2 1 5 d eg rees Cen

t igra de ( 42 0 Fah renh eit ) a llow i ng th em to tak e t he temper

,

S lowly . Th en let cool I n t he harden i ng of t he 2 5 0 pound die

.
-
,

take it f rom t he fi re keep ing t he fac e up an d pl ace in the water

, ,

w ith in th ree or fou r i nch es of t he face L eav e there unt i l t he .

back or shank gets moderat ely bl ack Take f rom t he wat er .

,

w ipe t he h igh pl aces w ith t he wet swab an d t u r n t he die ov er

t he st ream of water to h ard en being su re t he temperatu re of
,

t he wat er is not below 80 deg rees Fah ren h eit I f th ere is mo re .

than one i mp ression u se mo re than on e st rea m of water so ,

that t he water w i ll st rike all parts of t he die th at are to be

hard en ed T he die should not sit in mo re th an 54 inch of
.

water wh en h arden ing u nl ess t he imp ression s go deeper th an

,

th is Ev en if th ey do an d are on t he in side an d center of t he

.

face t he fo rce of t he water w il l be su ffi c ient to h arden that part

, .

T he idea is not to h av e t he die i n deep wat er wh i l e h ard en i ng ,

an d by cool i ng t he back s lowly wh i l e h ard en i ng t he fac e t he ,

die can be h eld st ra ight an d h ard en ed w ithout an y d anger of

losing it .

After t he die has bec om e bl ack on t he sid es an d end s th en ,

stop cool i n g t he b ack t u rn off a part of t he water an d let t he

,

die sit ov er t he g ently fl ow in g st ream u n t i l cool Th is ru l e .

appl ies to a l l d ies of 1 00 po u nd s or ov er wh i l e t he s m a l l er ,

d ies can be pl aced to on e side away f rom t he st ream in on e i nch

,

of wat er to fi n ish cool in g Be careful not to take t he d ies of

.

an
y s iz e ou t of t he w ater befo re th ey are th oro u hly cool
g A .
 I N D EX

Accu rac y of ou t l i ne, t es t in g wi t h Bat es Forg e Com pan y , 1 2 4

l ead p roofs, 1 9 Bell cran k die for form i n g t he en d
-
,

Accu rat e forgi n gs, 1 3 5 of 5 1 ,

Adv an t ages of oi l f u el 1 46 Bel t p u n c h. 1 2 6

West in ghou se 287
,

Ai r -brak e
, , Bem en t, M i les Co s t ea m -ha m .

Air power ham m er 2 09

-
, m ers 1 84 ,

Aj ax forg in g m ach n e, drop forg

- i - Ben d n g di e for st eeri n g -gea r p ar t
i -
,

i n g, 2 6 5 z3
Alaba m a Poly t echn i c I n st i tu t e 1 86 , Ben di n g dies
-
for con nec t i n g -rod
Al loy i n g m at er i a ls effec t s of, 1 3 6
, s t rap s 2 79 ,

Alu m in u m i n s t ee l 1 3 7 , Ben di n g ey e-bol t s i n b u l ldozer, 284 ,

Am bl er drop ham m er desc r i p t ion

-
,

176 Ben di n g -for m in f ron t drop -forg i n g ,

Am b ler drop ham m er , fron t v iew

-
di e showi n g, 2 2
of, 1 73 Be d n g m achi n e, work i n g in drop
n i -

s ide v iew of 1 73 , an d .1 98
Am b ler M r A A 1 7 6
, . . .
, Bet hlehem S t eel Com pan y , 2 48
Am er ican m a chi n ery i n t rodu c t ion , Bi l l i n gs Spen cer Com p a n y Ha rt ,

of, 1 63 for d, Con n , 1 81 .

Amer ican M achin ist, a rt i c le on i ron B lack an d M F Kahm , M ess rs J. . . .

s t ra i n s 1 87, S.
, 1 87
Am er i can t ool st eel, sam p les work ed
-
B lack sm i t h , fi rs t i n t er c han g e
u p on , 1 89 a b l e, 1 66
An n ea l in g f u rn aces Br own 8: , B lan char d Thom as, i n 1 7 2 7 2 47
, ,

Sharpe hea t i n g an d 2 6 , Bl an k s, t r i m m in g wren ch 1 24 ,

An v i l block i m p rov ed 200

, , B l ast -for ge refi t t ed for oi l -fu el 1 45 ,

Ap p l ian ces, harden in g 83 , Block , i m p rov ed an v i l, 200, 2 01

st r o n g ob r i n g
-t oo di
l es 40 , Board fas t en i n g of ham m er, 1 69
Art , gr owt h of drop forg in g an d - Board i n ham m er, m et hod of fas t
st a m p i n g, 5 0 en in g, 1 6 8
Assem b l in g fl an ges an d spokes wi t h Board, s t ea m , hel v e t r i p , a n d drop
,

hu bs, 2 1 6 ha m m ers, 1 40
Assem b l in g wheel barrow wheel 2 04 Bol st er f r p ost al an d baggage c ars,
'

p
,

Au t hor , v i si t in g O K Tool Holder . . zs

Pl an t , 3 1 8 Bol t headi n g di es, 1 00
-

Au t ogen ou s weldin g 1 3 6 , Bossed lev ers, dies for fi n ishi n g 46 ,

ap p l i ca t i on s of 299 , B ra dl ey ha m m er, 2 84
con c l u s i on s on 3 02 , Br ad l y c u shi on ham m ers 1 7 9 ,

Au t om obi le shop rop forg in g p rae

d -
B raz i n g fu rn aces, 1 6 1
t i se 1 1, Break in g -down die, exa m p le o f 2 1 ,

Ax l e in t hree st ages forged 1 20 , , Br eak in g -down an d fi n i shi n g -d i es,

1 22
Badge em boss ed 6 5 , Break i n g -down dies, edg i n g an d
Ba ldw in Locom ot i v e Wor k s fi rs t
,

, fla t t en in g, 2 2
st eam ha m m er i n 1 84 , Brea k in g -ou t , u sin g t he c hi se l , 7 3
Ba l l v ise s pec i a l u se
-
. d i n d e s in k
i -
, B reak i n g ~t hrou gh Chi sels 7 0 ,

i n g, 1 5 Br i dg eport , Con n , Geo F Cha m p . . .

Barn u m Ri chardson car w heel

- n ey , 7 5
i ron , 7 8 Br i dgepor t Pa t en t Di e Com p an y , 7 9
3 31
3 32 I N D EX

B ri n e t a n k 1 43 , Check erin g an d g roov i n g v i se j a ws.

sp ec i a l 1 44 , t ool s for, 13 2
Brown Shar pe ( rus e ha rden i ng
-
Chi sel u si n g t he bra ki n g -ou t
, ,

fu rn ace for fu el oi l 1 48 1 49 , , Chis el s. brea k i ng t hrou gh. 7 0

B row n 8: Sha rpe fu rn aces 26 . Chrom i u m in s t eel . 1 36
B rown Shar pe hea t in g an d ah Cli pp er st eel 1 2 1 ,

n ea l i n g fu rn a ces . 2 6 di e of 1 2 1
,

B u ck et , des ign of elev a t or 2 6 0 , Clos ed an d Op en di es for forg i n g s ,

Bu ck et di es, m oldi n g elev a t or 26 1 , 88

Bu ckets , m ak in g elev a t or wi t h Coa l -forges an d fu rn aces for fu e l
oi l r efi t t ed
, 1 48 ,

B u i l t -u p di e 304 , Co l t Co lon el Sa m u el 1 6 4
, ,

Bu il t u p or we lded u p d ie wor k 302

- -
,
Co m bin at i on d ies . 94
Bu ll ard, E P of B r idgeport . 7 6
. .
, Co m bi n a t ion t ool -ho lders an d t h e i r
B u ll dozer app u r t en an ces 2 41 2 42 , u se 3 1 2
,

B u l ldozer ,ben d i n g ey e-bol t s in ,

2 84, 2 85 l ift i n g, 1 6 5
i —
wor k of t he form ng m ac hin e Con c l u s ion s on weldi ng. 302
Conn ect i cu t , The O K T ool Ho ld er . .

B u r d i ct hot p re
s - s ed nut - m ac hi n e,

Bu rn ers, for oi l fu el , 1 60
Conn ect i n g -r
ods, forgin g d isc f or ,

Ca rs, t er for p os t a l an d bagg age m ac h in in g i n side su r face of , 2 8 1

gg
o
z
,

p lan in g en ds of ,

Cas t ing , an d d r opp gi n dr op

-d i
es, Con st r u c t i on det a i ls of drop -h a m
m odel in g 7 7 , m er 1 7 6 , 1 7 7
,

Cas t i ron
- d i e -
holder 28 . Con st ru c t i on , j oin t ed s w in gh ea d ,

Cas t -i ron d i es, wooden pa t t ern s for 1 65

p a i r of heav y 40 , of drop ha m m er 1 67
-
,

Ca v i t i es . t yp in g t ool s u sed t o for m , Cost of forgi ngs 282 ,

18 Cou n t er ba l an ced t r eadl e, 1 6 4

Cha i n , det ail s of n ew short st i fi Cran e hook d i e for, 5 4
,

l i n k, 2 2 9 Cr an k d i e for forgi ng 5 9
, ,

dies for for m in g 2 30 , Crow bar for l ocom oti v e boi lers 2 6 5 ,

for m er m et hod of m ak ing 2 3 5 , Cu tt ers for t rick i ng s t ock 5 9 ,

m et hods of m an u fa c t u r i n g Cu t t i ng t he i m p re s si on i n di e -s i n k
welded, 23 4 in g, 6 7
p r esen t m et hod of m ak i n g Cy li n der, weldi ng t op of, 3 01
welded, 236
i
Cha n m ak in g d i e for , 2 40
-
,
Dav y B rot her s, Sheffi eld, Eng l an d ,

p rocess of weldin g i n , 2 40 249

screw -p ress for , 23 1 Deep form i n g di e m achin in g a , 43
‘
-
,

li
t he n k cu t t er , 23 8
- Dep ar t m n t , l ay ou t of har den i n g
g
,

t he l i n k -wi n der i n 23 6 23 7 , , 14
weldi n g ha m m er i n , 2 39 loc a t i on of di e-sin king 1 40 ,

we ldi n g m ac hi n e i n 23 8 , Dev elop rn en t of t he drop -ha m m er ,

Cha i n s dies for weldi n g 23 0
, , l fia
ear l y h i st or y of, 2 27 Di e a ssem b led , di e-holder an d, 2 8
n ew m et hod of m ak i n g wel d Die b loc k p l an i n g a, 1 2
-
,

l ess 2 28 ,
Di e-bl oc k s an d i m p re ss i on -bl
Ch a m p n e y d i e -
s in k i n g p r ocess , 7 4 96
Cha m p n ey , George F , 7 5 . Die, bu i l t u p , 3 04
Cha m p n ey i n Eu rope, 7 6 cool t he, t horoug hl y , 329
Cham p n ey p rocess, fin a l dev elop dr awi n g t he t em p er i n dr op , 3 2 8
m en t of 85 , dr iv i ng m odel i n t o t he, 7 9
Cha m p n ey shop di e-si n k ers i n 80 , , exa m p l e of br eak i n g -down 21 ,

s p ec i m en of w or k don e i n 81 , fi n ish i ng on p r ofi l i ng m a ch in e ,

Char coa l i ron sa m p les of good, 1 9 1 , 14

334 I N D EX

Di es, s t a k i n g t oo l s u sed for r ep ai r Dr op forg in g di e for wren c h an d

-
,

ing 2 0
, t r i m m n g di e for sam e, 24
i -

t a ck m ak i n g an d t hei r a c t i on
-
, , die, ha rden i n g t he face of, 2 7
2 45 di e showi n g ben di n g for m in
,

t a ck an d t ack 2 44 , f ron t , 2 2
t on gs for holdi n g 60 , di e, w i th edgin g an d brea k i n g
t o l s em p loy ed i n m ak i n g d rop , down dies, 22
o s di e work 8 ,

t r i m m in g 2 4 , for t he Aj ax forgin g -m a c hi n e ,

u se of, i n dr op -ham m er 94 , 2 65
u se of, i n d rop -p r ess, 94 on t he Paci fi c Coast , 41
u se of, i n forg i n g -m achin e 94 , or sq u eezi n g 1 34 ,

wi harden in g drop p rac t ise au t om ob ile shOp , 1 1

ég
u t l oss,
z
, ,

r em ov a l of fi n p roduced i n 54 ,

wor k i n g st ock in drop 1 93 , u n u su a l j ob of 120 ,

Dr il l n dl e drop -forgi n g a ra t chet Drop -forg in g di es, 2 1 94

h
a
, ,

exam p les of 25 ,
,

ex p an di n g t he s hel l of , 36 for gu n w or k, 1 1 8
Dr i l l in g ou t t he s t ock 72 , harden in g, 2 6
Dr i v i n g m odel - in t o t he di e 7 9 , m at er i a l s for, an d l i fe of 1 1 ,

Drop an d ben din g -m achin e work i ng , sa m p l es of l ead p roofs 19 ,

,in 1 98 sp ec i a l ba l l -v i se u sed i n s i n k
Drop an d hy dr au l i c forged cu t t i n g in g 1 5
,

t ools, 3 09 Drop -forg i n g di es an d work , 1 2

Drop, t he dies an d t he, 1 96 Drop forgi n gs, as t hey ap p ea r f ro m
-

Drop -di e, drawi n g t he t em p er 3 28 , dies, 3 8

harden i n g, cool t he di e t hor c ost of 1 36
,

ou ghl y , 3 29 m ak i n g of, 7
harden i n g, losses in , 3 2 5 Drop -ha m m er a t I n t ern a t i on a l Ha r
,

harden in g t he 3 2 7 , v est er Com p an y , 1 7 8

i
p p g i n for , 3 06 con st r u c t ion 167 ,

s u pp ly p i p es for 3 26 , det a i ls of con st ru ct i on 1 7 5 ,

t em pc rat u r e of cool i n g w a t er dev elop m en t of, 1 63

é
,

32 effect s, 1 7 4
Drop -di es com b i n a t i on , 94
, efi ec t s M i n er 8: Pec k M fg CO
, . .
,

fac i l it i es for rep rodu c in g, 1 94 1 74

harden in g of v ar iou s s t eels, 3 04 fi rst Un i t ed St a t es p a t en t of, 1 04
work in g s t ock i n , 1 93 forgi n gs, 1 34
D rop -fo ge an d ha rden i n g p lan t , for hea v y work , 1 80
g1 9 for s in k i n g -di es 79 ,

p l an of m o d e rn ,
1 41 fou n dat i on s, 1 7 0
u n der on e r oof, 1 3 9 fou n dat ion s, Port l an d c em en t
Drop -forge d i e, m ak in g a 1 3 , for , 1 70
m et hod of si n ki n g a 2 9 , Goldi n g Chen ey p a t en t of 1 6 4 ,

Drop forge di es for sh i p fi t t i n gs 43

- -
i m p r ov ed an d u p -t o-da t e, 1 8 1
Whit n ey CO 1 7 0
,

Drop -forg e wor k 1 1 , Pr at t .

,

Drop forged, lead p roofs of v ar iou s

- - sec t ion a l v iew of, 1 6 7

p art s t o be, 39 u se of di es in , 9 4
Drop -forged s hel l an d han d le for Drop ham m er s, board, st eam hel v e , ,

r at chet dr i l l , 3 4 t r i p an d, 1 40
,

Drop forged ship fi t t in gs 42

- -
, of Bi ll i n gs Spen cer Com p au
Drop forg i n g exa m p l e of br ea k i n g
-
, 1 81
down di e i n 2 1 , oi l heat i n g fu rn aces an d, 25
-

an a logou s hot st a m p in g an d 5 3
, , Drop -p r ess, for da t -wa r e Op era t i on s .

a n d s t a m p i n g ar t gr ow t h of 5 0
, , 32 1
an d s t a m p i n g l a rge p a rt s p r i n , u se of di es i n , 9 4
c ip l es of 5 1 , Drop -p r esses hol di n g di es i n 3 2 2 ,

a r a t chet dr i l l han d l e, 34 Drop rod, 1 7 4

-

die an d ben din g d i e for st eer Dr op -wor k fl a sh in 3 5

, ,

i n g gear p a rt , 2 3 l oc a t i on of fi n i n 5 4 ,
 I N D EX 33 5

Dr opp i n g dr op -dies m odel in g cas t , , F lang e form in g t ools, 2 1 4

in g an d 7 7 , F l an ges heat in g, 2 1 2
,

Drop s on st oc k effect of, 1 98 , m ak i n g t he, 2 09

Du ct i l i ty lost at 600 degr ees F 1 38 p u chi n g eight r iv et holes i n
g
.
, ,

Du sseldorf Ex pos i t ion t en t hou san d , 15

t on hy dr au l i c p ress at 2 9 1 , wheel s r eady for Sp ok es an d 2 1 1 ,

F lan gi n g hol es i n wor k , 5 5

Eberhardt Messrs Ul r i ch an d Fr ed
, . . F lash in drop work , 3 5
l 2 14 Fla t -wa re, dies for m ak i n g 3 2 3 ,

Econ om y i n u se t ool weldi n g 3 1 4

-
, , drop -p r ess, fou n dat ion s for 3 2 1 ,

Edg in g an d fl a t t en in g brea kin g -down O per at ion s drop -p r ess for 3 2 1

, ,

di es 2 2 , t r eat m en t an d u se of di es i n 3 23 ,

Effec t s of a l loy in g m a t er i a l s 1 3 6 , F l at -work , st ee l for ces for 6 4 ,

Elect r i c weldi n g 1 3 6 , F ly -cu t t ers u sed in die-s i n k in g, 1 7

Elev at or bu ck et des ign of 2 60 , , F0 0 3 M an u fac tu rin g Co , Sp r in g .

El e a t o
v r b k
u c et s w i t h s t ea m -
ha m fi eld Ohio, 1 7 6
,

m er m ak in g 2 5 7
, , Force holder , 6 9
Em bossed badge 6 5 , Force-m ak in g p rocess of, 1 0
,

Em bossed n u m ber p lat e, 66 Forces, di fferen t shap ed, 63

Em bossed orn a m en t n sheet m et a l
i -
, for em bossed work, m ak in g 6 2 ,

67 .
p roper ly m ade, 6 2
Em bossed pol i ce shiel d 6 5 -
, s t eel for fl a t -work , 6 4
Em bossed s t am p in g 6 8 , Forge, for cen t er -hea t in g, dou b le
Em boss ed work m a k i n g forc es for , , open in g 1 5 2 , 1 5 3
,

62 fo en d hea t in g, s in g le op en i n g
i
,

En d -
heat i n g forge fu rn a ce 1 5 5
En fi eld r i fle for En gl i sh Gov ern
m en t , 1 63
En gi n e con n ec t i n g -rod forgi n g 2 7 6
En g lan d i n 1 63 4 c ha i n p at en t s i n
, s1
fu rn ace, a dj u st abl e t op -s lot oi l,
154
, fu rn ace, en d heat i n g, 1 5 5
, , fu rn ace, t ool dress i n g, 1 5 7
-

2 28 fu rn aces ,s in g l e an d dou b le
En gl i sh Gov ern m en t En fi eld r ifl e , open in g, 1 5 6
for 1 63 , shop , s a b t ru c k for , 1 2 7
l - 128 ,

Essegy St efan Ki ss v
, 2 29 .
, w her e di es were hea t ed, 7 8
Ev ol u t i on of t he p r oc ess, hi st or y of Forged ax l e i n t hree s t ages 1 2 0 ,

Cham p n ey 7 5 ,
Forges an d hea t ers , oi l bu rn in g 1 5 4 ,

Exact n ess of si ze of di es 84 ,
Forges, in s t a lla t i on of 1 5 8 ,

m
Exa p l es of d rop forg i n g di es
- 21 , t op s ot a d en d heat in g 1 5 7
l n -
,

Exa m p l es of hy drau l i c forg i n g p r o Forg in g drop -ha m m er, 1 3 4

,

du c t ion 2 96 , en gin e con n ect i n g -rod 276 ,

Exp an din g t he shel l of dr i l l -han dl e , fi n i n t o t he ba r by rot at i n g 5 3 ,

3s high gr ade s t eels, 1 3 6

-

Ex per i m en t s m at er i al s u sed i n s t ee l
, hy dr au l i c 2 93 ,

an d i ron 1 86 , i n dies f r om t he ba r st ock , 5 1

p r ac t i cal r esu l t s of t wi st i n g 1 97 ,
i n t he heav y swagi n g -m achi n e,
Ey bol t di es for fi n i shin g 5 0
e -
, , 2 62
d ies for forg i n g 5 0 , l arge p ieces 1 3 3 ,

Ey e bol t s, di e for t u rn i n g 2 83
-
, m achi n e 2 7 5 ,

sh pes p rod u c ed by hy dr au l i c
g
‘

Far ist in Br idgeport , d e st eel m ade

i - g7
by 8 1, s t ra i ght p een ha m m er s 286 ,

F i l es, r i fi l ers et c u sed

, by di e .
, sw i n g han ger , di es for 2 68
-
,

s i n k ers 16 , t he high -speed s t eel cu t t in g

F i n di es p rov i ded w i t h sp ac e for
, poin t s 3 1 7,

r ecei v i n g 50 5 1 , , u n der st ea m -ha m m er, 1 3 3

l ocat i on of i n dr op -wor k 5 4
, , u n u su a l j ob of d rop 1 20 ,

rem ov a l of i n drop forgi n g 5 4

-
, , w i t h di es i n a r a i l road s hop 2 84 ,

s t r i p p i n g di e for r em ov in g 52 , w i t hou t s pec i a l t ools 29 1 ,

Fi n al dev elop m en t of Cham p n ey w i t h sp ec i a l t ool s an d u n sk i l l ed

p r oc ess, 85 l a bor 2 87
,
 I N D EX

For g i ng for k lev er 5 5

a -
, Fu rn ace , en d
hea t in g forge 1 5 5
-
,

Forgi n g a fu lcr u m bra ck et set of refi t t ed ea

l d ot fo o i l fu el , 1 46
-
, p r

t ools for 1 1 0 , t ool d ress i n g forge 1 5 7 ,

Forgi n g an d fl angi gn m an -
hole seat t u be-br azi ng. 1 5 9
i n gs die for 5 8
, , wi re braz i n g 1 5 8
-
,

, i
Forgi n g die for st eer g g ea r p a rt
n -
, Fu rn aces, brazi ng 1 6 1 ,

for 1 0 ]-o i l refi t t ed forg es an d,

i2
z3 ,

form in g cen t er hol es in bos ses , 4

49 heat i n g 2 6 ,

hob for, 92
p ra c t i se for a c cu ra t e 2 6 ,
G fi red l adl e hea t er 1 6 0 1 6 1
as -
Forgi g di f i -rod , ,
n es, o r co n n e c t n g s,
Gas -hea t in g fl an ges i n m u ffle u s i ng
zn
,

na t u r a l 2 12
for p i n en ds, 1 12
,

Gea rs, p ress ed s t eel 2 1 4

for r mn d an d sq ua r e u pset t in g
,

é Goldi n g 8: Chen ey p at en t of d r op
,

11
ham m er 1 6 4
v an adi u m 36
,

Groov in g v i se j aws t ool s for c hec k

Forgi n g m ac hi n e drop o g g for -f r i n ,

é eri n g an d 1 32
, ,

zs
,

Gun -wor k drop -forg i n g d ies 1 1 8

lar ge hy drau l i c, 2 5 6
,

.
m u l t i cy l in der hy drau l ic 25 3
-
,

Fo gi g m achin e dies 26 9
r n -
, Ham m er , p ower, 209
ai r
F g ig
o i -m achi n es u se of di es in board fas t en i ng , 1 69
r
r , ,

g‘ Bradley , 284
Forgi n g p ract ise, 294, 29 5 em ergen c y s t eam , 2 70
exa m p les of hy dra u l i c, 296 for heav y work, d m p , 1 80
For gi n g -p ress, rap id -ac t ion 2 47 , m ak in g a dou bl e-faced, 1 06
few di es n eeded for 1 08 , of fast en i n g boa rd in ,

Forgi n g rou n d work t o dest roy fi n ,

weight of ba se com pa red w i t h

Forgin g -
shOp , t i m e -c ar d for t he, fou n dat i on s 1 6 9 ,

Ham m e blows, di e wor k don e wi t h

- -

g
,

Forg i n gs , accu rat e, 135 s

accu racy of, 8 Ham m er -dies, 1 79
an d t heir m ak i n g m i crom et r i
, fi n i shi n g t he 1 06 ,

ca l , 32 m et hod of fast en i ng 1 7 9 ,

c l osed an d open di es for 88 Ham m heads, m et hod of secu r i ng

fg
é
, ,

cos t of, 282

i n fer ior q u a l i t y of, 1 3 7 Ha mm ers , board , st ea m, helv e t r i p , ,

locom ot iv e, m ade in hy dr a u l i c an d
drop , 1 40
m achin e, 2 58, 2 5 9 Bradl ey cu sh ion , 1 79
m icrom et r i ca l 3 1 for n g p ress d i es f or m ak i n g
g
i
, ,

p l an i n g t ool s for, 1 2 9 1
p prO e r p rac t i se fo r h y dr au l i c , forgi n g s t raight p een , 286
298 st eam , an d capa ci ty , 1 82
wrou ght iron for s m a l l 5 4
-
, Han d -v i se forgi n gs, p u n c hes, an d
Form i n g m achin e an d bu l ldozer
-
, dies for t r i m m in g, 1 3 1
wor k of, 2 66 , 2 6 7 wi t h shav i n gs, 1 30
F ou n da t ion s, d rop ha m m er
- 1 70 , , work on , 1 30
1 7 1, 172 Han d v i se han dle before an d a ft er
-

for fl a t ware drop p r esses, 3 2 1

- - c losin g 1 29 ,

ra t i o of base com pared w it h Han ge passen ger ca r t r u ck -swi n g,

-

weight of ham m er 1 69 , hag

F u el adv an tages of oil 1 46
, , Harden i n g ap p l ian ces, 83
Fu el for p rehea t i n g, 3 01 Harden in g cool t he die t horou g hl y
,

u sed i n t es t s on s t ee l 1 90 , i n , 329
F u el -
oi l refi t t ed forges an d fu rn ac es hea t in g of di es an d, 82
for, 1 48 p i p in g for d op di e, 306
r -

F u lcru m brack et set of t ool s for , Harden in g dep a rt m en t, l ay ou t of,

forg in g, 1 1 0 1 42
33 8 l x osx

Ladle ha t er
-
fi d 16 )
,
-
gas r e , M i l l in g d en ds 27 8
-ro
,

La y ou t of ha rden in g depa rt m en t 142 , M i l lin g si des of rods 27 8 .

Lead -a s t in g as pr oof of die 20 , Mi l l ing -t ools u sed i n d i e -si n k i n g ,

La d cast i n gs sam p les of proofs of

, 17
di es, 1 9 M in er Peck M fg CO . .
, drop -ham
Lend p ot fu rn ace re fi tt ed for oil
-

fu el 1 46
,

Lend proofs of v ari ou s part s t o be

-

forged. 39 Models , pI f Par is, 38

ast er -O -

Lehi gh V all ey Ra i l road Co m p an y , Modern drop forge an d har den i n g

-

p l an t p l an of 1 41
, ,

Li n k -cu t t erm chain m ak i ng 238 , Modern m a chi n ery v a l u e of 89 , ,

Lin k w der in chai n mak in g 2 3 6 . Mol di n g elev ator bu ck et di es 26 0

ga
, ,

z Mol in e t i r e-ben der , 205

Loca t i ori of di e-si n ki n g dep art m en t , Mov erri en ts s av i n g, u n n ec ess ary ,

1 ‘iO l 04
Locom ot i v e boi lers , cr owbar for , 2 6 5 M u l t i cy l in der hy dra u l i c forg i n g
Locom ot i v e forg in g m ade i n hy m ach i n e, 2 5 3
d rau l i c m achin e, 2 5 8,
Lon don , ri assem bl ed a t T ower i w l di
fl?
N at u ral ga s t r e - e n g,
0f 1e N at u ra l gas , u si ng for heat i n g 2 12 ,

New En g lan d S t a t es dr op ham m er

-
,

M achin e, h o t p essed n u t , 25 4 25 5
- r
, m en i n 99 ,

j ob for t he hea v y , N ew Z ea lan d ra i lw ay s, 2 87

Machin e dies forgin g, 2 a
-
, Ni ck el in st ee l 1 3 7 ,

Machin e-forgi n g 2 7 5 , N i les Bem en t Pon d CO

- - 1 85 .
,

Machin ery , v al u e of m oder n 89 N orway m “ sam p les wor k ed u p on ,

3
,

Machi n y e r -st eel

, aa m Nes worked 19
u pon , 1 90 N u m ber p l a t e, em bossed 6 6 ,

Mach n es, d
i i e-s i n kin
g 86 , N u t -m achin e hot -pres s ed 25 4, ,

Machin i n g i ns ide su r face of con

-bu rn i n
n ect i g rods, 28 1
- Oi l fo d h t rs, 1 5 4
'
i g r g e
s an ea e
Machir is' Amm m n, a rti c l e on st eel, Oi l fu el , adv an t ages of, 1 46
’

i?
s bu rn ers for 1 6 ) ,

Mak in g a do bl faced hamm er 1 06

u e -
, refi tt ed b l as t -forge f or , 1 45
M a k i n g a d r o p
-for i n
g g di e 13 , refi tt ed l ea d -pot f u rn ac e for 1 46 ,

Mal l eable i ron pa r t s, 7 Oi l hea t i n g f rn ac es an d drop ha m

-
u -

Man gan ese i n st eel, 1 3 7 m ers, 25

Man -hole sea t in gs, die for forgi n g O K St eel m ade i n Sheffi eld En g
. .
,

an d fl an g i n g 5 8 , l an d t he bes t , 3 1 8
,

Man u fac t u r in g con n ec t in g rods for

-
O K T ool Holder Com pan y Shel
. .
,

s t ea m en gi n es . 2 7 7
- t on , Con n , 3 1 2 .

Mare I slan d n av y y ard 41 , O . K T

. oo l -hol der
p l an t v i si t ed by
Mat eri a ls, effect s of al loy in g 1 3 6 , au t hor 3 18 ,

u sed for di es 5 0 , O K t ools an d holder, set of 3 1 6

. .
,

u sed i n st eel an d i ron eX p er i Open dies for forgi n gs c losed a n d, ,

m en t s, 1 86 88
Met a l p ar t s, un ion bet ween 95 ,

Met a l wheels, how m ade, 2 1 5 Paci c Coas t , dr op forgin g on t he,

fi -

det ai l s of 22 1 , 41
Met hod of i n st a llin g ap pa rat u s for Pap er p u ll ey s, 1 6 6
oi l fu el 1 5 6 Passen r -ca r t ru ck swi ng -han ger
gé
, ,

M icrom et er, i n side 1 9 ,

M ic rom et r i ca l forgi n gs, 3 1 Pat en t D i e Com p an y 7 6 ,

M i l es, f st ham m er m ade by Mr Pen n s y lv an i a Ra i l road. 25 6

g
g
.
,

l Pi n en ds for gi n g dies for , 1 12

,
-

M es, M
i l r . F B a st
. eam ha m m er
-
.
, Pip i n g arr an g em en t s of
, 50 ,

in v en t or, 1 84 Pip i n g for drop -di e har den i n g ,

?
3 5
M i li t ary r ifle d e sink ing for bu t t
i,
- Plan of m odern dr op -forge an d
p l at e of, 30 harden in g -p l an t , 1 41
 I N D EX 33 9

Plan of bel t -p u n c h di e 126 , Pu nc hing holes , sem i , 57

Pl an in g a d i e-block , 12 t hrou gh bosses
56 ,

Plan i n en ds of con n ec t i n g -rods, Pu n chi n g sm al l holes in work in

g 80 dies, 5 6
Pl an i ng ool s for fi n i shin g forg in gs,
lz g Rai l road shOp forgi ng wi t h dies in
, ,

Pl an t, rop -forge an d harden in g

d
1 sg
,

Rat ch t dr l l a dle, drop forgi n g a,

i -
h n -

p l a n o f m o d e rn d r o p
- f o r g e a n d g 4
harden in g 1 41 , fi rs t Op era t i on on , 3 5
Plast er of Par i s m odel s, 38
- - secon d operat i on on , 3 6
Pol i ce shi el d, em bossed 65 , Reed, Ezek iel, 1 786 an d 1 798, M 7
Port l an d cem en t for drop ham m er Refi t t blast forge for oi l fu el,
fg
- -

fou n dat i on s, 1 7 0 l
Pra t se
c i f o r h y d ra u l i c o g gs, 298
-f r i n Refi tt ed c oal forges an d fu rn aces
Pr at t Whi t n ey Com p an y drop for fu el -oi l , 1 48
ham m er fou n dat i on s, 1 79 Refi t t e l ad-pot fu rn ace for oi l fu el,
Preheat i n g fu el for, 3 01
, fig
Press an d t ool s, sp oke form in g 209 -
, Rep ai ri n g di es , st ak in g di es u sed
Pr ess, descr i p t ion of hy dr au l i c, 294
di es, forgi ng for ham m ers, 1 04 Ri fl es an d t hei r u se, 7 1
g i v es b e s t r e su l t s , h y d r a u l i c , 1 3 7 Riffl ers, fi les, et c , u sed by die .

p r e ssu r e f o r s m a l l w o r k i n h y s in kers, 1 6
drau l i c, 2 5 2 Ri m an d sp okes as m achi n ed, 225
rap i d - c t i on
a hy drau l i c Ri m -ben ding rol l s for wheels, 205
247 , 2 49, 2 50 Riv et i p ress ready t o go on t he,
ggé
,

t en t hou san d t on hy drau li c, 290

-

t r em en dou s p ressu re of hy Riv et i n g -sp ok es in wheel s, 2 1 0

drau l i c 248 , Rock d ll u sed as a st ea
r i m -ham m er,
wheel fl an ge, m u fl le, an d form
- ‘
z7 1
i n g, 2 1 3 Rou ghi n g t ool s 7 4 ,

Pr essed st eel gear b l an k 2 1 8 , Rou n d an d sq u ar e u pset t in g, forg

Pr essed st eel gear s 2 1 4 , in g dies for , 1 1 6
-

Pr essss fou n da t i on s fo fl a r t -war e

, Ru ben s, head of 82 ,

32 1
Pr essu re for sm al l work in hy drau Sacr am en t o , Ca li forn i a, r ail road
l i c p ress 2 5 2 , shop s at , 2 7 0
Pressu r e in di es, m et hod of app l y Scrapers, fi les, r i fi lers, et c u sed by .
,

in g i m pact or , 5 6 die-sin k ers, 1 6

Pr essu r e o f h y d ra u l i c f o r i
g g p ress,
n - Screw -p ress for cha in -m ak ing, 23 1
t r emen dou s, 248 Sect io n o f w eeh l -r i m
en l arged 22 6
, ,

Prev i s ion an d su perv i sion , 9 1 Sect ion v i ew of drop -hamm er, 1 6 7

Pr i n ci p les in holdin g dies fi rst , 99 , Sect ion a l di es, 46
Pr i n ci p les of d op forgi n g
r - an d Sect i on al drop -forge di es, 48
st am p i n g l arge p ar t s, 5 1 Sem i p u n c hin g holes, 5 7
-

Process of weldin g i n c a n m ak h i - Set t in g t he di e, 1 3 5

i ng, 240 S an
h k i n g d i es w i t h i
h gh speed cu t
-

Process, t yp i n g or hu bbin g, 6 0 t i n g t ool 3 1 1

-
,

Profi ler, work in g dies i n t he, 39 Shap es p rodu ced by hy drau l ic forg
Profi l i ri m ac n e,
h i fi n i sh i n g die on ,
- i n g, 2 9 7
l g Shap i n g of forgi n g-p u n ches, hy
Pr oof, t he lead cast in g as p roof of
- drau li c 298
,

di e 20
, Shear for cu tt in g off i ron 2 72 ,

Pu l l ey s, p ap er, 1 66 Shel t on Con n

, . The O K T ool
, . .

Pu n ch, bel t , 1 2 6 Holder Co at 3 1 2 .

,

Pu n ches an d di es for t ri mm ing Sheffi eld, En g lan d, 0 K St eel best . .

han d-v i se forgi n gs, 1 3 1 m ade i n 3 1 8,

Pu n ches, shap i n g of hy dr au l i c, 298 Shi p fi tt i n gs, drop -forge di es for, 43

-

Pu n chin g eight ri v et holes

- in drop -forged, 42
flan ges, 2 1 5 Si l i con in st eel, 1 3 7
3 40 I N D EX

Sing le an d dou bl e Open i ng forge St eel , se i es of Am eri can worked

m
fu rn a ces 1 5 6 , u pon 1 89,

i k
S n ng i -d ie s d r
,o p ham m er for 79
-
, s am p l es of J em ps worked
Sl a b t u c
r k f o f ge shOp
r o r -
12 7 , u p on , 188
Sm i t h work i n g a t t he an v i l 5 2
-
, sam p les of m achin er y worked
Sp au ld in g Mr R F
, 1 87
. .
, u pon , 1 90
Sp ec ai l b r i n e-
t an k 1 44 , s i l i con i n 13 7 ,

Sp ec i m en of work don e i n Cham p t i t an i u m i n , 1 37

n ey shop, 8 1 t u n gst en i n , 13 7
Spoi lin g di es, 1 95
-fo m i
Spoke r n g p ress an d t ools, 209
Spokes and ri m ass em bli ng fl anges,

an d hu b wi t h 2 1 6 ,

Spok es p un chin g hol es for wheel

, v an adi u m, 13 7
sp ok e
s 22 4 ,

Sp r in g c l am p for wheel spok es, 2 27

-
b en d ing -di e
for 23 ,

Sq uar e u pset t i n g, forgin g di es for St ock. dri ll ing ou t t he 7 2 ,

rou n d an d, 1 1 6 fo forgi ng rat chet dri l l -han dle

g
,

Sq u eezi ng, drop forgin g or 1 34

-
, ‘
Stak i g t ool s u sed for repa i r i n g
n -
St on e coa l i ron , samp les work ed
-

d ies, 20 u p on 1 90 ,

St eamed forgin gs, 58 St ri ppi ng di e for remov in g fi n an d

St am p i ng art , gr owt h of drop forg i t s work 5 2
'
,

i n g an d, 5 0
'

Su p er v i on, v a l u e of prev i si on an d
St am p i n g, em bossed, 68 g f ,

St eam , hel v e, t ri p, and dr op ha m Swag i n g -m achin e, j ob for 26 ) ,

m ers, 1 40
St eam -en gi n es, m anu fac t uri ng con Tack an d ta ck -di es, 2 44
Tack -di es, t ack an d, 244
St eam -ham m er 4 000-pou n d 1 22 , , , Tack -m ak in g t ools. com p l et e set of,
an l si ze of wor k, ca paci ty of
i
,

az an d t hei r act ion , 245

Bem en t , M i l es 8: CO 1 84 .
, Tan k , br i n e, 1 43
cap ac i t y of, 1 84 sp ec i a l br i ne, 1 44
Temper drawing t he, in chop -di es,
,

forgi n g un der 1 3 3
in Baldwi n Locom ot i v e Wor ks,
,

Ten s ion t est resu l t s of, 1 94

,

fi rs t , 1 84 Ten t hou san d t on hy dr au li c p ress,

- -

m lci n g el ev at or bu ck et s wi t h
i
,

sl Test s, on st eel, fu el u sed in , 190

‘

roc k -dr ill use as, 2 7 1 resu l t s of t en sion , 1 94

St eam ha mm ers, horse power , 1 84
- -
wrou ght -i ron an d machin ery
St eel, a l u m in u m in , 1 3 7 st eel , 1 95
an d i ron u n der di fl eren t degr ees T me
i -c a r
d for t he forgi ng -shop ,
of heat , 1 86
an d wrou ght ir on , di fi er en ce i n T re bender, Mol ine, 205
i -

t r ea t m en t of, 5 4 T i t an i u m i n st eel , 13 7
blan k for di e, 28 Ton gs for hold ing di es, 6 0
chro m iu m i n , 1 36 Tool dress in g forge fu rn ace, 1 5 7
o

c li p p er, 1 2 1 Tool -holder m ak in g, drop -forgi ng

c u t t i n g p oi n t s, forgi n g t he high p rac t i se i n , 3 7
speed 3 17
, Tool -holders an d t hei r u se, com bi
die-holder, et c , 28 . n at i on , 3 12
fu el u sed i n t est s on , 1 90 Tool -h l ers, high -sp eed st eel an d ,
gear b lan k s, p ressed, 2 1 8 2 1 9 , , gg
l
Tool -st eel, sam p l es of Amer ican ,
h g sp eed 309
i h -
, work ed u pon , 1 89
m an gan ese i n 13 7 , T ools, com p let e set of tack -m ak ing ,

n i c k el i n 137 ,

t est s, 1 95 em p loy ed i n m ak ing drop -di es 1 6 ,

 Do y ou k n ow
t he com p a ra t i v e

v a l u es of v a r iou s f u els ? Ha v e y ou
t he m os t econ om ica l f u rn a ce eq u i p m en t ?

T he q u est i on of fu el i s on e wh i ch t o-day dem a n ds carefu l

t
at t en ion , a n d c an on l
y b e d et e r m i n ed aft er ca refu l c on

s i der at ion of t he n a t u r e of t he work , base c ost of fu el a n d

t he m on ey i n v est m en t We a re prepa red t o fu r n ish fi gu res

.

s howi n
g r el at i v e econ om y of a l l f u e l s ,
t a k i n g i n t o con s i d
erat i on direct fi ri n ,
g p r eh ea i n g an d t r e g e n e r a i on t .

Thi s t abl e of com para t i v e fu el v al u es i s copi ed f rom page 3 of ou r Cat a

B eat u n i t s Cu feet t o equal

KI N D OF GAS
.

in 1 cu f t
. . 1 gal l on of oi l
N at u ra l Gas a

Coal Gas , 2 0 C P . .

Ca rbu ret t ed Wat er Gas

Gasol in e Gas , 3 0 C P . .

Wat er Gas from Bit u m i nou s Coal .

Wat er Gas from An t hracit e Coal ”

Produ cer Ga s .

Produ cer Gas . 1 555

equa l s B T U
. . .

Rockwell Furnace Company

is at y ou r s er v i ce

F u rn a ce bu ildin g, Econ om ic a l F u rn a ce bu i ld i n g, i s
s pec i al t y
. We can bet er you r c on dit i on s We em ploy a
t .

t
force of com pet en t exper fu rn ace en gin eers espec i ally
t ra i n ed a n d a re prepa red t o s u bm it s pec i fi ca t ion s an d

p r i ces o n com p l et e f u r n a ce eq p
u i m en t , U S I N G A N Y
FU E L , an d gu ar a n t ee t he proper operat ion .

Rock w ell Fu r n a ce Com p a n y

2 6 Cor t l a ndt S t reet F i s h er B u i l d i n g
N ew Yor k Chica go
If y ou lea v e ( m y t /zi ug in my i iu e ,

f u t y ou r l i m e a a in s t
g m i n e a n d
con s u lt m e if led? y ou e/m rg e

EX PE RT IN
Sho p Pra c t ic e Per t a i n i n g to Shee t
M e t al Fo r m a t io n , T he Press Wo r k
i n g o f M et a ls, Pa t en t C a u ses, M a
c hi n er y an d T o o ls I n v olv e d : In
St eel T rea t m e n t an d T em peri n g,
In I n t erc ha n gea ble M a n u fa c t u r i n g
of M ac hi n ery, I n D ro p Fo rgi n g a n d
D i e Si n ki n g, an d in t he Redu c t i o n
of Shep an d L a bo r C o st s .

J ose
ph V . W oodwort h
M eefi a u i ca / E xper t an d E ngi n eer
F ot t y T w o So u t h E i ght h St reet
-

Brook lyn , N . Y .

A11 in qu ir ies gi v en my p er son a l 0 t t erzt iou

 SU BJECT I N D EX

11
C 3
C 1 1
C 3 Perfu mery
C 1 0, 1 7 Pi pes
C Pl u m in g b
C 4 Produ cer G as
Com pressed Arr .
4 Pu n ches
Con cr et e 4. 5
C 4

S a ws
Sheet Met al or i n g W k
S hop T ools
S hop Con st ru ct ion

gimg
) men t
a per
k Pi
1 c in

g
3 o e er/ en t i on
9, u
10 3
10 S
lo S
7 S
20
19
u
u
18
u fact u r i n g 14 Tools 1
u
u
L ht ln E lect ri c) V al
ig i 7 S et t in
ve
L le ot o Walschaert al v e G ear g
Li q u i d Alt u Wat chrm k t n g .

Wi i
.

Locomot i v e E n m eet ing 1 2 , x3 , x r ng

Machxn tst s B oo
’
1 4, 1 5, 1 3 “fi reless T elep hon

P AG E
Ah m der
Ask t n son
, O H OG I OO Q Q O c O o o o o o o k
E rs i n e-Mu rr ay o o o o o o o Perr igo
Pra tt , ii
O scar E o o o o o o o o o o

F owler G eo L
B arr, Wm M b b
, .

G ar e, Po ert Pu t n am ,
W
.

B arr ows F G oddard, D wi ht R ad chfi e an d C u shi n g

G
. .

B auer, Dr
.

Gri m s haw' Ro t Ri chards-Coh an

W
. .

Harr ison , N ewt on R ou i lli on , L ou i s

E’m $t
g
n er, . . . .

Hasl a m , Ar t hu r P R oy le, H M
.

en a tn ark
G
.

B lackall , R H . H iscox , D 4 1 0, u . . .
, , 1 5 , 1 7 , 1 8, 1 9 Sau n ier , Clau di u s
B oot h a n d Kersha w H obart , P S loa n e, T O con or
’

W g b k
5, 7
3
. .
,

B oot h, m H Hom er , G 4, 1 1 , 1 4, 1 S t ar u c , R M
b
. . . .

B u chet t l J Hou ght on A A .

4, 5 S lv est er an d O er g
B yrom, T H P abet , John T
kil
ohn son , 17
V
an derv oort “
. .

B yron; an d Chri st op her n

g A ao 2
W
.

al k er S Ii
,
Cock m , T H K ei n han s , F A
8W
. . 1 .

-T
.

Col v in , F red H Krau s, H T al l i s a lor , A )

Weed A I
. . .

Cohan -Cheney H
b Wood Wm
. .
,

Colv m -S t a el L u m nu s-Pat ers on .

Cran e, W
,

Markham E R V
b
.

Mat hot , Ii E
.

D al y , H A
W
. .

E n gst rom , D Ag . Par se l l a n d eed

W AN Y BOO K ADV ERT I S E D I N THI S CATALOGUE W I LL B E S ENT PROM PT L T Y

ADDRES S I N THE WORLD. CHARGES PREPAI D. UPON RECEI PT OF PRI CE .

— Remit b Post al Mon e O rder, E x ress Mon e Order, B an k

W HO W t o Rem i t y y p y
or Regis t er ed Let t er.
 CATALOGUE O F GOO D PRACTICAL BOOKS .

BALLOON S AND FLYI NG MACHIN ES

MODEL BALLOONS AND FLYI NG MACHI NES WI TH A SHORT ACCOUNT OF THE .

PROGRESS OF AVI ATI ON B y J H AL E X AN DER . . . .

b k b
Th is oo has een writ t en wit h a v iew t o ass is t t hose who des ire t o con zt ru ct a m odel a irship
or ii in g m a chin e f
i t con t a ins fi v e old in g p l at es of work i n g dra wing s , each sheet con t a in i n g
b k
.

a d erc u t sized m ac h in e Mu ch i nst ru ct ion an d a m u sem en t can be o t a in ed f rom t he m a in g

.

an d fl y i ng of t hese m odels .

A short accou n t of t he p rogress of a v iat ion is in cl u ded , wh ich will ren der t he oo of grea t er b k
in t eres t f
Sev era l illu st ra t ions of u ll si zed ai rshi p a n d fl y in g m ac hi n es of t he la t es t t p es a re
k k
.

sca t t ered t h rou g hou t t he t ex t T his p rac t ica l wor gi v es da t a wor ing d rawin gs . a n det a i ls
b
.

which will ass is t m a t eria ll y t hose i n t eres t ed i n t he p ro lem s 0 fl ight 1 2 7 p ages , 45 i l l ust ra
p t
.

I IOnS , 5 " ol din g la es Pri m . o 0 0 o o ‘1 0 6 0

c c o o o o o

BRAZ I NG AND SOLDERI NG

BRAZ I NG AND SOLDERI NG . B y J AM E S F . HO B ART .

b k
The onl y oo t ha t shows y ou j us t how t o ha n dl e a n y j ob of ra zi n g or s old ering t ha t b com es
al ong t ells on what mi x t u re t o u se. how t o m a k e a u rnace if y ou n eed on e
°
Fu ll of f . ki n k s.
cu rt h edit
‘i'
2 5 ce n t s

CHARTS
BOX CAR CHART .

A chart s howin g t he a n a t om y of a box ca r , ha v i n g e v e ry p a rt of t he ca r num bered an d it s

p rop er n a m e gi v en i n a referen ce l is t . 20 ce n t s .

O
GOND LA CAR CHAR T .

A c ha rt s howin g t he a n a t o m y of a gon d ola ca r . ha v in g e v ery p a rt of t he ca r n u m be red a n d

it s p rop er referen ce n a m e g i v en in a referen ce lis t . 2 0 c en t s

PASSENGE R CAR CHART .

A cha rt s how in g
t he a n a t om y of a p as s n g e r ca r , ha v i n g e
e v e ry p a r t of t he ca r n u m be red a n d
it s p rop er na m e g i v en i n a re eren c e
lis t f . 20 cen ts

WESTI GH US
N E AI R O
-B R
AKE CHARTS .

Cha rt I —Shows ( in colors ) t he m ost m ode rn H ig h Sp eed a n d S ign a l I I u ip Wes t i nghou se

C
‘
.

m en t u sed on Passen ge r E n g i n es Passen ger E ng i n e Ten d ers , a n d Passen ger Ca rs ha rt

Shows ( i n colors } t he S t a n d a rd Wes t i ng hou se E q u ip m en t for F reight a n d S wi t ch E n
. .

Il —
F
.

gi n es , F rei g h t a n d S wi t ch 12 1 1 n Ten ders a n d re i g h t Cars Pr ice for t he set

. 5 0 ce n t s , .

TRACTIV E POWER CHART .

A c hart whereb y y ou ca n fi n d t he t ra ct i v e p ower or d ra w a r p u ll of a n y l ocom ot i v e, wi t h ou t b

k
m a in g fi g u re a Shows what c y l i n d ers a re e ua l , how d ri v i n g wheel s a n d st ea m p ressu re
Wha t S i zed eng i ne y ou n ee t o ex ert a gi v en d ra w a r p u ll or a ny t hing b
.

a ffec t t he power .

y ou des ire i n t his l in e . 50 ce n ts

H O RSE POWER CHART .

Shows t he horse p ower of a n y s t a t ion a ry en g i n e wi t ho u t ca lc u la t ion N o m a t t er wha t t he

k
.

c y lin d er d ia m et er of s t ro e ; t he s t ea m p res s u r e or c u t -off ; t he rev ol u t ion s . or whet her con

d en s in g or n on -c on den s in g . it s a l l t he re E a s y t o u se , a cc u ra t e , a n d sa v es t i m e a n d ca lcu
’

f
.

la t ions E spec ia l ly u se u l t o en g i n e rs a n d d es i g n ers

.
e
6 0 ce n t s .

B OI LER RO M CHAR T O By G e o L F O W L E R . . . .

A Cha rt — s ize 1 4 x 2 8 i n c hes — s howin g i n i som et r ic p e rspect i v e t he m ec ha n is m s elon g i ng b

in a m od er n oi ler room b Wa t e r t u be oners , ord i i i a r g ra t es a n d m echa n ica l st o ers . eed b k f
b
.

wa t er hea t ers a n d p u m p s CO RI p l l se t he eq u i p m en t , T e v a ri ou s p a rt s a re shown rok en or

’

re m ov ed , so t ha t t he i n t ern a l con s t r u c t i on i s u lly i ll u stra t ed

.

E ac h p art i s g i v en a re eren ce f f
b
.

n u m er , a n d t hes e , wit h t he c orre s p on d i n n a m e, a re g i v en in a g lossa ry i t ed a t t he s id es

g t n
T his c ha rt i s r ea ll y a d i ct ion a r y of t he boner roo m— t he na m es of m ore t a n 2 00 p a rt s ei n g b
.

g i v en I.t i s ed u ca t ion a l— wort h ma ny t i m es i t s cost 2 6 cen t s .

 CATALOGUE O F GOO D PRACTICAL BOO KS .

DI ES— METAL WORK

DI ES, THEI R CONSTRUCTI ON AND USE FOR THE MODERN WORKI NG OF SHEET
METALS B y J V Woon won r n . . .
'
.

A m os t u sefu l book , an d on e whi ch shou ld be in t he han ds of all eng aged in t he p m work i ng

of m et a ls ; t rea t ing on t he D es i gni n g Const ruct ing an d Use of Tools Fi x t u res a n d D ev ices
t oget her wi t h t he mann er i n which t he shou ld be used m t he Power P
. , .

ress for t he ch ea
'

and .

ra id p rod u ct ion of t he grea t v a ri et y 0 sheet m et a l art i cles n ow in u se

.

p I t is d es as a .

gu i de t o t he p rod u ct ion of sheet m et a l p art s at t he m in i m u m of cost Wi t h t he m a x im u m of

.

ou t p u t The harden ing a n d t em ri n g of Press t ools a n d t he cl asses of wor k w hi c h m a y b e

rod u ced t o t he bes t ad v an t a ge t he use of dies in t he p ower p ress are fu l l

.

t rea t ed it
g
s

illust ra t ions show d ies p ress x t u res a n d sheet m et al worki n g dev im e t e d w cr ip t iom
.

of whi ch are so cl ear an d p rac t i cal t hat all m et a l -workin g m

,

a will be a ble t o u n d e rs t an d
how t o desig n . const ru ct a n d use t hem Ma of t he d ies an s e fi x t ures t rea t ed were
ro
b
.

eit her const ru ct ed by t he a u t hor or u n der su rv isi on Ot ers were u il t by sk il f u l

b
.

m echan i cs an d are in u se in la rge sheet m et al es t a l en t s an d m achi n e shops . Pr ice

PUNCHES, DI ES AND TOOLS F OR MANUF ACTURI NG IN PRESSES . By J V . . V

V
oon
WO RT H .

Thi s work is a com p ani on v ol u m e t o t he au t hor s elem en t ary wor en t i t led D ies T heir
’
k
k
,
"
Const ru c t ion an d U se I t d oes n ot go i n t o t he det ails of d ie ma in g t o t he ex t en t of t h e

b k
.

a u t hor s p rev i ou s oo , b u t gi v es a com p rehen si v e rev iew of t he fi eld of o era t ions ca rr ied on
’

by p re A la r a rt of t he in orm a t ion g i v en has een d a wn rom t e a u t hor s

r f o al b f g ’

p
s ses rs n
k
.

ex p erien ce I t in wel l be t erm ed a n E n cy cloped ia of D i e Ma in g, Pu n ch Ma g Di e

k
S in i ng , Sheet Met al Work i n g . a n d Ma i n g of S k
. .

l Tools , Su b-p ress es , D ev ices an d M ec ha n i

b
cal Com ina t ions for Pu nchi n g Cu t t i n g B en F orm i ng . Pierci n g . D ra i n g Com p ress ing wM
an d Ass em lin g Sheet Met a l P b
a rt s , a n d a lso Ar t icles of ot her Ma t erials in achi n e T ools .

DROP FORGI NG, DI E SI NKI NG AND MACHI NE FORMI NG OF STEEL . By J V . . Woos

WO RT H .

This is a p ract ica l t rea t ise on Modern Sho Pract ice Processes Met hods , Machin es , T ools an d
D et a il s t rea t on T he H ot an d Co ld Mac
,

I
in c-F orm ing of S t eel an d ron i n t o Fi ni s hed S ha pes ;
f
,

Toget her wi t h 00 13 , Di es , a n d Machin ery i n v ol v ed i n t he m a n u act u re of D u lica t e F orgi n gs

I
an d n t ercha n gea le H ot an d Col d Pressed b f
Part s rom B ar a nd S heet Met a l l ’ll y ill us t ra t ed . g
by 3 00 det ailed ill ust ra t ions Pri ce . .

DRAWI NG SKETCHIN G PAPER

—

LI NEAR PERSPECTI V E SELF-TAUGHT . B y HE RMAN T C KRAU S . . .

k
Thi s wor gi v es t he t heory an d p ra ct ice of linea r perspect iv e, as u sed in archit ect ura l . en g i
n eer i n g , an d mecha n i ca l d ra win gs Persons t a in g u p t he st u d y of t he su bj ect by t hemsel v es
.

k
b b
.

will be a le
.

t he use of t he i n st ru ct ion g i v en t o rea d il y g ra sp t he su b a nd by u n sou

b
a le ract ice me good p ers pec t i v e d ra t s m en T he a rra ngem en t 0 t he oo is g ood f b k
f f
.

t he p i s is on t he le t -ha n d , wh i le t he d escrip t i v e t ex t ollows on t he o p os i t e p a ge. so a s t o

be rea d il y re erred t o f
T he d ra wi n gs a re on su ffi cien t ly la rge sca le t o ow t he wor cl m rly k
k
.

an d a re p la iu l fi g u red T he whole work ma e s a v ery com p let e cou rse on p ersp ec t i v e dra w
f
.

i ng , a n d wil l ou n d of grea t v a lu e t o a rchi t ect s , ci v il a n d m echa n ica l en gi n eers . t en t

a t t orn ey s , art desig n ers, en gra v ers , a n d d ra t sm en f .

PRACTI CAL PERSPECTIVE . B y R I CH AR D S an d COL V I N .

k
Shows i u s t how t o m a e all k i n ds of m echan ical dra wing s in t he onl y ract ical pers t iv e
isom et ri c k
Ma es ev ery t hin g p l a in so t ha t a n y m ech an ic can u n derst an ( P k a s et c h or ra w in g
k
.

i n t his wa y Sa v es t im e in t he d ra win g room , an d m is t a es i n t he shop s Con t ai ns rac t ica l

k
. .

ex a m p les of v arious classes of wor . 0 c en t s

SELF-TAUGHT MECHANI CAL DRAWI NG AN ELEMENTARY MACHI NE DESI GN .

B y F L S YL V EST E R, M E , D rafts m an , wi t h addi t ions by E R I K ORE RG, associ a te

. . . .

”
edi t or of Machin ery .

Th is is a p ract ical t rea t ise on Mechan i ca l D ra wing an d Mac hi n e Design com rising t he fi rst
k
,

p rin ci p les of geom et ric a n d m ec ha n ica l d ra wi n g , wor shop m a t hem a t ics , i n a n i cs , st re ng t h

-

of m a t eria ls an d t he ca lcu la t ion s a n d d esig n of m ac hi n e d et a i ls s ecia l l p re pared for t he

f p
.

p ra ct ica l m echa n ic a n d y ou n g d ra t sma n I t i s p r ima ri i n t en d ec f or t 0 ma n who m u st .

s t u d y wi t hou t a t ea cher I t i s cl ea rly wri t t en , com p rehensrv e, a n d ca ref u ll y a rra nged

. Pr ice .

A NEW SKETCHING PAPER .

A n ew spec iali ru led p ap er t o ena b l e y ou t o m a ke sket ches or d ra wings in isom et ri c pers p ect iv e
wi t hou t a n y gu rin g or fu ss in g I t is b ein g u sed for shop det a i ls as wel l as f or assem b ly
d ra win gs . as i t m akes on e s ket ch d o t he work of t hree a n d n o work m a n ca n hel p seei n g
.

u st ,

what is wan t ed Pads of 40 sheet s 6 x 9 in che

. s , 2 5 c en t s Pads of 40 sheet s , 9 x 1 2 in at
, . .

6 6 c en t s
ECTRI CI AN S HAN ’
DY
By Prof T O Con oa SLO ANE
B O OK . . .
’
.

Th is w ork of 7 6 8 pages is in t en ded for t he p ract ical elect ric ian who has to make t hi n gs go
The en t ire fiel d of elec t ri city is covered w ith i n i t s pages A m o ng some of t he su bjec ts t re ated
.

are : T he Theory of t he Elec t ri c C u rre n t an d C i rcu i t Elect ro-C hem ist ry Primary Ba tteries
.

S tora ge Batt eri es Genera t i on an d Ut i li zat i on of Elect ric Powers Alterna t ing Cu rren t A rma , , ,

t u re Win d i ng D yna m o and M oto rs Motor Gen era to rs 0 ra t io n of t he Cen t ra l St a t ion

, . .

s
S witchb oards Sa fety A p lia nces D ist rib u t i on of E lei ct ric lg bt an d Power S t reet Ma in
, . ,

s.
Transfo rm ers Are a n d n ca ndescen t Li ght i n g E lec t r c Measu remen t s Photo met ry E lect ri c
, , .

Ra il wa ys Telepho n y Bell Wir i n g E lect ro Pla t i ng E lect ri c H ea t i n g W i re less Tel eg ra phy et c

,
. . .
- -

I t con t ains n o u seless theory ; e e thing is to t he oi n t i t teaches y ou j u st wha t ou wan t

, , . , , .
,

v
to k n ow a bou t elec t ricrt I t is t e st an dard wor u blished on t he su bjec t
.

on one -

chapters 6 1 0 en gra v in gs y inn dsom el y bo u n d i n red lea t er w ith t i t le an d ed ges i n gol d

.
.

. , ice : .

ECTRI CI TY I N FA CTORIES AND WORKSHOPS , I TS COST AND CONV ENIEN CE .

By A RT HU R P H AS L AM . .

A pract ical book for power prod u cers an d power u sers showing wha t a con ven ien ce t he elect ric
m oto r in i t s va riou s form s has bec om e to t he m odern m a n u fac t u rer I t also dea ls wi t h t h e
co n d i t i o n s wh ic h d et erm in e t he cos t of elec t ri c d ri v i n g a n d com pa res th is w ith oth er m et hod s
.
, .

of prod ucin g an d u t il izi ng power

,

A m on g t he cha pt ers co n ta i n ed in t he book are The D irect Cu rren t Motor ; The A l t erna t ing :
Cu rren t Moto r ; The S t a rt i n g an d S peed Regu la t ion of E lec t r ic Moto rs ; The Ra t in g a nd
E ffi c ien cy of E lec t ric Moto rs ; The Cos t of E n ergy as A ff ec t ed by Con d i t i on s of W or k i n g T he
n a t i on for t he S m al l Power U ser ; I n d e
,

n den t Gen era t in g _ Plan t s ; O il a n d G as E ng i n e

la n t s ; S t eam Plan t s Power S t a t ion Ta 3 ; T he U se of E lec t ri c Power i n Text ile Fac to ries ;
E lect ric Power in Prin t in g Wo rks ; The U se of Elect ric Power in En gi neerin g W o rks hops ‘

M iscell aneous A ppl ica t ion of E lec tr ic Power ; Terhe I nl stallla tsion of Electrric Mo t ors ; The Lig ht in g
of I n d ust rial Es ta blis hm en ts 3 1 2 pa ges V y fu l y il u t rat ed P ice . . . .

ECTRI CITY SIMP LIFIED

By Prof T o con on SLOAN E . . .
'
.

T he ob ect of E lect r ic i ty S im pl ified is to ma ke t he su b j ec t as pla in as poss i b le a n d to s ho w

"

what t e m odern con cept ion of elect ric i ty is ; to show how two p lat es of d iff eren t m et als
im m ersed i n ac id ca n sen d a me s sa g e aro u d t he gl ob e ; to ex la i n how a b u n d le of c oppe r w i e
rot at ed by a st ea m en gi n e ca n be t he a gen t in lig ht i n g ou r reet a to t ell wha t t he vo l t ohm
a n d a m pere are an d what h ig h a n d l ow t en si o n m ea n ; a n d to a ns wer t he q ue s t io n s t ha t
n r
5
, ,

perpet u all y a rise i n t he m in d in th is age of elect ricity 1 7 2 pages I llust rat ed Price 1
,

. . .

ow TO BECOME A S UCCESSFUL ELECTRICIAN Prof T O CON OB SL OAN E By

’
. . . .

E very you n g ma n who w ishes t o become a su ccessfu l elect rician shou ld rea d this book I t tells
i n si m p le la n gu a ge t he su rest a n d ea si st wa y to beco me a su ccessfu l elec t ricia n The s t u d ies
.

e
to be followed m ethods of wo rk field of opera t ion a n d t he requ i rem en t s of t he su cc es sful
.

elect r ic ia n a re po i n t ed ou t a n d fu ll y exp la i n ed Every you n g eng i neer wi l l fi n d th is a n e

, ,

x
cel len t st epp i n g sto n e to m o re a dv an ced wo rk on elec t r ici ty wh ic h he m u st mas t er befo re
.

- s
su ccess ca n be a t t a i n ed Ma n yo u n g men beco m d i co u ra ged a t t he v ery o u t st art b e s
a tt em pt in g to rea d an d st u d ook s th a t a re fa r b eyo n d their com reh en sion Th is boo
.

ser ves a s fi re con n ect in g lin k et ween t he r d i m en t s t a u g ht in t he p u b i c sc hoo ls an d t he real

.

u
st u dy of elec t ri c i ty I t is in t ere t i n g from co v er to cover T welft h ed it io n 2 02 age
. s . . s .

AN AGEMENT or DYN AMOS . By Lu mmi s -PAT E BS ON .

A han dbook of theory an d p ra ct ice This work is arra n ged in three part s The fi rs t pa rt
cov ers t he elem en t a ry th eo ry of t he dy n a m o The secon d pa rt t he con s t ru ct ion a nd ac t io n
. .

of t he d ifferen t cla sses of dyna m os i n co m m on u se are descri bed ; while t he third pa rt rela t es
.
,

to su ch m a tt ers as a ff ec t t he p ract i ca l ma n agemen t an d worki n g of d na m oa an d m otors

T he fo ll ow i ng c ha pt ers a re co n t a i n ed i n t he book E lect ri cal Un it s agnet ic Pri n ci p les
.

Theo ry of t he D y na m o ; A rm a t u re ; A r m a t u re i n P ract ice ; F i eld Ma gn et s ; Fiel d Mag n et s in

Pract ce ; Regu lat in g D yn a m os ; Couali ng D y nam os ;uIrenssta lla t ionrs Ru2 n n ing and M ain tena nce
i
of D y a m o ; Fau lt s in Dy na m os ; l a u lt s i n A rmat ; Moto 9 2 pa ges 1 1 7 i ll u s t ra
, .

n s . .
.

81 5 0

AN DARD ELECTRICAL DI CTION ARY By T O CO N O B SLO AN

’
. . E .

An in d is b le work to all in t ere t ed in elect rica l scien ce _ Su it a b le al ike for t he s t u d nt

en sa s e
A pract ica l han d book of referen ce co n t a i n i n g defin i t ion s of a bou t
.

an d p ro es ion a i s -

d ist in ct wo rds t e m s an d ph ras T he defi n i t io n s a re t er a n d co n cise an d i n cl u d e ev ry

.

r es se e
t erm u sed in elect rica l c ien ce Recen t ly i u ed An en t i rely n ew ed i t i on Shou l d be in t h
.

s ss e
po ession of all who desi reto k ee a b rea st w i th t he p rog ress of th is b ra nch of scien ce Com
. . .

ss

p l et e ,c o n c i se an d c o,
n v en i en t 8 2 p a ges 3 9 3 i l l u s t ra t i o n s
. P ri ce . .
.

CHBOAR DS B y WI LL I AM B AX T E R JB
.
,
.

Th is book appea ls to every en gi n eer a nd elect ricia n who wa n t s t o kn ow t he pra ct ica l side of
thin gs I t t k u p a ll so rt s a n d con d i t io n s of dyna m os co nn ec t ions an d circu it s an d sho ws
a es
.

by d ia gra m an d ill u st ra t ion j u st how t he sw i t chboard sho u ld be con n ec ted I ncl udes d irect
. ,

a n d a l t erna t in g cu rren t boa rd a ls o tho e for arc l i g ht in g in ca n d escen t a n d p o we r ci rcu its

.

s. s
t t t h h o t bo d pow t o
.
. .

m v m i i
'i o gh
i l i l f 1 90 I ll t t
gmm
pa c a rea e n on g a ge a r s or e r ra n s ss n p a ges us ra t . .

s o s s o o s s o o o o 0 s o 0
s s s a o o o s

8
 CATALOG UE OF GOO D PRACTICAL BOO KS .

TELEPHON E CONSTR UCTION I N ST LATION AL WI RING , OPERATION AND

MAIN TEN AN CE B y W . . . R D CL I F F E an d
A C Cv sn m o
. .

Th is book gi v es t he prin ci ples of const ru ction a n d opera t ion of both t he Bell an d I n depen den t
i nst ru m en ts ; ap p rc v ed m ethod s of ins ta ll in g an d wm ng them ; t he m eans of prot ect in g them
fro m lig ht n in g an d a bn ormal cu rren ts ; thei r conn ect i on together for O pera t i on as series or
bridging st at io ns ; a n d ru les for thei r ins pect i o n a n d m ain tenan ce Lin e win ng an d t he wir
in g a n d opera t io n of special t ele hon e syst ems are a lso t reated
.

I n t ricat e ma thema t ics are avo i ed an d a ll a p pa ra t u s Ci rcu i t s an d syst ems a re thorou ghly
.

descri bed T he a ppen d i x con ta ins defini t i ons of u m ts an d term s used in t he text Selec ted
, .

wiring ta bles whi ch are very hel pfu l are also in clu ded 1 00 pages 1 2 5 i ll ust ra ti ons
. .

.
, , , .

WIRING A HOUSE By H ER B E RT PR AT T . .

Shows a ho u se alrea dy b u il t ; t ells ju st how toc startl abou t wcirinugs it ;e where to begi n ; wha t
wire to use ; how to ru n it accord ing to I nsu ran a Ru es ; in fa t j t t h in forma t io n y ou n eed
D irec t ions app ly eq ua ll y to a shop Fou rth edi t ion
.

2 6 ce t s
. . n

WIRELESS TELEPHON ES AND HOW T HEY WORK B y J AME S E RS K I N E-MUR RAY . .

This wor k is free from ela borat e deta ils a n d aim s at gi v ing a clea r su rve of t he wa in which
W ireless Tele bon es work I t is in ten ded for am a t eu r workers an d for t y080 whose owled ge
of elect ri ci ty sl ig ht Chapt ers con tain ed How We Hea r ; H istorical ; The Con version of
.

:
Sou n d in to Elect ric Wa ves ; Wirelless iTcraWnsameisss iaorne; RTh e Prod u ct io n of Al t ern at in g C u rren t s
.

_
of H ig h Freq u en cy ; How t he E ect r v a d ia t ed a n d Recei ved ; The Recei v i ng
umi it ; D et ecto rs ; A c h iev em en t s a n d Expect a t io ns ; G lossar y of Techn ical
g 0a £ 83
0
a a gram
s s
0 o . 0 o o s O O
o o o 0 a o o a
‘
o 0 o 0 0 0 0 o 0 Q

FACTORY MAN AGEMENT, ETC .

MORERN MACHI N E SHOP CONSTRUCTION EQUIPMENT , AND MANAGEMENT . By

0 E PE RRi Go ME
. .
, .

o y wo k p b h d th t d
The n l r u l is e b a esc ri es t he m ern m c in e s
a o r m a n u ac u ring la s t from od h hop f t
t ow
t he i m e t he g rass i s g r t
i ng on t he si e i n en e for i t u n i l t he ni she ro u c a sh i ped t d d t fi dp d t
f t y th ty two pt p t o o g d
.

B e l d of i t i r - cha ers t he rac ical m an ma y ec n m ically u il ,

a
a car u s u s
e cien t l y e u ip , a n d su ccessfu l l ma na ge t he m ern m ac in e s or m an u ac u rin g es a od h hop f t t b
l ishm en t book d d y tho
u st t he n ee e se c n em la in g t he erec i n
t m d ern s u il i n gs . o t p t o of o hop b d
b d to o t od t o od
.

t he t e- u i l in g an d t e-orga n i za i n of old n es , or t he in r u c i n of m ern st me thod

t t yt It
im e a n d cos s s em book is a writ t an a n d ill u s ra ed a pra c ica l s m an for ra ct ica t t by t hop
too b d w t It ot o d
.

sho m en who a re u sy t o rea theori es a n d an f acts i s t he m s com p let e a ar u n

boo of k d v p b h d I t p t book fo pp t
.

i t s i n e er u l is e is a rac ica l ract ica i m en , r m t he a ren ice

hop to p d t o It t t t ot
.

i n t he s t he res i en in t he di es m i n u ei descr bes an d ill us ra es t he m s aim is

tt t yt
.

an d y et t he m ost effi ci en i me an d cos s s em y et e 36. 0

FUEL

COMBUSTION O F CO AL AND THE By Wm M B ARR PR EVENTION OF SMOKE . . . .

This book ha s been p repared w ith specia l referen ce to t he generat io n of hea t by t he com bu s
t ion of t he co m m o n fu els fou n d i n t he Un i ted S t ates a n d des ia part icu la rly with t he con d i
t ions n ecessa ry t o t he econ o m i c an d sm okeless com b ust i on of bi t u m in ous coals in Sta t iona ry
,

an d Loco m ot i ve S t ea m B o i lers
T he p resen t a t ion of t hi s i m po rt a n t su bj ec t is syst em a t ic an d p rogressw e The a rra ngem en t
.
0

of t he book is i n a series of ra ct ica i q u est i ons to whic h are appen ded accu ra te ans we s wh ich
.

r
descri be in la n g uage free rom techn i ca li t ies t he severa l rocesses in vo lved in t he u rn ace
co m b u st io n of A m er ica n f u els ; i t clea rl y st a t es t he essen t ia re u is i t e
s for perfect com b u s t ion
. ,

n d po i t s ou t t he be t m ethod s of fu rn a ce con st ru ct i o n for o ta in i n g t he grea t es t q u a n t it

,

a n s
of hea t fro m an y gi ven q ua l ity of coal Nearly 3 5 0 pages fu ll y i llu st rated
.

.
, .

SMOKE PR EVENTION AND F UEL ECON OMY . By B OOT H an d KE RS H AW .

A co m plet e t rea t ise for a ll in t eres t ed in sm oke p reven t ion an d co m b u st ion bei based on
t he G erm a n wo rk of E rn s t Sch m a t oll a b u t i t is m o re tha n a m ere t rans la t ion of t e G er m an
,

t reat ise m uch bein g add ed T he a u thors show as b riefl y as possib le t he p rin ci p les of fuel
.

co m b u st io n t h e m ethod s whi ch ha ve b een a n d a re a t p resen t in u se as well as t he p ro

.
.

r
scien t i fic m ethod s f ar obt a i n in g a l l t he energy i n t he c oa l an d b u rn in g i t wi thou t sm o e
, ,

Considera ble s ace i s a lso gi ven to t he exa m i n at ion of t he wast e gases an d several of t he
.

n gl ish and A m eri ca n m ec ha n ica l stoker a n d si m i la r ap l ia n ces a re descri bed

.

re resen t a t i e
T e losses carried a way i n t he wast e gases are thorou g hl y ana lyzed an gd iscu ssed in t he a o
v .

en d i z an d a b st ract s are a ls o here g i v en of v ar i o u s p a t en ts on co m b ust i o n a pp ara t us T re i

ook is co m plete an d con ta ins m u ch of val ue to all who ha ve charge of large plan t s 1 9 3
, .

,
mm zm ‘w Price
.

pm . o 0 o o o o 0 o 0 o o 0 a a 0 s a a o a

9
 CATALO GUE O F GOOD PRACTICAL BOOKS .

GAS ENGI NES AN D GAS

RY or GAS M AN UFACTURE . By H M B on . . es .

This book covers po in ts likely to arise in t he o rdina ry cou rse of t he d u t ies of t he eng in eer or
m a na ger of a gas wo rks n ot la rge en o u g h t o necass ita t e t he emp lo m en t of a sepa ra t e chem ical
st aff I t t rea ts of t he test i n g of t he ra w ma t eria ls em p loyed i n tye ma n u fact u re of ill u m inat
in g coa l gas a n d of t he ga s p rod u ced The repa ra t i o n of st a n da rd so lu t ions i g i v en as wel l
.

s
t h h m i l
,

d 2 i ca l x m i t o ga o l i l d m o i t o t t.
— Prepa
ra t i ons of St a n d a rd £ u t ions Coa l F u rnaces
as e c e ca a n s e a na i n 0 s c a n c u i n g a n g s c n en s
Tes t in g an d Reg u la t ion Prod u c t s of C ar
A n a lysis of Cru de Coa l Gas A nalysis of Li m e A m m on ia A na lys is of Ox ide
, , .

bon iza t i on
of I ro n Na phtha len e A nal ysis of Fi re B ricks an d F i re-Cla y Weld om a nd S pen t O x id
. . . .

- e
Phot omet ry an d Gas Test in g Ca rb u retted Water Gas Met ropolis Gas Miscella n eo s
. . . .

u
Ext ra ct s Usefu l Tab les
. . .

. .

RI CULTURAL GAS ENG INES . By X EN o W . PUT N M A .

w th p t
The gas eng i ne i in t he as few ea rs is ein g so m u c y b h u sed on t he farm to sim p li fy work
th t p b t o of th t t p ov of grea t es t va lu e The au t ho r t ake
,

a t he u l ica i n is ract i ca l rea ise wi ll r e

P
s
fi t t t wo k then t he t ransm ission m ed i u ms a
.

up rs , an d rea s in dat a l t he r i n g a f t he eng i n e, re

t t d w
rea e . as t to
ell as rac i n eng i n es a n d ei r a li ca i n th pp t o Prrce .

ENGIN E CONSTRUCTION OR HOW TO B UI LD A HALF-HORSE-POWE R GAS

,

ENG IN E B y PAR LL
. SE an d WE E D .

A pra ct ical t rea t ise of 3 00 pages describ ing t he t heory an d p rin ciples of t he ac t i on of Ga s
Eng i nes of variou s types an d t he des ig n an d cons t ru ct io n of a ha lf ho rse power Gas E ng in e wit h -

ill ust ra t ion s of t he work i n ac t ua l p ro g ress togeth er w i th t he d im ensi on ed worki n g d ra w i ng

,

s
gi v ing cl ea riy t he sizes of t he v ari ou s det a ils ; for t he st u d en t t he sei en t ifi c i n v es t ig a t o r an d t h
,

e
a ma t eu r m ec ha mc
,

This book t rea ts of t he su b ect m orefrom t he sta n dpo in t of p ra ct ice tha n tha t of t heor y The
principles of o ra t ion of as En gi nes a re clearly an d sun p l y descrlbad an d then t he act al
.

u
a ha l f ho rse power en gi n e is t a ken u p st ep by st ep showmg in deta il t he m a ki n g
co nst ru c t i o n 0 _ -

of t he Gas E n gi n e 3 00 pages Pri ce

. .
, .

G ASOLIN E AND OI L ENGIN ES B y GAR D N E R D H i scox

,
. . .

J ust issu ed i 8t h rev ised an d en la rged ed it i on Every user of a gas eng i ne n eeds t his book
S im is in s t ru c t i v e an d righ t u p t o d a t e The o nl y co m p let e work on t he su b j ec t
.
. .

-
-
T ll e s
a ll a ou t t he ru n n i ng a n d m a na gem en t of gas gasol i n e a n d oil en gi n es as d es ig n ed a n d ma n u
.
, , .

fac t u red i n t he U n i t ed S t at e Explo i ve m otors for sta t ion ary m arin e an d vehicle p ower ar
, .

s s e

fu ll y t reated together w ith ill u st ra t io n of their pa rts an d t a b u t ed sizes also the i r ca re a nd

.

s
Elect ric ign it ion by in du ct io n coi l an d u mp spark a re fu ll y exp la in d
. ,

ru nn in g are i n cln ded e

an d il l u s t ra t ed in cl u d i n g va lu a b le i n f orma t io n on t he t es t i ng or econ o m y a n d p o w er a n d t he
.

erec t i o n of power p la n t s
,

T he ru les a n d reg u la t io ns of t he B oard of F i re U n derw i t ers i n rega rd to t he i ns t a l la t ion a nd r

ma na gem en t of gas o lin e m oto rs is g i en i n fu ll su gg es t i n g t he sa fe in s t a lla t io n of expl osi
v ve
m otor ower A list of Uni t ed S t a t es Pa t en t issu ed on gas gasoli ne a n d oil en gi n es a n d t hei
,

s r
adj un c s f rom 1 87 5 to d a te is in cl u ded
.

484 p ages 4 1 0 en gra v i ngs Price . t .

, ,

ne

DERN GAS ENG IN ES AND PRODUCER GAS PLANTS

O R E MAT H OT M E . By . .
, . .

A g u ide for t he gas engi ne des ig n er u ser an d en gin eer in t he con st ru ct ion s elect ion p u rchase
i ns t all a t i on opera t i on a n d m a i n t ena n ce of gas en gi n es More t ha n on e book on ga s en g i n es
. , , ,

has b een wr i tten bu t n ot on e has th u s fa r ev en en croac h ed on t he fiel d cov ered by th is book

.
. ,

A bove a ll Mr Mat hot s work is a pract ica l gu ide Recogn izi ng t he n eed of a v ol u m e that
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wou ld assist t he gas eng in e u ser i n u n dersta n d in g thoro u g h ly t he m oto u p o n wh ich he d epen d
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r s
for power t he au tho r ha s d iscu ssed h i s su b ect W i tho u t t he hel p of a n y ma t hem a t ics a nd
withou t ela bora t e theoret ica l exp lana t ions ery a rt of t he gas eng i n e is desc ri b ed in d et a l
,

v i
t ersely clea rl y w ith a thorou gh u n ders t an d in g of t e re qu i rem en t s of t he m ec ha n i c H el pf l
.
.

u
su g ges t ions as to t he p u rc h ase of a n en g i n e i t s i nst a ll a t o n ca re a n d opera t i o n fo rm a m o t
, , .

i s
v d ua b le fea t u re of t he wo r k 3 2 0 p a ges 1 7 5 d et a iled i llu s t ra t i o ns
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. Price . .

GEARI NG AN D CAM S

L GEAR T AB LES . By D AC E N GST R M

. . O .

A book tha t will a t on ce co m men d it elf to mecha n ic a n d d raft smen Does a wa y w ith all s s

t he t rig on o m et ry a n d fa n cy fig u r in g on b ev el gea rs a n d m a ke i t ea y for an yo ne t o la y th m

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s s e
ou t or ma ke them j u st ri g ht There a re 3 6 fu ll pa ge t ab le t ha t show every n ecessa ry d i m eh - s

sio n for a ll s izes or co m b i n a t i o ns yo u re a p t t o n eed N o p u lin g fi gu r in g or g u ess i ng

.

’
zz
G i ves placin g d ist a n ce a ll t he angi e ( i n clu d in g c u tt i n g a n g le ) an d t he correct cu tt er to u se
.
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s s
A copy of t his prepares y ou for a n ythi ng i n t he bev el gea r l in e 6 6 pages
. . .

.
. .
TUR NING AND T APERS B y FR E D H CO LV I N
B ORIN G . . .

There a re two ways to t u rn ta pers ; t he right way a nd on e other This t rea t ise ha s to do w i th
t he righ t wa y ; i t t ells y ou how to st a rt t he wo rk ro erl y how t o set t he la t he w ha t t ools t o
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use an d how to use them an d fo rty an d on e other i t t n e thi n gs t ha t y ou s ho u l d k n ow

. .

F ou rt i i
e O e e e e e e e e e e O O
. .

O 0 e 8 5 “ n ‘. e 0 e e 0

LI QUI D m
LIQUI D AI R AND THE LIQUEFACTION
O F G ASES By T O CO N O R SLOAN E . .
’
.

Th is book gives t he history of the theory d iscovery an d m an u fact u re of Li u id Air an d

con t a in s an i l l u st ra t ed d esc ri p t i on of a l l t h ex per i m en t s tha t ha ve x Ci t ed t e wo n d r of
. .
.

e e e
a u d ien ces a ll over t he co un t ry I t shows how l i q u i d a ir li k wate is ca i ed h u n d re d s of .

e r, rr

m il es a n d is ha n d led in open b u cket s I t tells wha t ma y be expect ed fr om i t in t he n ea r

.
.

u t u re
.

A book tha t ren ders sim ple one of t he m os t perplex in g chem ical p rob lems of t he cen t u ry
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Start l in g developwmen t s illu st ra t ed by a ct ua l exper i m en t s

I t is n ot on ly a ork of sc ien t i fic in t re t an d a u t hori t bu t is in ten ded for t he gen eral rea d er
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e s
bein g wri tt en i n a popu lar style— easil y u n derst
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b y e very on Secon d ed it ion 3 6 5 e . .

.

mm . Prim e e e e e

'

L OCOMOTI VE ENGI NEERI N G

AIR B
- RAKE CATECHI SM B y RO B E RT H B LACKALL . . .

This book is a st an da rd t ext book I t covers t he We t in ghou se Air B ra ke E q u i pmen t in s -

cl u d i n g t he No 5 an d t he N O 6 E T Loc o m ot i v B ra ke Eq u i p m en t ; t he K ( Q u i ck Sen
.
.

e - t
Trip le Va l ve for Ereig ht Serv ice ; a n d the Cross Co mp o u n d Pu m T he opera t ion of a ll pa rt
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of t he a pp a ra t us i s expla in d in d et a i l an d a p ra ct i ca l way of n
s
ri d i n g their
.
.

e c u liari t iee a n d
defect s with a p roper retri ed is gi ven I t con t a in s q uest i on thei r a n sw
.

w it s e rs .
which will ena b le a n y ra i lr oa ma n t o pass a n y xa m in a t i on on t he su bjec t of Air Bra k
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e es
En dorsed an d u sed b air b ra k i n t u to rs n d exa m i n ers on n ea rly every ra ilroa d in t h
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- e s r c a e
Un i t ed S t a t es d i t i on 3 80 p ages f u l ly i l l u t ra ted W i t h fold in g p lat es a n d d is .

23d . .
. s

AME RICAN COMPOUN D LOCOMOTI VES H COL V I N . B y FRE D . . .

T he o n ly book on com po u n d s for t he en g i n eman or hop m an tha t shows i n a p la i n ra ct ica i s

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to do when they b rea k down or a lk Co n t a i n s se t i on s as follows — A B it of H istory T he

ory of Co m pou n d in g S t ea m Cv l i n d ers
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c z
B a ldw i n Two C y l i n d er C o m pou n d Pi tt sb u rg T wo
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Cylin d er Com ou nd R hode rsla n d Com ou n d R ch m o n d Com u n d Rogers Co m pou n d

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i
Schenecta dy wo Cylin dver CWom umn d a u celma in Com pou n d an dem Com ou n ds Ba ld
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win Tan d em ig t a n Ta n d Sc henect ady Ta n dem la n ced Loco

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T he CO l m -

m ot i ves Ba ld win B a ian oed Com p ou n d Pla ns for Ba la n in g Loca t in g B lows B rea k
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c
down s Red u cin g Va l ves D ri ft i n g Va l ve Mot ion D iscon n ect in g Po wer of Co m pou n d
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Loco m ot i ves Pra ct ica l Not es

. . . . .

F u ll illu st rat ed a n d con t ain in g t en 3 Cia l D u ot on e i nsert s on hea vy Pla t e Pa per sho w
. .

"

in g ifi eren t types of Com pou n d s 1 4 pag es Pri ce .

“
.
o .

APPLICATION OF HIG HLY S P U ERHE ATED ST EAM TO LO COMOTIVES . Bv

R OB E RT A
G R BE .

A p ract ica l book Con ta in s sp ec ial cha pters on G en e a n o g u er ea e ea m r t i o f H i hl y S p h t d S t

S u perhea ted Stea m an d t he T wo Cey lsi n der nSsimrupclei Een g i nee ;
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a n d S u erh ea t i n g
-
p
Des ign s of Loco m ot i ve S u perhea t r : Co t t v D t a i ls of Loco m ot i ves u sm g o

Su rhea t ed S t ea m ; Experi m en t a l a n d W o rk i n g R es u l t s I llu st ra ted w ith fold in g

ta b les Pi
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an . r ce

COMB USTION O F CO AL AND THE PREVENTION O F SMOKE By WM M B ARR . . . .

Th is book ha s bee n p rep ared W i t h Sp ecia l referen ce t o t he gen era t io n O f hea t by t he com b u s
t ion of t he co m m on fu el fo u n d in t he Un i t ed St at es a n d d e ls pa rt icu la rly w ith t he con d i
s a
t ion s n ecessa ry t o t he econ o m ic a n d sm okel ss co m b u t i on of b i t u min ous coa ls in St a t io n a y
.

e s r
a n d Loco m ot i v e S t ea m B o i l ers
T he p e en t a t ion of t h i i m port a n t u bj e t is sy st em a t i c a d p ro gre i ve T he a rra n gem en t
.

r s s s c n ss
of t he b ook is in a series of t a t ica l q u t ion s t o wh i h e a p pen ded accu rate a nswers wh ich
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c es c ar
d es i be i n la n g ua ge free om t ech n i a lit ie t h s vera l oce se in vol ved in t he fu rna ce
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cr r c s. e e r s s
co m b u st io n O f A m e ica n f u els : i t c lea ly t t e t he es en t ia re u is it es for p erfect co m b u st io n
.
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r r s a s s
a n d po i n t s ou t t he best m et hod s Of f u rn a co n t ru ct o n for o t a m i n g t he g rea t est q an t it v
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ce s i
u
of heat i ron an y gi ven q ua li ty of coa l N ea ly 3 5 0 p ages fu lly i l lust rat ed
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»
. r . .
 CATALOGUE O F GOOD PRACTICAL BOOKS .

LIN K MOTIONS, V ALVES AND VALVE SETTIN G . By FRE D H CO L V I . N , Associat e

Edi t or of Am eri can Machin i st
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A ha n d book for t he en g in eer or mach in ist tha t clea rs u p t he m ysteries of val ve set t in g
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l ve Gea r G ooc h V a l v e G ear Alfie e u bbell V a l v e Gea r F u l ly il l t ra t ed

, , . . ,

ga
et c et c
ga
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08 . e e e 0 cen t ,

LOCOMOTI VE B OI LER C ON STRUCTION . By FR AN K A . KLE I N H AN S .

o of bo
The con s ru ct i n t ilers in gen era l are rea e . a n d ll in g t d fo ow th
is . t he l com i e boiler t
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oc m i e ilers resen m re d ifii cu l t y in la i n g ou t an d u il in g a n an y er e,

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can A yo who
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em ca n
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Co t h pt a i n g Ou t W r ; y ok F P h Sh t
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n a in s c a L
ers on lan g in g a n d F org in g ; u n c in g ; ea rin g ; Pla e
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la n in g ; T b
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De a ils ; S m ok B ox e D e a i ls ; ssem lin g a n d a l in g ; t .

A b C k Bo
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et c
Th t who yt to do w th bo wo k th p wo k who
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a m an er n ew or re a i r
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ere isn ha s an h i n g i iler r . ei r
do tesn
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d th book
n ee is The m a n u act u rer . su er in t en en , f p
reman . a n d d t fo
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m a er t he il er . u ll fi n d a m in i nf rma i n
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a ll n ee it a e a y ou
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ul n
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be i u O er 400 pages. fi v e la rge l ing la e
. v s . rice P

LOCOMOTIVE BR EAKDOWNS AND THEIR REMEDIES . By GE O L F LE R . . OW

R ev ised by WM
.

. W W OOD Air Brake I nst ru ct or J us t

-.
,
. i ssu ed Rev ised pocket
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ed it ion .

I t i ou t of t he q ues t ion to t an d t ell y ou a bou t every u bject t ha t is covered in th is pocket

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, ,

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H ea dl ig t T rou b le as well as Q u est i on s an d A n swers on t he Air B rake are all in cl u ded
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,

s. 2 94
pa ges F ull y ll lust ra t ed
.

. .

LO COMOTI VE CATECHISM . B y R O B E RT GRI MSH AW .

The v ised ed it ion of Loco m ot i ve Ca t ec h is m b y Robert G rimsha w is a New Book fro m

re
" "

Cover to Cov r I t con ta in s twi ce as m an y pa ges an d dou ble t he n u m ber of illust ra t ions
, ,

e
of prev io us ed it ion s I n clu d s t he grea t est a m ou n t of p ract i cal inf orma t ion ever p u b lis hed
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e
on t he co n t r u ct io n a n d ma n a gem en t of m od ern l oco m ot i ves S pecia l ly Prepa red Cha t ers
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s
Walscha rt Locom ot ive Va lve Gea r t he Air B ra ke Eq u ip m en t an d t he Elect ric ea d
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q u st ion s a s ked by t he exa m in i n g en g in eer a re g i ven b u t t hose wh ich t he o u n g a nd less

.
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e
exp r i n ced wo u ld ask t h v t eran an d wh ich Old ha n ds ask as st i ckers t is a verita b le
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"
e e e e
E n cy lo d ia of t he Loco m ot i v n t ire ly f ree from ma thema t ise eas il y u n derstood an d
,
.

c is e. e
thoron s ly u to d at Con t a in s ov Exa m ina t ion Q u es t ion s with their Ans wers
.
- - e er
82 5 pa ges 43 i ll u st ra t i o ns an d t hree fo ld in g p la t es
.
.
.

, .

NEW YORK AIR R AKE CATECHISM By R O B E RT H B LACKAL L

-B . . .

Th is is a co m plet e t rea t ise on t he N ew Yo rk Air B rake an d Air S igna llin g A pa ra t us g iv ing - -

a det ai led d e c ri t io n of a l l t he pa rt s th eir: opera t i o n t ro u b les an d t he m et god s of l oca t i n g

,
s
a n d re m ed y m g t e sa m e 2 00 pa ges f u ll y i ll u st ra t ed
. , .

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PO CKET R AILRO AD DICTION ARY AND VADE MECUM By F RE D H CO L V I N . .

,

Associa t e E dit or Am eri can Machin is t

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T he Ra i lr oa d Pocket B ook is of va l u e to ever m a n on t he roa d as it con t a i n s v a l u a b le Ra il

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’
,

e
a n d v a io u oth r Ru l s a n d Ta b le
. , ,

r s e e s.
A a reco rd of re
s t p ract ice in all ect ion s of ra i l wa y work it st a nds alon e gi v in g fact s an d
cen s
fig u res f ro m a ct ua l experien ce on su ch ma tt ers as Acety len e Lig ht in g Ai r B ra kes A x le
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ea
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e
'
s
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W heels Eq u al izers Fl u es G rades G ra t es Hea t in g su rfaces I n j ectors Locom ot i es Main

, , , . . ,

v
t n a n c of wa y O i l s Power of Rails Rods Shops S peed T ires T u rn t a b les
.
, . . . , .

V al v e M ot ions W
e e
Secon d Edi t i o n Price
, , , , . .
at er et c et c , , ., . .

1 3
 CATALOGUE O F GOO D PRACTICAL BOOKS .

AI N RULES AND DESPATCHIN G . By H . A DAL B Y

. .

Every railroa d man n o matter wha t de men t he s in n eeds a co f t his book I t gi v es

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’

t he st an da rd ru l es for both S in gle an d ou bie t rack shows a ll t he is wi th col ors wh er

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co un t ry T he ru les are ex pla in ed wherever there is an y dou bt a bo u t t heir m ea n ing or wh ere

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they are m od i fied by d ifferen t rai lr oads I t s t he on ly p ract i cal book on t rel u rules in m i
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Pi
. .

0 v er 2 2 0 p ages . Lea t her cov er . r ce

ALSCHAERT LOC OMOTIVE VALVE G EAR . By WM W Woo» . . .

I f y o wo l d u t horou ghl u d t d
u n ers a n v G
t he Walschaert V al e o d ea r y ou sh u l
—
py p om e
s s s ee
of th book
is , as t h e a u tt k
o r a es p t he t ola in es ft r m o f a s e at to y
m e n g i n e a s a i na r eng i n e in
o h th t w o y t
t he r u g . a ill n l u rn i t sk cra n d to
in o n e fo
i rec i n —b d
a nd r m w th
i t ui l s u p — i t he
d
rea er s hel H
’
od o o ot v
m ern l c m i e eq u i p d w th i t he Wa lschaert V a l v e
G ea r , com p let e
The po t d d y t
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t he gea r wh en t he cran k d t po
is at ni ne iff eren vo t o
in s in i t s re v
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‘l a et i n tl 0 c er
ook d v d d to o dv fo ow I A y II
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The is i i e in f u r gen era l i is ions , as ll s: na l sis of t he gear De

t A dv t to
. .

IV
.

s ig n ing a n d erec in g t he gear 111 an a ges Of t he gear Q ues i ns a n d ans wers

t to v G
t he Wa lschaert V a l e ea r
. . . .

rela in g
Th tdv o o t x ty q t W th f w f t of
.

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th t p of v v w hi ch- w b to fi p p
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is y e a l e gear , be es iall y va l u a le re a r
x t
i ng for an e a m ina ion for rom i n p ot o y p
ea rl P
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IN GHO USE E—T AIR-B R AKE IN STRUCTION PO CKET CATECHISM By .

War W . W OO D A.i r-B rake In st ru ct or

, .

Here is a book for t he railroa d man a n d t he man who a i m s to be on e I t is withou t dou bt

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,
-

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m en t in cy u d in g t he S t an d a rd N O 5 a n d t he Perfect ed No 6 S tyl e of b ra ke is t rea te d in d e

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t ail Wri tt en in lain E n glis h an d rofusely il l u st ra ted Wi th Colored Plat es which ena bl
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on e to t race t he g
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ow of fi s su res t rou ghou t t he en t ire equ ipm en t The best book ever
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I n dispensa b le to every eng in eman an d t ra in man

. .

Con t a ins ex a m in at ion qu est ions an d an s wers on t he E T eq u i men t Covering wha t t h

.

e
E-T B ra ke is How i t shou ld be opera t ed What t o do when de ect iv e Not a u est ion ca
.

n
be asked of t he en gin em an u p for p ro m ot ion on ei ther t he N O 5 or t he N o 6 E eq u i p m ent
. . .

tha t is n ot asked an d an s wered in t he book I f y ou wan t to t horou u n d ers t a n d t he E T

. .

eq u i p m en t get a cop of th is book I t covers every d et a il Makes A Brake t rou b les and
.
.

. .

exa m ma t ion s easy . rice

MACHI NE SHOP PRACTI CE

MERICAN T OO L MAm e AND i NTERCHANGEAB LE MANUF ACTURING . By J v . .

W OO DWORT H .

are n o bw
A S ho b ook con tain ing n o t heorizin g n o p roblema t ical or ex perimen tal dev ices there
y p roport ion ed an d i m oss i ble d ia gram s n o ca t al ogue cu ts bu t a valu ab le coliec t ion
. - ,

of dra wmg s an d d escr ipt i o ns of ev loec t he r ich fru i ts of t he a u tho r s own ex per ien ce
.
.
'
l n its
5 00-od d a ges t he on e su bj ect onl y Tool M aki n an d wha t ever rela tes theret o is d eal t with
. .

The worpst a n ds wi tho u t a ri val I t is a com p et e pract ica l t rea t ise on t h-e art of A mer ican
, , .

Tool M a k ing an d s stern of in t ercha ng ea b le man ufact u ring as carried on to d ay in t he Uni ted
.

Sta tes I n i t are escribed a n d illu st ra ted all of t he d ifferen t t y an d classes of sma ll tools
fix tu res devices an d special applia n ces whi ch are in gen era l use n all machine man u fac tu ring
.
.

a n d m et a l wo r ki n es t a b li sh men t s where eco n o m y ca ci ty an d i n terchangea b il i ty in t h

. .

e
produ c t ion of ma c in ed m eta l pa rts are irn p era t i v e
.

e c ien ce of m ak in g is ex ha us t i v el y
d iscussed an d part icu lar a tt en t ion is pa i d to drill lgs bo ring p rodlifi an d m illing fix t u res
. s

an d other d evi ces in wh ich t he rt s to be m ac ed a re l oca t ed a n d fas t ened wi thi n t he

, . .

h
con t ri van ces All of t he tools x t u res an d dev wes ill u s t ra t ed an d d escri bed ha v e been or
a re u sed f or t he a ct u al p rod u ct i on of wo rk suc h as pa r t s of d rill resaca la th es p a t en t ed
.
. .

m achi n ery typewri t ers elect rica l a pa rat u s m echan ica l a pp l ia n ces rass goods com pos it ion
. , ,

parts m ou l d p rod u c t s sheet m et a art i cles drop forgings j ewelry wa t ches medals co ins
. . . . .

O O O
. . , , ,

O O
,
O O
. .

et c 5 3 1 p a ges
. Pri m . 0 l 0 0 O 0 0 0 0 0 O O

ENLEY S EN CY CLOPEDI A O F PR ACTI CAL EN GIN EER IN G AND AL IED TRAD ES

’
.

Ed it ed by J OS E PH G H O RN E R A M I M E .
, . . .
, . .

Th i set of fi v e volu m es con ta in s a bou t

s pages with thou san ds of ill ust ra tions in clu d ing
d a m m a t i c a n d sec t ion a l d ra wi n gs w ith fu ll ex p lana t o det a ils This work covers t he .

t of v h E es t kn own experts i n a ll b ran ch es

.

e p rac i ce C i i l a n d M ec a n ica l n g i n eer i ng T he

of en gi n eer i n g ha v e con t ri b u t ed to th ese vo l u m es The Cy cloped ia is ad mi ra b l y well ad a t ed
.

to t he n eeds of t he begin ner an d t he self ta u g ht p ract ical m a n as well as t he m echa nics en

.

meer desi g n er d ra ft sma n s hop su perin t en den t fo rem a n a n d m ach in ist The wo rk w il l be
.

nou n d a m ea ns of a d vancem en t t o a n y I t is encycl oped ic in scop e thoroug h

. , . . , .

rog ress i v e m an
an d p ract ical in it s t reat men t Of t ca l su b j ect s sli n p le an d cl ear in it s descrip t i v e mat t er
.
,

, .
MO DERN MI LLING MACHINES : THE IR DESIGN CON STRUCTION , AND O PERA
TION By J OSE PH G H ORN E R
. . .

This book descri bes an d il l ust ra t es t he ng ac ne an

. s r n su ch a plai n clea r M illi M hi d it wo k i
an d fo rcefu l ma nn er an d i l lus t ra t es t he su bj ec t so clearl y a n d co pletel y that t he u -t o-d a t e
, ,

m
mac h in i st st u d en t or mecha n i ca l en gi n eer cann ot affo rd to do w i tho u t t he val ue is in for
, ,

m a t io n w hich i t co n t a ins I t descri bes n ot on ly t he ea rly mach i n es of thi s class bu t n ot es

,

t heir g ra d u a l d evelop men t into t he sp len d i d mach in es of t he p re sen t gi vin g t he des ig n

.
,

a n d co nst ru ct i o n of t he v a ri o us types
d
forms and special fea t ures p[ ocyced by prom in en t
a

m a n u fact u rers A meri ca n a n d fo rei g n

, .

M illin g cu tters in all their deveio m en t and modernized forms are illust ra ted an d described
, .

an d t he o ra t i ons t he a re ca pa is of rod ucin g u pon d i fferen t classes of wor k are ca refu ll y

.

descri bed % deta il an t he speeds a n d P eeds n ecessa r y a re d iscussed a n d va l u a b le a n d fu l

da ta gi ven for det erm in in g these u sua lly ei i lex ing prob lems The book is t he m ost com re
,

hens i v e wo rk p u b lished on t he su bjec t gozpa ges 3 00 i ll u st ra t ions Pri ce

.

. . .

MO DE RN MECHANISM Edi ted by PAR K B E N J AM TN . .

A p ract ical t reat ise on ma chi nes m otors an d t he t ransmission of po wer b eing a com let e
work an d a su pp lemen ta ry vol u m e to Ap let on s Cycloped ia of A pplied Mechan ics
, ,
'
is
so lel y w i th t he rin cipa l a n d m o st u sefu l ag van ces of t he past few yea rs 9 5 9 pa ges con ta in
.

in g o v er Bl ust ra t ions ; bo u n d in ha lf m orocco

.

SHOP KI N KS ” By RO . B E R T G R i MS rAw
i- .

A book of 400 pa ges an d 2 2 2 ill u st ra t ions bein g en t irely d iffere n t fro m a n y other book on
m achin e shOp p ract ice Depa r t in g fro m co n ven t iona l st y le t he a u tho r a voi ds u n i versal or
,

co m m o n shop u sa ge an d lim i t s his wo r k to s how in g 8 ia l wa y s of d c m g th i n gs bet ter m o re

. ,

ch ea p ly a n d m o re ra p i d l y tha n u s ua l As a res u lt t e a d van ced m ethod s of re resen t at i v e

,

es ta b l is h m en t s of t he world are p la ced a t t he d is 1 of t he rea d er Thi s boo sh ows t he

.
.

p roprietor where large sa v in gs a re p ossi ble an d ow prod u ct s ma y be i m proved To t he

.

em p l oyee it hol d s ou t su ggest i o ns tha t p r operl a pp li ed wi ll hast en his a d va n cemen t

.
, .

No
shOp ca n a ffo rd to be W i tho u t i t I t bri st les wy t h va lua b le wrink les a n d hel pfu l sugge st ions
, , .

I t will ben efit all from a ppre n t ice to proprietor Every machin i st at an y a ge should st u d
. .

P
.
, , ,

i t s p a ges . F ift h Ed i t ion . ri ce

THREADS AND THRE AD C UTTI NG By CO LV IN an d STAB E L . .

Th is c lea rs u p man y of t he i n st eries of th read cut t in g su ch as dou b le an d t riple t hrea d -

s
i n t er n a l th rea ds ca t chi ng t h s u se of hobs et c Con t ai ns a lot of u sefu l h in t s an d sev ere
..

t a b les Price
.
, , ,

. 8 5 cen t s

TOO LS FOR MACHINISTS AND WOO D WORKERS IN CLUD IN G INSTRUMENTS ,

O F MEASUREMENT B y J OS E PH G HORN E R . . .

T he prin ci ples u pon wh ich cu tt in g t ools fo wood m et a l an d oth er su bsta n ces a re ma d e are r
id en t i ca l wh et her u sed by t he m a ch in is t t he ca rpen t er or by an y other skilled mecha n ic i n
. ,

thei r da il work a n d t he object of this book is to gi ve a co rrect a n p ract ica l descri pt ion of
, ,

i s e too y as they are co m m o n l y d esrg n ed const ru ct ed an d u sed 3d

o pages fu l ly ill ust r t d
,

grdw O ‘gg
.

O
, , , .

0 0 0 0 0 0 O 0 e ao a a e a a o e 0 O O O 0 Q Q Q Q

E CON OMICS OF MAN UAL TRAIN I N G . B y LO U i S B ou i LL i ON .

o y book
The n l th t v j t
u bli shed o to a d d by t
gi es u s t he inf r m a i n n ee e a ll in eres e in Manual t d
T B d
ra in i n g , rega in g S
u il i n gs E how wh
i i p m en t , a n d S u p ii es s ex a c t l is n eed e for t d
dt to t g H
a
d wo k f o No Gv t
.

r m t he
'
a l l gra es of t he r l n d erga rt en e ig h an d rm a l ool i es i em
t v yth d Wo k t wh t o ht o
.

ized l is s of e er in g use in Ma n u a l Tra in in g r an d t ells Jus a it ug t o c st

A o how wh pp Co t p f y t
.

ls s s ere t o bu y su l ies , et c n a in s , 1 7 4 ages , an d is ull il lus rat ed .

P
.

ri ce

MARI NE ENGI NEERIN G

MARIN E EN GIN ES AND BOI LERS , THEIR DESIGN AND CONSTRUCTI ON . By
DR G B
. . AU E R ,
LE S L i E S R . OB E RT S ON , an d S BRY . AN Doi N .

I n t hewo d of r s B Dr p t wo k ow
a u er t he re o
sen to oftr t of Co d d
es i t s rig i n an fel t wa n a n en se
T t body ho t P t d E
.

rea is em i n g t he T e re i ca l an d i l R u les u se i n D es ig n i n g Mar in e ng in es

e rac ca
a nd Bo i lers d h wo k
T he n ee for su c a b f tb ot r has een el m s eng i n eers en gaged in t he con
t to of E o y by t tho of
.

s ru c i n a n d work in g Ma ri n e n g in es n ot n l e ou n gen m en , bu t a lso b

y
se
t xp
grea er e f t th t
eri en ce
o

The aco G a w tt by
t he ri g in a l erm an wor was ri en t he chic en gin eer
f o V o k t tt t f t th t t book
u lcan W r s S e in , i s in i sel a gu ara n ee p
.

of t h e a m u s a his is i n all res ect s

tho o h y t th t bod fo t o wh h y
,

r ug l i t em i es a ll t he in rm a i n
.

u p -t O-d a e . an d a ic is n ecessa r for t he

d o t o h h t ty of
es i g n a n d c ns r u c t i n of t h e ig es bo
p es It d
m arin e en g i n es a n d i lers m a be sa i ,
th t
a ot v ow wh h
t he m i e p erB p d
ic D r f tG
a u er ha s th t b
lace in t he as er m a n l in ers a av e een
.

t d t y fo tt ok p v yb t p t
W
.

rs r m t
.

o u t of la e h S t r re sen t t he rac ice in m arin e

e
ur
n e e a e e i n s, r er e s
p
en g i n eer i n g of t he t resen d ay
Th wo k yw t yt t th o t y d wh h
.

s c lea rl r it en , t horou g hl s s ema i c , ca ll

is r i e re i sou n il e t he c a ract er
of p
it s d w
la n s t b
ra in gs , w ho t p o h
a les an d S t a s t i cs is t to it u re r a c T he illu s ra i ns ar e care
po to fo t wo k d w wt o w d
. .

v
,

fu l re r d u c i n s r m ac ua l i h s me
‘

r in g ra i n gs , ell -ex ecu t e p hot ogra hic iews

p td
of c om le e engin es o p
and b il ers 722t t a ges 5 50 ill us ra ions .
n ot . .
 CATALOGUE O F GOOD PRACTICAL BOOKS .

MI NI NG

ap osrrs, WI TH A CHAPTER ON HINTS To PROSPECTORS By J P

d
. . .

O HN BON
This book gi ves a con densed accou nt of t he ore-d os it s at resen t k n own in Sou th A frica
I t is a lso in ten d ed as a gu id e to t he p ros pecto r dpn ly an e em en t ary kn o wledge of geo logy
.

a n d so m e m in i n g experien ce a re n ecessary in o rd er to u n derst a n d th is wo rk W ith these

.

q ua li fica t ions it w ill m a t eria ll y ass ist on e in his ea rch for m eta l li fero us m in era l occu rren ce
.

s s
o fa r a s s i m p le ores a re con cern ed shou l d ena b le on e to form som e id ea of t he p oss
,

and s e
b ilit ies of an y they ma fi n d
, ,

A mon g t he chapt ers g v en a re : Tita n ifero us a n d Chro m iferou s I ron O x ides— N ickel—Cop
.

r— C oba lt — T i n— Mo l ybd en u m — T u n gs t en — Lea d — Mercu ry— A n t i mo n y— I ro n — H i n t t

0 8m t 0 m . O O O O O 0 D 8O O O 0 O O ‘sz og 0 0 0 C C 8 8 C O

ACTI CAL C OAL MININ G

H Coce . By T . . .

An i m po rta n t wd rk con t a inin g 42 8 pages a n d 2 1 3 ill ust ra t ions com plet e with p ract ica l de
t ails wh ic h wi ll i n t ui t i vely i m part to t he rea der n ot on l a gen eral k nowled ge of t he prin ci
, ,

p les of coa l m in ing bu t a lso considera b le ins ight i n to ay li ed s u bj ect s The t rea t ise is posi
, ,

t i el y u p to d a t e i n every in st a nce an d s ho u ld b e i n t he ha n ds of ev ery co lli ery eng in eer

, .

v
geo l og i st m i n e Opera tor su peri n ten d en t forem an a n d al l ot hers who a re in t eres t ed in or
, ,
.

co n n ect ed wi t h t he i n d u s t ry
, , , ,

srcs AND C HEMI STRY OF MININ G . B y T H B m ou . . .

A ra ct ical wo rk for t he u se Of all repa rin g for exa min a t ions in min in g or q ualify in g for
colP iery m an agers cert i fica t es The a m of t he a u tho r in this ex cellen t book is to p lace clearl y
'

before t he re ader u sefu l an d a u thorita ti ve data whi ch will ren d er hi m va lua b le assistance i n
.

his st u d ies The o n l y wo rk of it s k in d p u b l is hed The i n fo rm at ion in co rporat ed i n it w il l

p rove of t he grea t es t p ra ct ical u t il ity to st u den t s m in in g engi neers colliery mana gers a n d
. .

a l l others who are s pec ia ll y i n t erest ed in t he p resen t d a t rea t men t of m in in g rob ems
, ,
-

Am ong it s con ten t s a re cha pt ers on : The A t m osphere ; ws Relat ing t o t he B e v l o r of

.

C ases ; T he D ifi uSi on of G ases ; Co m pos it ion of t he A t m osphere : S u n d y Const it u en t s of t he r

A t mos phere ; Wa ter ; Ca rbon ; Fire-Da m p ; Co m b us t ion ; Coal D ust a n d I t s A ct ion ; Ex
losrv es ; Co m posit io n of V ari ou s Goals an d F uel s ; Methods of A n a l ysis of Coa l S t ra t a Ad
.

i in in g t he Coal Meas u res ; M agn et ism a n d E lect ri ci ty ; A ppen d ix ; Usefu l Ta b les et c ;

discelian eous Q uest ions 1 6 0 pages I llust rat ed . . .
.

PATTERN MAKI NG

CTI CAL PATT E RNBy F W B ARROWS MAKIN G . . . .

Th is is a very com p let e a n d en t irely p ract ica l t reat ise on t he su bject of pa tt ern makin g ill us
t ra t m g att ern wor k i n wood a n d m et al From i t s ages y ou are t au gh t j ust wha t on S hou l ;
,

k n ow a ou t patt ern m a kin g I t co n t ai ns a deta lped de cript ion of t he m a teria s u sed b]

.

s
a tt ern m a kers a l so t he too l both those for han d u se an d t he m ore i n t ere st in machi ne tools ;
.

s.
v in g com let e chapt ers on t he ban d saw T he B uzz Saw a n d t he Lathe I n d v idu al pa tt ern s
, ,

of m a y d eren t k i nd s a re f ull y i ll u st ra t ed a n d d escr i b ed an d t he m o u n t i n g of m et a l pa tt ern :

, , .

n
on p la t es f or m o ld in g ma chi n es is i n cl u d ed Price .
,

PERF UMERY

NL EY S TWENTI ETH CENTURY BOOK OF RECEIPTS

’
, FORMUL S A AND PROCESSES
Edi t ed by G D H i sc ox . . .

The m ost v alu ab le Techn o chem ica l Receipt B ook pu b l ished Con ta in s o ver
-
ra ct i ca i
recei pt s m a n y of wh i c h w ill ov e of specia l v a lu e t o t he perfu m er a m in e of inf o rma
.
o

pr ion u p
to d ate i n every respect Pri ce C loth
,
ha lf m orocco
,
- .
, ,

RFUMES AND THE IR PREPARATION B y G W AS KI N S ON Perfu m er . . .

, .

A co m p rehensive t rea t ise in which there has been n othing o m itt ed tha t cou ld be of val u e
to t h Perf u mer Com lete d irect ion s for m a kin g ha n dk erchief perfu mes smell in g -sa l ts
e
sa c het fu m igat in g pa st i les ; pre ra t ions for t he ca re of t he skin t he m ou t h t he hair co
.
,
s, s
m et cs ha i r dyes a n d other t orle art ic les a re g i ven a lso a d et a iled desc ript io n of a ro m a t ic
. , ,
i
su b t a n ces ; thei r n a t u re test s of u rity a n d who lesale man u fact u re A book of gen era l
, ,

rofess i on a l in t eres t m eep

s
as wel l as in g t he wa n t s n ot onl y of t he d ru ggist a n d perfu m m a n
, , .
,

e
u i also of t he gen eral p u b l ic Third ed it ion 3 1 2 pages I ll ustrated
,

u fa ct u rer , . . . .
 PLUMBIN G

MEC HAN I CAL DRAWI N G FOR p LUMB B Rs

‘

. By R . M Smm
. u cx .

o
A o p h v
c n c ise, c m re en s i e an d p t
rac ica l t t j of
rea ise on t he sub ect mec an ih d w
ra ing in it s
v o od
a ri us m ern a p t o to
lica i ns t he wo k of
r all who are i n a n y way con ne t e
c id w th
t he
p b t dlu m ing ra e. ot h ing wi ll 80 h el p t he p b t x
l u m er i n est i ma i ng an d i n e pla i n i ng w k to
or
to
cu s wo k
mers a n d r m en as a k ow d of d w
n le ge ra i ng , an dto wo k
t he r m a n t is i of
i n est i m a l e b
“ - to b v p t o to t t po b ty
p osi i ons of gre a er res
gl gd
a i ue rise a o e his osi i n ns i ili 1 5 0 i u st a
y‘om PIiw
l e is .

. 0 0 O O O 0 O O Q Q 0 0 O O O 0 0 Q 0 C O 0 O O 0 O

MODERN PLUMB I N G ILLUSTRATED By R M STARB U CK . . . .

Thi s book represen t s t he highes t st an da rd of p lu m bing work I t has been adopted an d used as a
re ference book by t he U n i t ed S t a tes G overn m en t in it s sani t work in Cu ba Port o Rico an d
.

t he P hili pp in es a n d by t he p rin ci pa l Boar ds of H ea lth of t he ni t ed S ta tes an d Canad a

, , ,

.
,

I t gi ves conn ect ions sizes an d working da t a for all fix t u res and grou ps of fi xt u res i t is
hel p fu l to t he m ast er lu m er i n d em onst ra t i ng t o his cu stom ers an d i n fi g u ri ng wo r k It
.
, .

gi v es t he mechan ic an ( pst u dben t u i ck an d easy acc e ss to t he best d p b t

.

m o
Su gges t io ns for es t i ma t i ng p lu m in g co nst ru ct i on are cont a i n ed i n i t s
ern l u
ages
m i ng
T ra e i
book
cs .

rep resen ts in a word t he la t est an d bes t u to-da te pract i ce and shou ld in t he ha n ds of

.

arc h i tect sa n i t a ry en gin eer an d pl um er who w is hes to keep hi m self u p t o t he m i n u te

, , ,

ev e
on t im port a n t fea t ure of co nst ru ct ion 400 oc t a v o pages fu ll y i l l ust ra ted by 5 5 mu
,

al "
r
. ,

ST ANDARD PR ACTICAL PLUMBI NG R M SrrAIt B c . By . . .

A com plete ract ica i t rea t ise of 45 0 gee covering t he su bject of Modern Plum bin g in a ll it s
Bra n ches a rge a m ou n t of space be ng devoted to a very com plete an d pract ical t rea t m en t of
t he su bj ect of Hot Wa t er S u p l an d C ircu lat ion an d Ra n ge Bo il er Wo rk p
,

i ncl u de a bou t every p hase 0 pt y

th
I ts _ i ty h t
;e su bject on e can thi n k of ma king i t an in d isp ensab le w ork
r c a ers .

to t he master plu m ber t he ou m ey man plu m ber an d t he a ppren t ice plu m ber F u lLy illu s
, ,
‘

t rated by 3 47 eng rav rngs

, , .

cs .

RECEI PT BOOK

HEN LE Y S TWENTIETH CENTURY B OOK OF RECEIPTS

’
, FORfi ULAS AND PROCESSES .

E di ted by G AR DN E R D H i s cox . .

The m ost va lu a ble Techno-chemical Receipt Book u bli shed in clu ding over sel ec t ed
t fic chem i cal techn ol ogica l a n d pract i cal rece p t s an d p rocesses
,

sc ien i , , , .

Th is is t he m os t com p lete B ook of Receipts ever pu b l ished giv i n thousa n ds of recei p t s fo r

t he m a n u fact u re of val u a b le a rt icl es for ev eryd a y u se H i n t s elps Pract ica l I deas a d ,
n
Secret Processe s are rev ea led w it hi n i t s pages I t covers every b ran ch of t he u sefu l ar t s an d
.
, , ,

t ells thousan ds of wa ys of m a k i n g m oney an d is j u st t he book everyon e shou l d ha v e a t h i

.

RUB B ER

RUBB ER HAND ST AMPS AND THE MAN IPUL ATION OF INDI A RUBB ER . By
T
O C N R SL N E
’
. O O OA .

Th is book gi ves fu ll det a ils on all po in t s t rea t in g i n a con cise an d si m ple mann er t he elem en t s
of nea rly everythi ng i t is n ecessa ry to u n dersta n d for a co m mencem en t in any bran ch of t h
,

e
I n d ia R u bber Manu fact u re The making of al l ki n ds of Ru e Han d Sta m ps S ma ll Art icles
of I n d ia Ru bber U S G overn men t Co m posi t i on Da t in g Ha n d St a m s t he Man i p u la t io n
.
,

of Sheet R u bber Toy Ba ll oo ns I n d i a Ru bber Sol u t ions Cemen t s B ack in gs Re n ov a t in g

.
, .
, ,
.

Varn ish a n d Trea t m en t for I n d ia Ru bber S hoes et c ; t he Hektograph Sta m p I n k s a n d

, , , , ,

Mis cellaneo u s Notes wi th a snort A cco u n t of t he D isc ov ery Collect io n an d M a n u fac t u re of

, , .
,

i n d ia R u bber are set forth i n a m an n er d es ign ed to be rea d il y u n ders t ood t he ex p lana t i o n s

, . ,
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bein g piam an d sim ple Secon d ed i t i on 1 44 pa ges I ll ust ra t ed

,
. . . .

SAWS

SAW FI LI N GS AND MAN AGEME NT OF SAWS By ROB E RT Cam sm w . .

A pract ica l han d book on filin g gu mm in g swag in g ha mm ering a nd t he brazin of ban d sa ws

t he sp d work a n d power to ru n c ircu la r saw et c A han dy book for those w 0 ha ve char ge
, , , , ,

ee s.
of a ws or for those m echa n i cs who do t hei r own filin g as it dea ls wit h t he proper s ha pe a nd
.
, .

s
p it ches of sa w t eeth of a ll k in ds an d gi ves man y u sefu l hin t s an d ru les for gu m m ing sett ing
, .

a n d fi ri n g a n d is a p ract ica l a id t o tho se who use sa ws for a n y p u rpose New ed it ion rev ised
, ,

. .

Pri ce
,

an d enla rged I llsu t rat ed

 CATALOGUE O F GOOD PRACTICAL BOO KS .

ST EAM E N GIN EE R S A R IT HM E TI C ’
B y CO L V I N CHE N E Y
- . .

A pract ica l pocket book for t he st ea m eng ineer S hows how to work prob l e m s o f t i t he
en gi ne room a n d s hows Tel ls how t o figu re horse ower of en g in es an d b o i l e ; a
.

"
why rs n
of bOi l ers ; has t a bl es of a reas a n d ci rc u mferen ces ; st ea m t ab es ; ha a d ict iona ry of e n g i n e r i i
.

-
s e
t erms Pu t s y ou on to all a ll oft t hhee litetale ku inni ks i n figlu rieng what ever there is to fig ure o r a r u
a power pla n t Tells y ou abo u t h t t; a bso u t zero ; a d ia ba t ic ex pa nsion ; d u t y
.

eng i n es ; fac to r of sa fety ; a n d 1 00 1 ot her thi n gs ; a n d ev ryt hi ng is p la in a n d a i m

.

l — m e e
t he ha rd es t way to fig u re bu t t he easrest
,
o

, 0 . t ce n

STEAM HEATI N G AN D V ENTI LATI ON

PR ACTICAL ST EAM , HOT-W ATER HEATIN G AND VENTILATION . By A G . . Km a .

This book i t he stan da rd a n d la test wo rk u blished on t he su b ect an d has been p re p a re d f o

s
'

t he use of a ll en gaged i n t he b usi n ess of s ea m hot wa t er h ea t ri g a n d v en t ila t i o n It i s

origi na l an d exha ust i ve wor k Tells how t o get heat i ng con t ra ct s how to ins tal l h ea t i n g a m
, , .

ven t ilat in g ap a ra t us t he bes t b us i n ess m et hod s t o be u sed w ith Tricks of t he T r a d

.
,
"
fO e
shop use R u es a n d d a ta for es t i ma t i n g ra d ia t i on a n d cost a n d su c h ta b les an d i n f o m a t i o r
, ,

r
as ma ke i t an i n di spensa b le wo r k for ev e yon e i n t erest ed i n t ea m hot wa t er h ea t i n g a n d
: .

r t s ven l
lat ion I t d escr i bes all t he n n crpa l syst em s of st ea m hot wat er vacu u m v ap o r a n d v a c u m
, ,

vapor hea t in g together wi t gt he n ew accelera t ed systems of hot wa t er ci rcu la t i on i n c l u d in g

.
, , , . u

cha pt ers on u t o-d a t e m ethods of ven t ila t io n an d t he fan or b lower sy st em of h ea t i n g a n c

, ,
-

v en t ila t ion 6 7 p ages

. 3 00 deta il ed en gra v in gs
. Pri ce .

STEAM PIPES
E
ST AM PIP S : E THEI R DESIGN AND B oom CONSTRUCTION . By WM . H . .

This book fi lls in a deep ga p in scien t ifi c li t era t u re as there ha s been v ery litt le wri tt en on
t he pract i ca l srde of s t ea m p i co ns t ru ct i on S t ea m p i p in g t o d e y ra su c h a cos t ly i t m
.
,
- e
an d t h e su ccessfu l Opera t io n 0 a la rge p la n t d epen d s so m u c h u p o n i t t ha t t he p rob le m of
.
o ,

m in i m u m cos t a n d m a x im u m effi ciency beco m es very i m po rt a n t The wor k is w ell i l l u

,

s
t ra t ed in rega rd to i pe jo in t s expansi o n off set s fl ex i b l e D ru m a n d sel f c on t a in ed s l d n g
.

j oin ts for t n k in g u p phe expa n si on of long p i

i i
I n fact t e c ha pt ers on t he fl ow of s t ea m
, ,
,

a n d ex pan s i on of i pes a re m os t va l u a b le to a i st ea m fitt ers a n d u sers T he p ressu re s t re g t h

,

n
of p ipes an d m et 0 d of ha n g in g them is wel l t re a t ed a n d i l l u st ra t ed Va l ves a n d by pa ss
.

- es
a re fu l l y illu st ra t ed an d d es cri b ed as are a ls o fi an ge j oin t s an d t hei r p roper p ropo rt i o n s e
.

x
hau st hea ds a n d sepa rators O n e of t he m ost v a l u a b le cha pt ers is tha t on su per hea ted s t m
, ,

ea
a n d t he sa v i n g of st ea m b i ns u la t io n w i th t he v a riou s kin ds of felt in g a n d other m a t
.

l eria s
wi th co m pa rison t a b les of t e l oss of hea t in therm a l u n i t s fro m n ak ed a n d fel ted st eam ip es
“ Da ms 1 87 mm . h im 0 O C 0 O O 0 O O O O 0 0 O O O

STEEL
AMERICAN STE EL
WORKER By E R MAR KHAM . . . .

Thi s book t ells how t o select an d how to work t em per harden and ann eal st eel for everyt hi n g
on ea rt h I t doe n t t ell how to t ern er on e clas s 0 t ools an d then lea ve t he t rea tm t of
s
’
, , ,

en
an other k i n d of too l t o ou r ima gi na t on a n d j u dg men t bu t i t g iv es ca refu l in s t r uct ion for
.

s
ev ery d et a il of ev er y too whether it be a t a p a rea mer or j ust a screw-d ri ver I t tell a bo t
.

s u
t he t em perin g of s m all wa t c h sp rin gs t he ha rd en i n g of cu t l ry a n d t he a n n ea l in g of d ies
, .

In e
fact t here isn t a t hin g that a st eel worker woul d wan t to k n ow tha t isn t in cl u ded Price
.
, ,
' ’
.

HARDENING TEMPERING ANNEALIN G

, , , AND FORG IN G OF STEEL . By J v . . woo» .

WOR TH .

A n ew work t rea t in g ln a cl ea r con cise m ann er all m odern processes for t he hea t in g annea ling
forg in g weld in g ha rden in g a n d t em peri n g of steel m a ki n g i t a book of grea t pract i cal a lue
, , ,
.

v
t o t he m et a l wo rk in g m echa n ic in g en eral w ith sp ec ia l d i rect i o ns for t he su ccessfu l hardenn g
, . , ,
- i
a n d t em peri ng of a ll st eel too ls u ed i n t he a rt s i n cl u d i n g m ill i n g cu tt ers t a ps thread d e
,

s i s
both sol id an d shell ho ll ow m ills p u nc hes a n d d i es an d a ll k i n ds of sheet meta i
, ,

rea m ers
wo rk ing t oo ls shea r b la d es sa w fi n e c u t lery a n d m et a l cu t t in g too ls of a ll descri p t i on a
, , , ,
t
s
s,
well as for a ll i m p lem en t s of s t eel bot h la rge a n d sm a ll I n t his wo rk t he S i m p lest and most
.
, , , .

sa t is fac to ry ha rd en ing a n d t em peri ng p rocesses a re g i v en

.

The u ses t o wh ich t he lea d in g b ran d s of st eel m a y be ad apt ed are con c isel y presen t ed and their
t rea t m en t for wo rk in g u n der d ifferen t co n dit ions ex p la i n ed a lso t he speci al m ethods for t he
,

harde ing a n d t em perin g of specia l b ra n ds

,

n .

A c hapt er devoted t o t he d ifferen t p roce es for Ca e h a rd i g is al o in cl u ded and special ss s - en n s

refer en ce m a d e t o t he a dopt i on of m a ch n ery t el f or too l of i ou s ki n d Pri ce i s e s v ar s.
,

WATCH MAKI N G
WAT CHMAKE R S ’
HAN DBOOK . B y CL AU D i U s S AU N I E R .

Th is f ou s work ha s n ow r ch d i t s e t h d t io n d th re is n o work issued that can

am ea e se v n e i n a e
com to it for cl a rn
re d com p let e i t c on t a i s 49 8 p a ges an d i s i n tended as a
ess a n e n e ss n
,

wor hop co m pa n io n for t ho ga g d i n W t ch m a k i n g an d a l l ied Mech a n ica l Art s

.

s se e n e Near a -

2 5 0 eng ra v i ngs an d four t een p la t es a e i n c l u d d

.

Pri ce r e .

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