Abstract: A progressive former and method of producing progressive formers is disclosed in which the bed frame is formed of two side frame members and a spacer member. The two side frame members and the spacer member are substantially fully machined before the side frame members are assembled on opposite sides of the spacer member. Within a given machine size, the side frame members are identical and the width of the spacer member is adjusted to provide the proper spacing between the side frame members for the particular number of work stations in a given machine. By utilizing component parts to produce the machine bed frame rather than a one-piece casting, substantial cost savings are achieved. Further, since the side frame members are identical in machines of a given size having different numbers of work stations, it is economically feasible to produce side frame members for inventory and then assemble them with an appropriate spacer member to provide the desired number of work stations.

Abstract: A progressive former having quick-change tooling provides tooling supports with means for adjusting the tools. The tooling is mounted so that the tooling and the structure for adjusting the tooling can be removed as units without loss of the fine-tuning of the adjustments and so that reinstallation does not require readjustment of the tooling. A transfer also provides adjustable cams for opening and closing gripper fingers which transport workpieces from one work station to the next. The adjustable cams are removable with the dies as units and can be reinstalled without further fine-tune adjustment. With the invention, entire tool sets can be changed in a very short time to eliminate loss of production capacity of the machine. Similar sized machines are provided with a fixed spacing between the locating surfaces for the stationary dies and the reciprocating tools so that tool sets having adjustments fine-tuned in one machine can be installed in a similar machine without further retuning of the adjustments.

Abstract: A method and apparatus are disclosed for forging a wrenching socket in the end of a fastener which permit the production of such fasteners from materials which are difficult to forge, such as titanium and some high strength steels. A cylindrical preliminary socket is formed in the end of the blank forming the fastener with a punch having a circular cross section. The preliminary socket is sized to be at least as great as the maximum lateral dimension of the finished wrenching socket required. Subsequently, a tool having a cross-sectional shape corresponding to the required finished socket is positioned in the preliminary socket and the material of the blank is extruded inwardly against the tool to form a cylindrical exterior surface and a finished socket having a non-circular cross section. With this invention, even very small hexagonal sockets can be formed in titanium fasteners.

Abstract: A closed die forging machine is disclosed in which the dies are clamped in their closed position by a hydraulically operated piston and cylinder means. A spacer is positioned between the clamping means and the movable die during the forging operation. Subsequent to the forging operation, the clamping means are released and the spacer is removed so that the movable die can be mechanically moved to its fully open position. By combining a removable spacer and hydraulic clamping means, it is possible to produce high die clamping forces without requiring substantial fluid flow to and from the clamping means. Therefore, pumping requirements are reduced and the tendency of the hydraulic fluid to become excessively hot is substantially reduced. Immediately after the completion of the forming operation within the closed die cavity, the hydraulic forces are released and a spring-powered system controlled by a cam-operated operator causes partial ejection of the finished workpiece from the stationary die.

Abstract: A progressive forging machine is disclosed in which a tool pack is removably mounted on the machine to facilitate tool changeovers and the like. The tool pack includes tool carriers guided in bearings on the tool pack for reciprocating movement by a bolster mounted on the machine frame. Because the tools are guided by the tool pack itself, inaccuracy of bolster alignment does not adversely affect the position of the tooling. The tool pack also provides a shear, a transfer, strippers, and kickouts for both the dies and the tools. The drives for the various components on the tool pack are provided on the main machine frame and are either automatically connected during installation of the tool pack or are easily connected at the time of such installation. Because the tooling is guided by the tool pack itself, deflections within the main machine frame created by forming loads do not adversely affect tooling alignment.

Abstract: A thread rolling monitoring system in which one or more signal generating devices is provided in the mounting system of the stationary die of a pair of thread rolling dies. A sensor develops a signal which is a function of the reaction forces in a direction substantially parallel to the axis of the workpiece being threaded. The signal provides a running indication of the match or mismatch of the dies, as well as other conditions of improper operation. The signal is used to control the operation of the machine and to separate improperly formed parts as they are produced.

Abstract: A method of producing bimetal electrodes in which a core of copper is enclosed within an outer covering of a nickel alloy. The alloy is extruded into a relatively small diameter, deep cup by first forming a cylindrical blank with a rounded indentation in one face and thereafter extruding the cup using a punch having an end conforming with said indentation to form a central opening having a diameter at least three times the diameter of the punch. A cylindrical copper core is then firmly seated within the cup, which is then extruded by two stages to form an elongated, cylindrical blank. In one embodiment, the end is finished by trimming away a flaring skirt portion at the open end and thereafter upsetting the blank. In another embodiment, the flared skirt portion of the nickel alloy is bottled inwardly and pressed flat against the exposed end of the core so that no scrap is produced.

Abstract: A transfer system for forging machines or the like is disclosed in which a transfer assembly is cantilever-mounted on a powered support for easy removal and replacement, e.g., to provide access to the forging machine dies. Mounting means including mating surfaces on the support and the transfer assembly, which, when engaged, position the transfer assembly with respect to the support. Such surfaces are contained in at least three mutually perpendicular planes. A wedge operated by a piston and cylinder actuator operates in one position to lock the transfer assembly on the support and, when retracted, permits removal of the transfer assembly by vertical movement. The mounting means is arranged to provide locating surfaces and cam surfaces which assist the operator in guiding the transfer assembly to its mounted position.

Abstract: A method of making a bimetal electrode for spark plugs on a single progressive header starts with a cylindrical bimetal blank having a diameter substantially equal to that of the finished electrode, with a core of high temperature-resistant metal and an outer layer of highly thermally conductive material, with the outer layer comprising substantially one-third of the material of the blank. In progressive operations, the blank is coned and then headed to a diameter so that the core at the headed portion has a diameter greater than that of the blank. A shearing operation then shears the outer portion of the headed portion and the thermally conductive material away to leave an end for the firing tip having a diameter equal to that of the rest of the blank but consisting essentially of the temperature-resistant core material.

Abstract: A method of producing bimetal electrodes is disclosed in which a core of one metal is positioned within a cup of another metal so that the core is recessed back from the open end of the cup. In two embodiments, where the core is fully encapsulated, the open end of the cup is initially bottled or bent inward and subsequently the assembly is pressed through an extrusion die with a tool having a nose with an area substantially equal to the area of the core. In one such embodiment, a weld lug is produced by said tool during the extrusion. Such tool completes the closing of the open end of the cup to fully encapsulate the core and applies the principal extrusion force through the closed end to the core and from the core to the forward end or originally closed end of the cup. Subsequently, the extruded part is trimmed and additionally worked as required. In another embodiment, similar tooling is provided to produce an electrode in which the core is not fully encapsulated.

Abstract: A misalignment detector for forging machine transfers is disclosed. Such transfers provide grippers which move from a first position in which workpieces are not present to a second position when a workpiece is properly gripped. If a misaligned workpiece is present, the gripper moves to a third position beyond the second position. Each of the embodiments provides a beam-type spring mounted for deflection as the associated gripper or grippers move between the three positions. In some embodiments, the spring is bent as a function of the relative position of two opposed grippers and in other embodiments a spring is associated with a single gripper and is bent as a function of the gripper position. In some embodiments, strain gauges are mounted on the springs to produce a modulated signal to indicate the gripper position and operate the machine's emergency stop if necessary. In one embodiment, the spring is associated with a pneumatic system and allows a bleed orifice to open when misalignment is present.

Abstract: An adjustable kickout drive for forming machines is disclosed which can be adjusted while the machine is running. The drive includes a drive cam and a kickout lever, both of which oscillate about pivots. The drive cam is driven through a predetermined angle of oscillation from the main machine drive. The kickout lever is provided with a cam surface adjacent to the drive cam and a roller system is positioned between the cams so that the kickout lever oscillates through an angle in response to the oscillating rotation of the drive cam. The rollers are mounted on a lever, which is in turn pivoted on an adjusting screw which threads through a nut journaled on the machine frame. Rotation of the nut moves the screw, and in turn changes the position of the rollers with respect to the cam surfaces.

Abstract: A double-blow header particularly suited for producing semitubular rivets is disclosed. The header is provided with three separate adjustments for controlling the position and operation of the extrusion pin, all of which can be adjusted while the machine is operating. A first adjustment determines the rearwardmost position of the extrusion pin and, in turn, adjustably determines the mass of material contained within the shank of the workpiece. A first powered drive adjustably determines the stroke of the extrusion pin during a piercing operation without altering the rearwardmost position thereof. A second powered drive adjustably determines the kickout stroke without altering the final position of kickout. The kickout drive adjustment and the first adjustment are interconnected so that both of them are adjusted in a related manner.

Abstract: A transfer for hot forging machines or the like is disclosed. Such transfer includes a gripper support structure including a housing providing a longitudinal bore in which spaced cylindrical sleeve bearings are mounted. A gripper support provides the cylindrical portion journaled in the bearings for limited longitudinal movement. Mounted within an axial bore in the gripper support is a spring which resiliently urges the support in the direction of workpiece gripping. The support is provided with a longitudinal opening through which a key projects to prevent relative rotation between the housing and the support, and against which one end of the spring abuts. The housing provides substantially full enclosure of the working parts of the gripper to prevent damage by scale or the like.

Abstract: A double-blow header particularly suited for producing semitubular rivets is disclosed. The header is provided with three separate adjustments for controlling the position and operation of the extrusion pin, all of which can be adjusted while the machine is operating. A first adjustment determines the rearwardmost position of the extrusion pin and, in turn, adjustably determines the mass of material contained within the shank of the workpiece. A first powered drive adjustably determines the stroke of the extrusion pin during a piercing operation without altering the rearwardmost position thereof. A second powered drive adjustably determines the kickout stroke without altering the final position of kickout. The kickout drive adjustment and the first adjustment are interconnected so that both of them are adjusted in a related manner.

Abstract: A tool changer for forging machines or the like is disclosed. The tool changer includes a carriage which is manually movable along a track between positions over a forging machine and a position over a tool storage area. Detents are provided to give an indication when the carriage is properly positioned at each station where a tool changing operation is required. A power lift supported by the carriage is turn supports a tool head for vertical movement. Mounted on the lift is a tiller which extends laterally from the tool changer. Controls for the lift are mounted on the tiller. The tiller and the controls mounted thereon are conveniently located to permit the operator to move the tool changer from an operator's position intermediate the machine and tool storage area and to control the operation of the tool changer from such position. A camming system operates to accurately position the tool changing head as it is lowered into an operative position at each work station.

Abstract: A forging machine transfer is disclosed which is operable in response to transfer movement to turn a gripped workpiece about an axis perpendicular to a plane containing the axis of an elongated workpiece. A single pivoted gripper grips the workpiece against a flat, nonrotating platform and causes the workpiece to slide along such platform as the workpiece is transferred to a subsequent work station. The pivot axis is eccentrically located so that the workpiece is moved toward the die face during transfer to be properly positioned for subsequent working at the delivery position. A pivoted drive linkage provided to produce the rotation is located above the work station to reduce the likelihood of bearing damage resulting from scale or the like. The angle through which the workpiece is rotated can be selected within a range substantially greater than 90 degrees and substantially less than 90 degrees.

Abstract: A sensing probe for monitoring working forces in compressive elements such as found in presses and other machine tools. The probe has an elongated configuration which allows it to be mounted at a point remote from its load sensing end and enables it to be conveniently used with a plurality of like probe units in relatively confined spaces. A wedge profile of its sensing end permits the probe to be preloaded in compression for an increase in accuracy and reliability.

Abstract: A forging machine is disclosed which is provided with means to determine when an undersized or short blank is produced by the shear and to provide for the automatic rejection of such blank. Such short blanks can occur if the stock feed into the shear is insufficient. The illustrated embodiment includes a shear for progressively cutting blanks from the forward end of a piece of stock in which the shear is provided with a load cell in the stock gauge to determine when improper feeding has occurred. Such load cell includes a strain gauge and the signal produced by the strain gauge actuates an overstroke ejection which pushes the blank from the first working station through the transfer fingers so that it does not transfer to a subsequent work station. The overstroke is provided by a piston and cylinder actuator mounted on the ejector lever which operates in response to a signal that the blank in the work station is of improper size.

Abstract: A fully automated tool changer system for multi-station forging machines is disclosed. This system provides a tool and die supporting head providing spaced support rails on which the tools or dies are supported during the transfer between the machine and the tooling rack. Such head is operable to properly position tools and dies which have different diameters for insertion into the cylindrical cavities in which they are mounted within the machine. A second tooling head is rotated to an operative position when the elements of the shear are to be changed. The tool heads are directly supported on the machine frame or the tool rack so that the loads of installing and removing the tooling are directly transmitted to stationery supports and need not be absorbed by the power transfer system. Further, the supports are arranged so that a high degree of positional accuracy is provided during the tool changing operations.