Drop Forging, Die Sinking and Machine Forming of Steel

The hot and cold shaping, squeezing, forming, and bending of duplicate metal parts and high-speed steel cutting tools by forging in drop-dies, drop-hammers, steam-hammers, hydraulic presses, and forging-machines, are becoming more appreciated by the most advanced manufacturers and mechanics; but, until the publication of this work, to the average mechanic familiarity with the advanced shop practise, tools, and processes has been denied, because of the almost total lack of descriptive practical literature, and also the conservatism of manufacturers and experts in publishing their shop-practise and knowledge evolution. Therefore, to make possible among mechanics a broad and comprehensive knowledge of these arts I present this book, hoping it wil! find a valuable and permanent place in its field.

JOSEPH V. WOODWORTH.

BROOKLYN, N. Y.,

January, 1911.

INTRODUCTORY..

CONTENTS

.Pages 7 to 10

CHAPTER I

DIE-SINKING AND DROP-FORGING PRACTISE AND DESIGN FOR MODERN

FORGING, PRESSING, AND STAMPING OF DUPLICATE METAL PARTS

Drop-Forge Work-Materials for, and Life of, Drop-Forging Dies

-Automobile Shop Drop-Forging Practise-Making a Die-

Tools Employed in Making Dies-The Lead Casting or Proof

-Staking Tools Used for Repairing Dies-Examples of Drop-

Forging Dies-Trimming Dies-Heating Furnaces-Harden-

ing Drop-Forging Dies Die Practise for Accurate Forging-

Method of Sinking a Drop-Forge Die-Micrometrical Forgings

-Drop-Forging a Ratchet Drill Handle-Vanadium Forging

Dies Die-Sinking and Shop Practise in the Making of Cut-

ting Tool-Holders for Machine Tools-Drop-Forgings on the

Pacific Coast-Machining a Deep Forming Die-Dies for

Finishing Bossed Levers-Sectional Dies-Materials Used for

Dies-Principles of Drop-Forging and Stamping Large Parts-

Removal of Fin Produced in Drop-Forging-Difference Be-

tween Treatment of Steel and Wrought Iron-Work with

Holes Flanged Through It-Methods of Applying Impact or

Pressure on Dies-Methods Used for Making Dies-Marking

and Working Out Dies-Typing or Hubbing Process.

CHAPTER II

Pages 11 to 61

DIE-SINKING AND EMBOSSING PRACTISE METHODS, PROCESSES,

MACHINES, AND TOOLS

Making Forces for Embossed Work-Properly Made Forces-Dif-

ferent Shaped Forces-Steel Forces for Flat Work-Copper and

Brass Forces-Cutting the Impression in Die-Sinking-Riffles

and Their Use-Drilling Out the Stock-Using the Breaking-

Out Chisel-The Champney Die-Sinking Process-History

and Evolution of the Process-Modeling, Casting, and Drop-

ping-Driving Model Into the Die-Heating and Hardening

of the Dies-Exactness of Size of Dies-Final Development

of Champney Process-Die-Sinking Machines -Closed and

Open Dies for Forgings-Value of Modern Machinery-

Prevision and Supervision-Hob for Making Forging Dies.

Pages 62 to 93

CHAPTER III

DROP-FORGING DIES, THEIR DESIGN, CONSTRUCTION, AND USE IN

DROP-HAMMER, DROP-PRESS, AND FORGING-MACHINE

Combination Drop-Dies-Union Between Metal Parts-Die-Blocks

and Impression-Blocks-Making Die to Resist Wear-Keying

Wide-Seat Dies-First Principles in Holding-Dies-Bolt-

Heading Dies-Forging-Press Dies for Making Hammers-

Saving Unnecessary Movements Making a Double-Faced

Hammer The Finishing of the Dies-Few Dies Needed for

Forging-Press-Set of Tools for Forging a Fulcrum Bracket—

Forging Dies for "Pin-Ends"-Forging Dies for Round and

Square Upsetting-Drop-Forging Dies for Gun-Work—Unusual

Job of Drop-Forging-Trimming Wrench Blanks in Dies--

Trimming Cheap Hardware-A Slab-Truck for Forge-Shop-

The Possibilities of Planing-Tools for Finishing Forgings-

Work on Hand-Vise Forgings-Forging Under Steam-Hammer

-Forging Large Pieces-Drop-Hammer Forging-Drop-For-

ging or Squeezing-Setting the Dies-Accurate Forgings-

Forging High-Grade Steels-Effects of Alloying Materials-

Hydraulic Press Gives Best Results-Heating Too Suddenly.

Pages 94 to 138

CHAPTER IV

DROP-FORGING AND HARDENING PLANTS:-DESIGNS, FUNDAMENTAL

CONDITIONS, AND EQUIPMENT INVOLVED IN THEIR ATTAINMENT

The Drop-Forge and Hardening Plant-Drop-Forge and Hardening

Departments Under One Roof-Location of Die-Sinking De-

partment Board, Steam, Helve, Trip, and Drop Hammers-

Plan of Modern Drop-Forge and Hardening Plant-Layout of
Hardening Department Advantages of Oil Fuel-Refitted
Coal-Forges and Furnaces for Fuel-Oil-Arrangement of Pi-
ping Finishing Department-Oil-Burning Forges and Heaters
Single and Double Opening Forge Furnaces-Top-Slot and

End-Heating Forges-Installation of Forges-Burners-Brazing

Furnaces-Heaters...
. Pages 139 to 162

CHAPTER V

DROP-HAMMERS: THEIR DEVELOPMENT, WEIGHTS, FOUNDATIONS, AND

DIES

The Development of the Drop-Hammer-Counterbalanced Treadle

-Compound Lever Device for Operating the Lifting or Head

Mechanism-Jointed Swinghead Construction-Paper Pulleys

-Method of Fastening Board in Hammer-Foundations—

Ratio of Base as Compared with Weight of Hammer-Founda-

tions for Drop-Hammers-Drop-Hammer Effects-The Ambler

Drop-Hammer-Securing Hammer-Heads — Hammer-Dies-

Improved and Up-to-Date Drop-Hammer-Capacity of Steam-

Hammers and Size of Work-Rules for Finding the Capacity

of Steam-Hammers, and the Horse-Power Required for Opera-

tion Development of Steam Drop-Hammers.

Pages 163 to 185

CHAPTER VI

STEEL AND IRON: TWISTING, REDUCING, AND FORGING TREATMENT

FOR WORKING IN MACHINE-FORGING

Action of Steel and Iron Under Different Degrees of Heat-Ma-

terials Used in Experiments-Fuel Used in Tests-Practical

Results of Experiments Working Stock in Drop-Dies-Facil-

ities for Reproduction of Drop-Dies-Spoiling Dies-The Dies

and the Drop-Economy of Dies-Practical Effect of Working

Iron-Effect of Drops on Stock-Working in Drop and Bend-

ing Machine-Improved Anvil Block....... Pages 186 to 202

CHAPTER VII

PRESS AND HAMMER FORMING OF HEAVY HOT AND COLD BAR AND

SHEET STOCK IN DIES, TOGETHER WITH MANUFACTURE AND

ASSEMBLING OF FINISHED PRODUCTS FROM SUCH

Making a Wheelbarrow Wheel-Operations on Wheel-Making the

Flanges Pressed-Steel Gears-How Metal Wheels are Made-

Wheel Tire Making-Steel Wheels-Early History of Chain-

Making A New Method of Making Weldless Chains-Dies

for Weldless Chains-Modern Methods of Manufacturing

Welded Chain-Former Method of Making Chain-Present

Method of Making Welded Chain-The Link-Winder-The

Link-Cutter-The Welding Machine-The Die-The Process

of Welding....
Pages 203 to 240

CHAPTER VIII

FORGING-MACHINE, STEAM-HAMMER,

BULLDOZER, AND SWAGING-

MACHINE METHODS AND PROCESSES

Handy Bulldozer Appurtenances-Tack and Tack-Dies-Tack-
Making Tools and Their Action-A Rapid-Action Hydraulic
Forging-Press-Tremendous Pressure of the Hydraulic Press-
Operation of Process-Pressure for Small Work-Hot-Pressed

Nut-Machine-A Large Hydraulic Forging-Machine-Making
Elevator Buckets with the Steam-Hammer-Locomotive For-
gings made in Hydraulic Machine-A Job for the Heavy Swa-
ging-Machine-Drop-Forging for the Ajax Forging-Machine
-A Rock-Drill Used as a Steam-Hammer-Shear for Cutting

Off Iron....
. Pages 241 to 274

CHAPTER IX

MACHINE-FORGING, WITH EXAMPLES OF MODERN PRACTISE AND

TOOLS INVOLVED

Machine-Forging- Manufacturing Connecting-Rods for Steam-

Engines-Die for Turning Eye-Bolts-Forging with Dies in a

Railroad Shop-The Advantage of Special Tools in Forging-

Forging Without Special Tools-Ten Thousand Ton Press at

the Dusseldorf Exhibition...
Pages 275 to 292

CHAPTER X

HYDRAULIC FORGING METHODS, AUTOGENOUS WELDING AND

GENERAL SHOP PRACTISE