Abstract: The present invention is a method of determining the quality of a crimped electrical connection by collecting force and displacement data during the crimping cycle and comparing that data with data that represents standard crimped connections of known high quality. Of the collected data, selected portions are related to corresponding portions of the standard data and, if a deviation exists of more than a specific amount, a reject signal is generated and displayed to the machine operator. The standard data is continually updated to account for slowly changing environmental conditions that occur over a relatively long period of operation.

Abstract: An electromagnetically-driven punch press has an electromagnetic drive thrust motor comprising a fan-cooled solenoid winding and movable armature mounted in elevated location for isolating the magnetic circuit from the tooling to avoid tool magnetization and isolating winding heat from tooling for stabilizing tool dimensions. Stroke length, "open" height and "shut" height are conveniently adjustable; and tool performance is optimized by adjusting armature-thrust versus travel. Four-way access to tooling enables convenient material feeding and handling, including multi-direction or multi-layer feed. Scrap pieces are freely downwardly ejected. Multiple electromagnetic drives are mountable side-by-side at the same elevation, or they are stackable at multiple levels for increased power or for tailoring force-versus-distance relative to materials being worked. Materials-handling and/or tool-handling robots or pneumatic actuators can be installed on an elevated platform.

Abstract: A press is described using piezoelectric actuators to achieve both the hold down of the work piece during the processing operation as well as powering the die used in deforming the work piece. The sub-assembly containing the piezoelectric element is structured to allow convenient removal from the main body of the press thereby facilitating repair operations, as well as coarse and fine adjusting facilities for the position of the piezoelectric element within the actuator assembly.

Abstract: A punch press is oriented horizontally with the first and second opposed tools being mounted on first and second members both of which are movable horizontally. These motion members are driven with rapid acceleration toward each other for impacting the fast-moving first and second tools simultaneously against opposite sides of material to be formed between the tools. The two opposed motion members are arranged for the momentum of the first tool with its associated moving parts at the instant of impact be equal to the momentum of the second tool with its associated moving parts so that equal and opposite impulses resulting from momentum cancel each other out. As a result of this opposed motion with momentum-balanced-at-impact, very little energy or work is wastefully lost into the platform on which the punch press is supported and only an insignificant or very modest amount of mechanical shock and vibrations are induced into t he platform.

Abstract: A method and apparatus for the high energy rate forming of metal. A mold (11) of cage-like construction and of the shape to which the sheet metal is to be formed is lined with sheet metal and a liquid medium. A number of explosive charges are then placed at strategic locations within the liquid medium and detonated, causing deformation of the sheet metal and taking up by the metal of the shape defined by the mold. The mold is normally buried in a pit and supported therein during the deformation process. The cage-like structure of the mold enables air trapped between the sheet metal and the mold to escape during the deformation process. A method of forming boat hulls using this method is also disclosed.

Abstract: The apparatus includes a driver (86). The driver (86) includes a front portion (90) which is adapted to receive a riveting die (92), and a rear portion (88) which is a copper plate. The copper plate (88) is receptive to the establishment of magnetic field currents therein. The actuator further includes a coil (72) which is positionable in close proximity to the copper plate (88) of the driver (86). The apparatus further includes a bank of capacitors having a stored charge so as to produce a current pulse through the coil (72) when the capacitors are connected to the coil (72). Still further, the apparatus includes a control means for selectively connecting the stored charge from the capacitors to the coil. The copper plate (88) is relatively thick compared to that used in high voltage electromagnetic actuators, such that the present apparatus requires only a relatively low voltage in order to produce the required high forces to accomplish the desired riveting.

Abstract: This invention provides a method for expanding at least a portion of a cylindrical sidewall of a generally cylindrically shaped, electrically responsive, metallic body. This method comprises the steps of retaining at least a first portion of the metallic body, disposing a coil of electrically conductive material inside the metallic body, and energizing the coil to create an electromagnetic force sufficient to expand at least a portion of the generally cylindrical sidewalls of the metallic body outwardly of the original generally cylindrical shape. During such expansion, a fluid is introduced between the coil and the inside surfaces of the container to maintain positive gauge pressure as the sidewalls expand. This invention also provides an apparatus for expanding at least a portion of a cylindrical sidewall of a generally cylindrically shaped, electrically responsive, metallic body.

Abstract: Apparatus and a method for processing work pieces, such as semiconductor lead frames, wherein the apparatus includes a power device such as a solenoid assembly, for driving an upper die into processing relationship to a work piece on a lower die with the stroke of the power device being relatively short, such as in the range of 0 to 0.375 inch. This is achieved by providing a second power device, such as a piston and cylinder assembly, in which the piston rod of the assembly raises the upper die high enough to allow clearance between the dies for the passage of the work piece between the dies, then the second power device is allowed to lower relatively slowly until the upper die is substantially in proximity to the work piece.

Abstract: In a method of explosively expanding a tubular metal component into engagement with a surrounding metal component, an explosive charge is disposed axially and fired in an insert having a hollow cylindrical container fitting closely within the portion of the tubular metal component to be expanded and having charge holding device, for example an axial pocket, to accommodate the explosive charge, the container being filled with a shock wave-transmitting liquid. Compared with solid inserts, the novel hollow insert is cheaper and requires a smaller explosive charge for a given operation. The method is especially advantageous for expanding large diameter tubes.

Abstract: The apparatus includes a driver (86). The driver (86) includes a front portion (90) which is adapted to receive a riveting die (92), and a rear portion (88) which is a copper plate. The copper plate (88) is receptive to the establishment of magnetic field currents therein. The actuator further includes a coil (72) which is positionable in close proximity to the copper plate (88) of the drive (86). The apparatus further includes a bank of capacitors having a stored charge so as to produce a current pulse through the coil (72) when the capacitors are connected to the coil (72). Still further, the apparatus includes a control means for selectively connecting the stored charge from the capacitors to the coil. The copper plate (88) is relatively thick compared to that used in high voltage electromagnetic actuators, such that the present apparatus requires only a relatively low voltage in order to produce the required high forces to accomplish the desired riveting.

Abstract: A method for drawing seamless metal tubing particularly copper tubing under inclusion of a floating mandrel and a diameter reducing die wherein the wall thickness is reduced under cooperation of the mandrel and of the die in an action zone defined by a drawing gap between the mandrel and the die, a drawing force is applied to the drawn tube downstream from the die, a plurality of tubings are connected to each other end-to-end thereby providing a joint in each instance of connection; normally and regularly the tubing is drawn in portions not havng any point; the die is shifted in the direction of drawing while holding the mandrel as the joint approaches, or the mandrel is shifted while the die is held; the tubing is hollow drawn in and adjacent to the joint without the mandrel being in the action zone of the die for reducing the diameter of the tubing with little or no concurring reduction in the wall thickness; subsequently the mandrel or the die is returned to the action zone of the die after the joint has p

Abstract: A solenoid actuated blind rivet tool having pulling impulse intensifying apparatus co-acting with the mandrel pulling mechanism. One type of impulse intensifying mechanism is a slidable connection of the tool's nose housing, housing the assembly for engaging and tensioning the mandrel, and power chamber which comprises the remainder of the tool housing, which power chamber carries a solenoid for powering the tool. The solenoid pulls the nose housing rearwardly until it impacts against the power chamber, creating a high-magnitude impulse force to break the mandrel. In lieu of a slidably mounted nose piece, the tool may include a member linked to the pulling mechanism and a ram which is driven against the member by the solenoid thereby creating an impulse force which is transmitted to the pulling mechanism.

Abstract: A mandrel rod is rotatably held against axial displacement and serves as rotor for an asynchronous motor causing the mandrel to rotate so that little, if any, wear occurs on the mandrel as engaging the rolled hollow.

Abstract: A tool and method for removing dents from automobile bodies or the like. An outer tool unit comprising an electromagnet having an inner face which engages the outer surface of a body panel on at least one side of the dent. The outer tool unit is rigidly mounted from an external frame or its inner face must span the dent. The electromagnet is actuated at low amperage and then an inner tool unit positioned inside the body panel against the dent's inner surface. The inner tool unit may be simply a ferrous alloy material or it may be an electromagnet itself. The electromagnet is then actuated at a higher amperage, i.e., full operating power. In either event, the inner tool unit is rocked or "ironed" on the dent's inner surface and cooperates with the outer unit to progressively and uniformly remove the dent.

Abstract: Apparatus for mounting a pair of die members so that one die member can move toward and away from the other die member. The apparatus includes a pair of spaced die shoes for mounting respective die members and an electromagnetic unit for moving one of the die shoes toward the other die shoe. The electromagnetic unit includes a coil mounted on one of the die shoes and an armature mounted on the other die shoe, the electromagnet and the armature being between the die shoes. The armature is aligned with and partially extends into a recess in the central portion of the coil so that, when current flows through the coil, the armature is attracted to the coil and moves the other die shoe toward the one die shoe. A bias structure biases the other die shoe away from the one die shoe. Such bias structure can take the form of an air cylinder or a spring.

Abstract: Press for manufacturing molded or pressed products, comprising a press tool fixed at one end of a moving cylinder. Said moving cylinder is coaxially mounted inside a fixed guiding cylinder fixed and coaxially suspended inside a cylinder forming the outer envelope of the press. The press has a moving wall defining a first variable volume chamber, eight hydraulic jacks with free differential pistons arranged in crown about the central cylinder. The outer envelope comprises a widening provided with at least a bore wherein are arranged explosion means to cause the displacement of the press tool when the press is used as a combined pneumatic/explosion press. The press has reduced overall dimensions, and may be adapted to the manufacture of different articles at various working rates by simple and fast modifications.

Abstract: Work piece surfaces are peened by electromagetically controlled steel nees which are guided for back and forth sliding movement in a guide plate. Each needle has its own electrically controllable drive magnet. All the magnets are energized in a controlled sequence by a control unit which energizes the drive magnets in a given sequence or pattern and in accordance with adjustable parameters such as the stroke amplitude and frequency of each needle stroke. Thus, the work piece may be deformed into a particular shape and/or its surface may be work hardened or densified and areas of different surface stress may be produced in the work piece surface. Work pieces may be shaped into any desired three-dimensional curvature.

Abstract: A flexible lightweight short pulse power cable assembly for electrical power transmission, e.g., for transmission of electrical power at 20,000 volts at short pulse D.C. halfwave currents of 30,000 amperes. The cable for electrical transmission utilizes an inner conductor and an outer concentrically disposed conductor, the inner and outer conductors having substantially equal cross-sectional areas and consequent resistances to equal and opposite current flows in the respective conductors thereby placing the cable current forces in compressive balance and further reducing electro-magnetic interference from transmission of power through the cable.

Abstract: A ram assembly for an electromagnetic work tool which includes a ram shaft, conductive driving plate, and insulator plug, which elements are bonded together to form an integral ram assembly thereby reducing shear stress on the insulator plug since no counterbores or screws are utilized in the ram assembly. The insulator plug utilizes a composite of unidirectional glass fibers in an epoxy matrix, which glass fibers are oriented parallel to the axis of the ram shaft thereby providing superior load distribution of the insulator plug. A reduced number of interfaces in the ram assembly provides less interfaces for reflection of shock waves.

Abstract: An electric pulse tube expander for a bed with a vertical guide and horizontal guides mounted thereon. An electrode is movably mounted on the vertical guide. Mounted on the horizontal guides are drives for moving the electrode in vertical and horizontal planes. The drives include electric motors, reducers and mechanisms for setting the distance of movement of the electrode. Each of the mechanisms comprises a reducer whose drive gear is kinematically coupled to a lead screw, whereas its driven gear has an arm affixed to, and extending from, its shaft. The arm periodically interacts with a limit switch of a tube expander control system.

Abstract: A joggling machine including a joggling tool for forming an indentation in a workpiece comprising means for securing the workpiece, means for heating the workpiece to a preselected temperature, means for moving the joggling tool and the workpiece into proximity with one another and means for actuating the joggling tool. Interlocks and circuitry are provided to effect safe automatic sequencing of the joggling machine. A universal form die and a multiple chambered magazine assist in the efficient operation of the joggling machine.

Abstract: An electromagnetic device for straightening dents in automotive vehicle bodies and the like comprises a carriage on which is mounted a boom means for positioning an electromagnetic head at selected positions about the sides and top of a vehicle body. Control and power apparatus including electric power and a hydraulic fluid supply are mounted on the carriage, and quickly adjustable brace means are provided to engage the vehicle body adjacent a damaged area for bracing the body against the pull of the magnet.

Abstract: The invention relates to metal forming equipment. In the hammer according to the invention, an explosion device is provided with a check valve to establish communication of the inner space of the casing of the explosion device with the explosion chamber and to close the explosion chamber after a blow-up of granular explosive. The casing of the explosion device is mounted in a load-bearing frame for axial adjustment to vary the volume of the explosion chamber. This construction enables the amount of charge of granular explosive, hence the impact energy of blow of the upper die against the blank to be varied over a wide range thus resulting in considerable enlargement of manufacturing capabilities of the hammer.

Abstract: The invention relates to metal forming equipment and may be most advantageously used for the manufacture of single-tailed blades preferably for gas turbine engines. The hammer according to the invention has a stationary bed incorporating a load bearing frame carrying a lower die and a hammer cylinder. The hollow piston rod of the hammer cylinder accommodates a hammer body with an upper die, and its upper chamber is an explosion chamber. The invention resides in that the hammer body is mounted in the inner space of the hollow piston for an independent axial movement relative thereto under the action of a hammer piston arranged thereabove in the same inner space. The hammer piston is caused to move by pressure of gases released upon a blow-up in the explosion chamber. The chamber communicates with the inner space of the piston rod through a central opening of the piston. This construction considerably enlarges the manufacturing capabilities of the hammer according to the invention.

Abstract: An apparatus for utilizing electromagnetic energy for producing high impact forces by means of a ram propelled against a work piece. The work center of the apparatus includes a ram assembly of bolted construction having a hollow ram shaft, which ram assembly includes a gap between opposing conductive surfaces including associated fastener screws of driving disc and ram shaft of at least about five-sixteenths of an inch. A solid mass recoil assembly provides integral housing and recoil mass, enabling aerostatic bearing functioning, and also lowers shock and vibration levels to operator and equipment.

Abstract: An apparatus for utilizing electromagnetic energy for producing high impact forces by means of a ram propelled against a work piece. The work center of the apparatus includes a ram assembly of bolted construction having a hollow ram shaft, which ram assembly includes a gap between opposing conductive surfaces including associated fastener screws of driving disc and ram shaft of at least about five-sixteenths of an inch. A solid mass recoil assembly provides integral housing and recoil mass, enabling aerostatic bearing functioning, and also lowers shock and vibration levels to operator and equipment.

Abstract: A method and apparatus therefor using the stress wave phenomenon for sizing and working a hole in a workpiece. A mandrel of the desired size, shape, and finish is "driven" into the hole by a stress wave to work the hole and impart thereto a desired shape, size, and finish. Electromagnetic means are used to generate the stress wave whose characteristics are such that it can be propagated through the mandrel and into the workpiece with a pulse energy level, rise rate, and duration sufficient to put the material in the walls of the hole into a condition of plastic flow so that a permanent deformation thereof conforming to the working area of the mandrel is achieved. A straight or a tapered hole can be worked or a straight hole can be converted into a tapered hole having the desired final shape, size, and finish. In a further embodiment, the mandrel used in the method can be the fastener for which the hole has been drilled.

Abstract: An apparatus for utilizing electromagnetic energy for producing high impact forces by means of a ram propelled against a work piece. The work center of the apparatus includes a ram assembly of bolted construction having a hollow ram shaft, which ram assembly includes a gap between opposing conductive surfaces including associated fastener screws of driving disc and ram shaft of at least about five-sixteenths of an inch. A solid mass recoil assembly provides integral housing and recoil mass, enabling aerostatic bearing functioning, and also lowers shock and vibration levels to operator and equipment.

Abstract: A novel die set and a power pack that is adapted to be mounted thereon define, in part, the improved punch press comprising the present invention. Hollow, magnetizable leader pins having spring actuated stripper buttons therein are used as the armature for the power pack which also includes coil means positioned concentrically about at least one end of the leader pins. The coil means may be made in several discrete sections which are electrically connected parallel to each other and where more than one coil means is utilized, the plurality of coil means are also connected in parallel to each other. The power pack comprising the present invention is readily attachable to the movable portions of the die set.

Abstract: An apparatus for forming a sinterable compact of a powder comprises a pair of respective shafts displaceable toward one another by the action of respective cams and serving to displace opposing ram members to compact a powder between them. Respective plates carrying the ram members are entrained with the shafts and are displaced in the opposite direction by respective pairs of pneumatic cylinders. The rams are thereupon displaced at high rate against the precompacted powder by energizing a disk-shaped coil which repels electrodynamically the plate carrying the rams.

Abstract: This invention relates to a device, actuated by a propellant, for crimping heavy-walled terminals about large size electrical wire.