Abstract: A mold assembly for casting or molding a multiple portion article in sequential shots without opening the mold assembly. The mold assembly includes a movable mold insert that permits the portions to be interconnected as an integral part of the casting process. The mold insert includes a first or male void for defining a male end and a second or female void for defining a female end. In operation, the mold insert is placed in a first position and molten material is introduced into a first cavity portion to form a first portion with a male end. The mold insert is then placed in a second position with the female portion surrounding the male end of the first portion. Molten material is introduced into a second cavity portion to form a second portion with a female end at least partially surrounding the male end of the first portion.

Abstract: A assembly of mated molded parts and a method for making same are disclosed in which the assembly has first and second parts with precisely mating surfaces. The first part is formed by molding, casting, or the like such that the mating surface of the first part is formed with at least one protrusion. The second part is formed in place against the first part such precisely mating surfaces are formed with the second part enveloping the protrusion. The two parts thus formed are forced apart from each other. The protrusion may be formed with a head which interlocks with the second part. When the parts are separated, the head breaks from the protrusion. In a particular embodiment, a bearing cap is disclosed having a central opening for the passage of a shaft.

Abstract: A die casting shot sleeve having an overflow hole and an overflow valve for selectively opening and closing the overflow hole. The overflow hole extends through the shot sleeve at a level below the pour hole to allow molten material in excess of a predetermined volume to spill from the shot sleeve. When open, the overflow hole permits excess metal to spill from the shot sleeve. When closed, the metal can be expelled from the sleeve without additional material spilling through the overflow hole.

Abstract: The stroke of the shot sleeve plunger is set at a high-volume setting corresponding to the volume of the die. Pre-production articles without an insert are cast within the die. The stroke of the shot sleeve plunger is set at a low-volume setting corresponding to the volume of the die minus the volume of the insert, and production articles each having an insert are cast within the die.

Abstract: A die casting apparatus having a die assembly with multiple die cavities that are filled with sequential shots of metal. The apparatus includes a slide that is movable to selectively define a flow path between the metal delivery system and the desired die cavity. By moving the slide between shots, the die cavities can be filled in sequence without opening the die assembly.

Abstract: A variable volume metal delivery system for a die casting machine. The system includes a shot sleeve having a plunger propelled by a shot cylinder. A stroke adjustment rod operated by a second cylinder extends into the shot cylinder to define the backward stroke limit of the shot cylinder and consequently that of the plunger. The stroke adjustment rod is movable by means of the second cylinder between a high-volume position, permitting a relatively long stroke, and a low-volume position, providing a relatively short stroke. Accordingly, the volume of the shot sleeve can be changed easily, for example, to accommodate the manufacture of articles either with or without structural inserts.

Abstract: A die casting system having an inclined shot sleeve. A pour hole is located in the upper end of the inclined sleeve. The size, shape, and position of the pour hole and the inclination of the shot sleeve are selected so that, when the sleeve is filled to capacity, the volume of air remaining in the sleeve equals the volume of material displaced by the plunger as it closes the pour hole. As the plunger is advanced, the air in the shot sleeve is expelled through the pour hole; and preferably the last air is expelled just as the pour hole is closed.

Abstract: A method for making mated molded parts in which the assembly has first and second parts with precisely mating surfaces. The first part is formed by molding, casting, or the like such that the mating surface of the first part is formed with at least one protrusion. The second part is formed in place against the first part such precisely mating surfaces are formed with the second part enveloping the protrusion. The two parts thus formed are forced apart from each other. The protrusion may be formed with a head which interlocks with the second part. When the parts are separated, the head breaks from the protrusion. In a particular embodiment, a bearing cap is disclosed having a central opening for the passage of a shaft.

Abstract: The vent includes a plurality of passages formed by a plurality of stacked plates. The passages are dimensioned to permit the free flow of air but to prohibit the passage of molten metal. During die casting, air is free to exit the die while molten metal is retained.

Abstract: A microfinishing machine particularly adapted for microfinishing external cylindrical surfaces such as found on internal combustion engine crankshaft bearing journal. The machine includes a microfinishing tool assembly which presses an abrasive coated film against the workpiece and a gaging tool assembly which enables in-process diameter measurements to be made. The microfinishing tool assembly features means for shifting the center of pressure exerted on the abrasive coated film along the axial surface of the cylindrical surface being machined. Such adjustment can be achieved by shifting the pivot axis of the tool or by exerting an external torsional load onto the tool. The microfinishing tool assembly according to this invention allows axial form errors such as tapering of journal surfaces to be corrected in the microfinishing operation.

Abstract: The system includes a shot sleeve having a bore and a transverse fill hole communicating with the bore. A closure member is rotatably mounted on the shot sleeve and defines a window. The closure member rotates between a fill position in which the window is aligned with the filling hole and a casting position in which the closure member seals the filling hole. Any excess molten material from the fill is poured from the closure member as it rotates. Preferably, the closure member is mounted eccentrically with respect to, and intersects, the bore. In this case, the closure member defines an arcuate recess that aligns with the internal bore when the closure member is in the casting position, thereby allowing the plunger to reciprocate through the internal bore.

Abstract: An apparatus for microfinishing an interior cylindrical surface. The apparatus includes a mechanism which holds and rotates the workpiece about an axis. A tool, having radially directed work areas, is positioned within the workpiece and causes a strip of abrasive sheet material, positioned over the work areas, to engage the rotating workpiece. With the abrasive sheet material engaging the rotating workpiece, the tool is axially oscillated.

Abstract: A torque converter having an impeller, turbine, and stator each formed of interconnecting upper and lower members, and a method for producing the same. The upper and lower members each include a number of spaced apart blades disposed about a central axis. Preferably, the corresponding upper and lower members are die cast with blades spaced apart at twice the distance desired in the completed assembly. When the upper and lower members are interconnected, their blades nest such that each member provides every other blade of the assembled component.

Abstract: A structural baffle for reducing both crankshaft torsional vibration and oil aeration in an internal combustion engine. The baffle includes a baffle plate and a number of upright members. The baffle plate isolates the oil reservoir from the turbulence generated by the crankshaft, and includes openings allowing oil flowing from the engine to return to the oil reservoir. Preferably, the baffle plate includes a number of oil return towers which align with the oil return ports of the engine to channel oil to the reservoir. The upright members are mounted to the bearing caps both to bolster the bearing caps and to support the baffle plate beyond the throw of the crankshaft.

Abstract: A three-deep low profile push-back rack maximizes head space in a vertically stacked series of storage bays. A first pair of tracks extends longitudinally through the bays supported by the rack. The middle bay contains a second pair of tracks parallel to the first tracks. The second tracks are spaced apart a distance which is greater than the spacing of the first tracks and are mounted on the outside of the first tracks. A first flat pallet truck rolls along the first track. A lower second cart having a U-shaped frame has a front pair of wheels rolling on the first track and a pair of rear wheels rolling on the second track so that a clear nesting space is provided within the center of the frame of the lower second can to accept and receive the higher first cart. A low profile is provided to maximize head space because the frame of the higher cart does not have to roll over the top of the second cart, it only has to fit within the nesting area slightly above the loading surface of the lower cart.

Abstract: A assembly of mated molded parts and a method for making same are disclosed in which the assembly has first and second parts with precisely mating surfaces. The first part is formed by molding, casting, or the like such that the mating surface of the first part is formed with at least one protrusion. The second part is formed in place against the first part such precisely mating surfaces are formed with the second part enveloping the protrusion. The two parts thus formed are forced apart from each other. The protrusion may be formed with a head which interlocks with the second part. When the parts are separated, the head breaks from the protrusion. In a particular embodiment, a bearing cap is disclosed having a central opening for the passage of a shaft.

Abstract: A covered buckle comprises an upper annular member of inverted U cross-section into which is telescoped a lower annular member of U-shaped cross-section having a generally upstanding outer peripheral leg which either cants outwardly or is provided with an outwardly extending lip and an upstanding inner peripheral leg provided at its top with upstanding serrations to ensure adequate gripping and retention of even thin coverings.

Abstract: A method for making a bearing cap in which the bearing cap has first and second parts with precisely mating surfaces. The first part is cast such that the mating surfaces thereof are formed with protrusions terminating in enlarged heads. The second part is cast in place against the first part such precisely mating surfaces are formed with the second part enveloping the protrusions. The two parts thus cast are forced apart from each other such that the protrusions fracture across the narrowed neck portions by which the heads are joined.

Abstract: An improved micro-finishing machine is disclosed in which a transfer system is provided to move workpieces into and out of the machine in a path perpendicular to the axes of the machine drive rollers. The transfer system further enables an inprocess size control gauge to be added to the machine to monitor the diameter of the workpieces during micro-finishing. The machine offers greater flexibility by enabling the machine to be easily reconfigured to micro-finish other parts. The transfer system utilizes ejectors that are simple in construction, requiring a minimal number of components.

Abstract: A method and apparatus for closed shot die casting is disclosed in which a molten metal filling cylinder is provided intersecting a shot sleeve in fluid communication with a filling hole in the shot sleeve. Molten metal is introduced into the filling cylinder. The molten metal passes from the filling cylinder through the filling hole into the shot sleeve until the shot sleeve is completely filled with molten metal. The filling cylinder includes a piston-like, reciprocating internal valve which moves into position to seal off the filling hole. As a result, the shot sleeve is completely filled with molten metal and pressure-sealed prior to the advancement of the shot plunger.