Abstract: A rail forming part of a backing strip for a windshield wiper squeegee is formed from a blank comprising a flat metal strip of narrow width. The metal strip is deformed to create an offset portion that extends transversely on a longitudinal axis of the strip so as to protrude on one side of the flat metal strip and a claw retention notch is edge-punched from the offset portion. At least one pair of rubber squeegee-retaining barb elements is formed from the flat metal strip on the side opposite from the offset portion proximate to the claw retention notch, the barb elements being longitudinally spaced from each other on the metal strip with the claw retention notch disposed between at least two barb elements so that pressure applied to the windshield wiper through the superstructure and transmitted by a claw retained in the claw retention notch to the rail urges the outwardly extending barb elements into engagement with the squeegee.

Abstract: A movable scroll element for a scroll type compressor is produced by a combination of a mold casting process and a machining process. The mold casting process produces a cast product having an end-plate forming portion, a spiral-member-forming portion and a projecting portion for forming a drive power receiving portion. The cast product has an entire outer faces covered with black scale, and the machining process machines the end-plate-forming portion, a spiral member forming portion, the projecting portion by cutting. Nevertheless, at least an outer circumference of the drive power receiving portion, i.e., a boss portion of the movable scroll element is covered with an outermost layer consisting of black scale. Thus, a sufficient mechanical strength of the movable scroll element is obtained even if the wall thickness of the drive power receiving portion, i.e., the boss portion of the movable scroll element, is reduced.

Abstract: The present invention provides for a sign consisting of an alloy substrate encapsulated in a porcelain coating which can be selectively applied to different areas of the substrate. The coating provides a smooth transitional region on graphic indicia of the sign to make the sign impervious to vandalism, fire and dirt. There is also provided a process of selectively applying a second coat of porcelain to the existing coating to only those elevated portions elevated or Braille portions of the substrate.

Abstract: A grease fitting is made by forming its outer shell in a series of cold forging steps to make a blank with the necessary thread blank at one end, a hexagonal center portion, and with a grease-fitting-mating nipple outline at the other end. Threads are rolled onto the thread blank, and the grease-gun-mating nipple is rolled to smooth and burnish its surface. The grease fitting is then successively drilled to make a hole of three different diameters to form the one-way valve ball seat and two ball spring clearance diameters. The ball and spring are inserted, and the end of the hole is formed over the end of the spring to capture the spring into place.

Abstract: A method for making a builder's tool such as a rafter square includes severing a segment from an elongate strip of material, forming a plurality of holes in the segment and marking the segment with dimensional indicia. The segment is then divided into two semi-finished components which are finish-machined to make two of the tools. In more specific aspects of the method, the forming step includes forming, in sequence, first and second sets of holes. The second set of holes includes a tool-receiving hole and the dividing step includes moving a cutting tool along the tool-receiving hole. Most preferably, the method is carried out using a press having a bed with first, second and third work stations, a movable platen carrying first and second hole-punching tools above the first and second work stations, respectively, and a marking tool above the third work station.

Abstract: In a method of making deformation Lest samples of metallic mechanically rigid, single crystals as they are required as sample rods for tension-, compression-, or bending tests in the precision testing of materials, the samples are first generated by known methods as cylindrical raw single crystals having varying diameters and rough surfaces. The raw single crystals are then shaped by wire erosion to provide testing samples of a desired shape and surface quality.

Abstract: A working tool and a cladding device are interchangeably mounted on a working head of a working apparatus. First, in a condition in which the working tool is attached to the working head, a die blank is subjected to profiling, and also a predetermined portion is cut to thereby form a beveled portion Then, the working tool on the working head is changed to a cladding device to thereby perform cladding on the beveled portion with a required material. Thereafter, the cladding device on the working head is changed again to the working tool to thereby finish the clad portion into a predetermined shape.

Abstract: A method for use in mass-producing, from a plane sheet of metal, a three-dimensional structure consisting of plane mirrors and plane structural members, said three-dimensional structure of a type in which each mirror or structural member has at least one edge that is collinear with an edge of another mirror or structural member, whereby said three-dimensional structure can be formed by bending the sheet of metal along various edges, the method including the steps of: producing masks bearing images defining the location of bending grooves, shallow grooves, separation grooves and holes for indexing pins, selecting a mask, applying a coating of photoresist to both sides of the sheet of metal, transferring the images on the selected mask to the coating of photoresist, removing those portions of the coating of photoresist to which the images were transferred, etching the sheet of metal where the portions of the coating of photoresist were removed, removing the remaining photoresist from the sheet of metal, and rep

Abstract: A method of producing an aperture extending from an optically flat surface through a substrate defining the optically flat surface to a surface of the substrate remote from the optically flat surface comprising the steps of: a) forming the optically flat surface; b) etching to form the remote surface to produce an area of the substrate of a desired thinness bounded by the optically flat surface; and c) laser cutting through the area of desired thinness from the remote surface toward the optically flat surface to produce aperture, of a desired shape and size; and a structure when made by the method.

Abstract: An extrusion die for forming a honeycomb structure such as a catalyst carrier of a catalytic converter for internal combustion engines is provided. The extrusion die includes material inlet ports and latticed slits. The slits are formed in a die base and have first inner walls leading to an outer surface of the die base and second inner walls leading to the material inlet ports, respectively. Metal-plated layers are formed on the first inner walls of the slits to define outlets of the die and have the width smaller than those of the second inner walls of the slits, respectively. This die structure facilities easy extrusion of the honeycomb structure made up by thin honeycomb walls with a smaller extrusion resistance.

Abstract: In fabricating an inner roller for use in an internal-meshing planetary gear construction, the outer periphery of an inner-roller blank 30c is chucked in the state in which depressive forces are equally exerted on the outer periphery in all the directions thereof by a chucking jig 50A, and the inner-peripheral wall of the blank 30c is subjected to a burnishing work in this state. The resulting inner-roller blank 30c is heat-treated in the state in which the depressive chucking is released, whereupon the outer periphery of the blank 30c is finished by grinding. It is accordingly possible to fabricate at low cost the inner roller which can suppress angular backlash owing to a smaller clearance defined between it and a mating inner pin, and which exhibits a high durability and favorable slip characteristics.

Abstract: A method of forming a baitcasting reel is disclosed, the baitcasting reel being formed by two end cases provided on either end of a spool and connected by an integral reel body. The reel body may form a portion of either of the end cases. Each of the cases forms a wall having a spool inserting opening which may be formed by the reel body. Further, each of the cases are enclosed by an outer wall portion.

Abstract: The present invention provides a method and apparatus for forming a plurality of parts, such as spade-type boring bits, from a continuous stock material. Thus, the various steps of the forming method of the present invention can be performed to predetermined portions of the continuous stock material, prior to separating the continuous stock material into a number of discrete parts. The efficiency of the forming process is enhanced since individual parts need not be individually transported and oriented during the forming operations. By not requiring that the individual parts be separately transported and oriented during the forming operations, the quality of the parts formed by the forming method and apparatus of the present invention will also be enhanced since such separate transportation and orientation of individual parts generally increases the opportunities for misalignment and contributes to poor tolerance control during the manufacturing process.

Abstract: A process for manufacturing an upper work roller for use in the deep rolling of crankshafts including the steps of: rough sawing tool steel to form a generally cylindrical wafer, heat treating said wafer to provide it with a desired hardness, grinding of said wafer to desired dimensions to form a properly dimensioned heat treated blank wafer, a second grinding of said wafer to form a finished shape of work roller, and vibratory finishing said roller to achieve a desired microfinish thereon.

Abstract: A method for casting a plastic die including constructing an open ended container having a floor configured to the desired contour shape of the die. The open ended container is segmented by longitudinal members and traversing members. A plurality of box-shaped cores are spaced within the container and secured in place by the traversing members. A cavity is formed in the container therebetween for the injection of hardenable material.

Abstract: A method and apparatus are provided for cutting through flat stock with at least one cutting tool, such as a torch, drill, or the like. The stock is supported in a plane defined by X and Y axes of a mutually orthogonal X, Y, and Z-axis coordinate system. The stock is supported for movement along the X-axis. At least one tool is supported over the flat stock for movement along the Z-axis and for movement along the Y-axis. The stock is moved along the X-axis. The tool is moved along the Y-axis. The tool is moved along the Z-axis toward the stock and is operated to cut the stock. If the tool is a cutting torch, the stock may be moved along the X-axis, and/or the cutting torch may be moved along the Y-axis, to define a desired cutting path.

Abstract: The invention concerns a method of producing a one-part piston which, in the region of the piston ring zone, has a closed cooling duct and a recess between the piston ring zone and the box-shaped piston body. The method comprises the following steps: a piston blank is produced by a forging process; the annular recess is produced by machining, the axial height of the recess corresponding at least to the axial height of the cooling duct; the cooling duct, which is open at the bottom, is produced by machining; hub bores are formed and the outer contour of the piston is finished; and the cooling duct, which is open at the bottom, is closed by a two-part cover ring.

Abstract: A process for forming a profiled element from a generally longitudinally extending extruded sheet-form member having a plurality of transversely spaced longitudinally extended ribs upstanding therefrom is provided. The process includes the step of removing longitudinally spaced apart portions from some of said ribs by means of a transversely acting punching means.

Abstract: A method of manufacturing a wide assortment of parts at least some having hardened and ground pin sections of various lengths and diameters, and various end features such as heads, keeper slots, cotter pin holes, snap ring grooves, flats, etc. in which an inventory of pin blanks of long lengths and various diameters is manufactured as well as separate end caps of various end feature configurations, sizes and spacings. By cutting off the pin blanks to a desired length and assembling a proper end cap to the cutoff pin, a pin part can be quickly manufactured.

Abstract: A honeycomb extrusion die and a method of making the die are disclosed, the die being made by bonding a die discharge section formed as a separate pin array to a separate die body incorporating an array of feed channels, the pin array comprising a plurality of pins attached to and extending outwardly from a body-compatible pin support which is removed after bonding the pins to the body. The pins may be formed of hard wear materials, and may have any of a variety of cross-sectional shapes adapted to improve extrusion uniformity as well as to form honeycomb cells of a variety of different cross-sectional shapes.

Abstract: The present invention comprises a harmonic drive transmission assembly for use in contamination free manufacturing fields such as computer chip making. The harmonic drive unit includes a flexspline having a diaphragm at one end and an outwardly flared lip adjacent its other end which is integrally connected to a mounting flange. The flexspline including the diaphragm and mounting flange are all integral with one another, all being machined from a single piece of steel bar stock.

Abstract: An apparatus for loading, chamfering and unloading a ceramic or ceramic/polymer substrate for electronic components. An automatic part loader moves substrates in a row as a unit, using a frangible pin to push the parts. The part loader separates the first of the substrates from the rest, and a load pedestal pushes the first substrate up into a loading/unloading nest. The load pedestal is mounted on rods so that the substrate may move laterally to center itself in the nest. The nest then rotates to load the substrate onto a movable process pedestal. The chamfering apparatus includes a pair of spaced, rotatable cutting spindles for chamfering edges and corners on the substrate.

Abstract: A process for manufacturing wire or needles having a taper point. Needle or wire blanks are cut from a roll of wire and mounted to a carrier strip. The carrier strip and needles are moved through a succession of forming and trimming and grinding stations. The blanks are preferably rotated in the strip while being ground.

Abstract: A rail forming part of a backing strip for a windshield wiper squeegee is formed from a blank comprising a flat metal strip of narrow width which is formed with an offset portion that extends transversely on a longitudinally axis of the strip so as to protrude on one side, a claw retention slot being edge-punched from the offset portion and a pair of rubber squeegee-retaining barb elements being formed opposite from the offset portion so as to retain the squeegee to the backing strip.

Abstract: A method of making a book box which comprises utilizing a solid block of wood which is either of a square or rectangular shape. In the side edge of the solid block there is cut a plurality of closely spaced parallel grooves causing the side edge to resemble the leaves of a book when the book is closed. Within the top surface of the block of wood there is formed an enlarged concavity with the bottom surface of the block of wood being adhesively secured onto the inside surface of a back flap of a book cover. The spine of the book cover is adhesively secured to the side edge. The front flap of the book cover is capable of pivoting between a closed and an open position, and when in the closed position covers the concavity, and in the open position provides access into the concavity.

Abstract: A metal mirror manufacturing method effectively uses the precision of a polygon mirror blank obtained by press working by omitting a peeling step, thereby improving the productivity. In order to achieve this object, there is provided a method of manufacturing a polygon mirror by finishing each surface of a metal mirror blank having undergone press working into a mirror surface by a cutting process, including the steps of cutting intersecting portions between the respective surfaces of the mirror blank by a cutting process by a predetermined amount, and flattening each of the surfaces by causing a mirror-working cutting tool to enter the mirror blank from a cut mark of each cut intersecting portion.

Abstract: There is disclosed an apparatus for forming curved and rectangular bodied needle blanks from a length of needle stock which includes a generally cylindrical inner mandrel having a plurality of longitudinal channels formed in an outer surface thereof, the mandrel being dimensioned and configured for insertion within the length of needle stock. The apparatus also includes a plurality of broaches insertable into the longitudinal channels such that an edge of each broach projects radially outwardly of the mandrel to form a plurality of inner grooves on an inner surface of the length of needle stock.

Abstract: A process for manufacturing wire or needles having a taper point. Needle or wire blanks are cut from a roll of wire and mounted to a carrier strip. The carrier strip and needles are moved through a succession of forming and trimming and grinding stations. The blanks are preferably rotated in the strip while being ground.

Abstract: An improved method of hollow metal screen frame production allows screen frames to be produced far more quickly than has heretofore been possible. Each of the cutting dies in the production line is provided with an accelerator that moves the prenotching dies at the speed of the flat sheet metal strip used to form the screen frames. As a consequence, the sheet metal strip can be fed continuously without stopping for punching of corner openings. Also, the configuration of the corners are improved by die cutting locking tabs and corresponding locking tab openings in adjacent members. Once the screen frame has been longitudinally bent at its corners to form the jamb, head, and sill members, the locking tabs of one member project through locking tab openings defined in an adjacent member. The locking tabs are simultaneously bent over using forming dies arranged in pairs with the forming dies within each pair acting in opposition to each other.

Abstract: A method for manufacturing a flanged shaft from a forging having a shaft and a flange having an inboard side and an outboard side using a first lathe and a second lathe. The method comprises chucking the forging in the first lathe such that at least the outboard side of the forging may be worked on and finishing at least the outboard side of the flange. The forging is then removed from the first lathe and chucked in a second lathe while referencing the forging off the outboard side of the flange such that the remainder of the forging may be worked on. The remainder of the forging is then finished into a flanged shaft.

Abstract: A method of manufacturing a hydraulic actuator body such as, for example, a brake wheel cylinder or a clutch or brake master cylinder. The method includes the steps of forming a basic actuator body having at least one spigot projecting externally therefrom, holding the body by gripping the spigot between co-operating jaws and machining the body while it is held by the spigot. If desired the spigot can be removed from the body when all other machining is complete.

Abstract: A process for forming a profiled element from a generally longitudinally extending extruded sheet-form member having a plurality of transversely spaced longitudinally extended ribs upstanding therefrom is provided. The process includes the step of removing longitudinally spaced apart portions from some of the ribs by means of a transversely acting punching means.

Abstract: Scoreline, profiling and reinforcing features are provided for an easy-access sheet metal end closure (20) and an integral opener (44). An endwall panel (28) is formed so as to substantially eliminate flexing of the sheet metal during rupture of residual metal of scoreline means defining a U-shaped tear strip (30). Such tear strip is oriented with its arcuately-shaped closed end (32) contiguous to the periphery of such endwall panel with scoreline legs (34,35) directed toward a portion at its geometric center (26). The opener is fabricated with a chisel-point (92) at its working end (66) to initiate puncture of such arcuate-shaped scoreline by Class I lever action. Rupturing of the scoreline is followed by pivoting of the opener about a pair of fulcrum points (82,83) which contact the panel one each external to a side of opening 62, with movement of the opening about such fulcrum points rupturing the scoreline legs by Class II lever action.

Abstract: A process for forming a profiled element from a generally longitudinally extending extruded sheet-form member having a plurality of transversely spaced longitudinally extended ribs upstanding therefrom is provided. The process includes the step of removing longitudinally spaced apart portions from some of said ribs by means of a transversely acting punching means.

Abstract: A method is disclosed for manufacturing a cube corner article comprising the steps of providing a machinable substrate material suitable for forming reflective surfaces, and creating a plurality of geometric structures including cube corner elements in the substrate. The step of creating the cube corner elements comprises directly machining at least three sets of parallel grooves in the substrate so that only one side of at least one groove in at least one groove set forms cube corner element optical surfaces.

Abstract: A method of manufacturing a distal femoral knee prosthesis includes the initial step of forming a rough prosthesis workpiece member that has the approximate size and shape of a final polished distal femoral prosthesis. The rough prosthesis workpiece member can be a casting, forging or a rough machined part. The prosthesis member is then attached to a fixator and movably supported adjacent a rotary grinder. Relative motion between the rotary grinder and the prosthesis is controlled with a computer. An articular surface of the prosthesis is shaped by engaging the prosthesis with the rotary grinder. The workpiece is primarily polished to remove "scallops" that form on the outer surface during a shaping with the rotary grinder. The prosthesis workpiece member is then secondarily polished until the articular surface provides a highly polished mirror finish.

Abstract: A method and apparatus for manufacturing panels and major airplane fuselage sections, including a reconfigurable fixture that holds panels for routing and drilling by accurate numerically controlled machine tools using original numerical part definition records, utilizing spatial relationships between key features of detail parts or subassemblies as represented by coordination holes drilled into the parts and subassemblies and making the parts and subassemblies intrinsically determinate of the dimensions and contour of the assembly.

Abstract: Square inside corners are formed in raised panels from a single workpiece to be used in the manufacture of cabinetry, furniture and the like. A machine with a rotatable spindle provides the drive for the square corner forming tool bit. The tool bit is mounted on a support that translates the rotary motion of the spindle to a reciprocating motion of the tool bit. The tool bit has a pair of side wall surfaces that are displaced at an angle equal to one half the angle formed by the corner, relative to the line of travel of the tool bit. The lower edges of the side wall surfaces are formed with cutting blades, ridges, or abrasive surfaces or, alternatively, the bottom wall surface of the tool bit is formed with such cutting edges.

Abstract: A flashless metal connecting rod of the type having a one-piece construction and being fracturable into a cap portion and a body portion is produced by providing a precise preform of predetermined dimensions and a precise weight, induction heating the preform to a suitable forging temperature, sequentially compressing the preform between a plurality of unique sets of forging dies. The resulting final forging is both flashless and burrless. Preferably, the sequential compressing of the preform is accomplished through three sets of forging dies which progressively form the precision preform to its ultimate shape.

Abstract: A process for manufacturing wire or needles having a taper point. Needle or wire blanks are cut from a roll of wire and mounted to a carrier strip. The carrier strip and needles are moved through a succession of forming and trimming and grinding stations. The blanks are preferably rotated in the strip while being ground.

Abstract: A punch for removing material from lead frames has a substantially rectangular body with an array of grooves along one side and a step removed on one end from the side opposite the grooves to provide an array of punch teeth extending from the body of the punch. The grooves provide a means of reworking the punch to provide a new array of teeth, by machining away all or part of the teeth and then extending the step in the direction of the groove to provide substantially the original length for the individual teeth. By providing a punch with groove length several times the tooth length, the punch can be reworked several times before being discarded. Methods for forming the punch and for reworking the punch after breakage or wear are disclosed.

Abstract: A punch for removing material from lead flames has a substantially rectangular body with an array of grooves along one side and a step removed on one end from the side opposite the grooves to provide an array of punch teeth extending from the body of the punch. The grooves provide a means of reworking the punch to provide a new array of teeth, by machining away all or part of the teeth and then extending the step in the direction of the groove to provide substantially the original length for the individual teeth. By providing a punch with groove length several times the tooth length, the punch can be reworked several times before being discarded. Methods for forming the punch and for reworking the punch after breakage or wear are disclosed.

Abstract: A machine for positioning clips in channel-shaped airplane fuselage stringers, and drilling holes in the stringers and clips, includes an elongated beam support having a box beam supported on five floor engaging legs and supporting a carriage assembly positioned on said beam and supported on bearings traveling along rails on the beam for longitudinal movement therealong. A motive mechanism, including a servomotor in the carriage and driving a pinion engaged with a rack fastened to the beam moves carriage longitudinally along the beam. An index mechanism including a fixed end stop at a known position indexes a stringer on the beam at a fixed reference position thereon. The stringer is centered under a drill by a centering mechanism mounted on the carriage, and a drill system drills a series of vertical holes along the channel floor of the stringer at locations specified in a digital product definition of said part.

Abstract: A process for manufacturing wire or needles having a taper point. Needle or wire blanks are cut from a roll of wire and mounted to a carrier strip. The carrier strip and needles are moved through a succession of forming and trimming and grinding stations. The blanks are preferably rotated in the strip while being ground.

Abstract: An air gun pellet is formed to include providing a pellet member having a conical skirt, to include a pellet head along a pellet axis, with a skirt cavity directed into the skirt and a head cavity directed into the head coaxially aligned along the axis, wherein the skirt is arranged for filling with a solder insert, whereupon subsequently, a bore member is directed coaxially through the pellet member coextensively thereof.

Abstract: A plunger barrel has a sliding bore in which a plunger is slid, a sleeve acceptor in the shape of a hole for a control sleeve which is formed in an intermediate portion of the sliding bore and a window portion which is opened in a wall defining the sleeve acceptor. The plunger barrel is manufactured by the steps of preparing a blank having one end portion and another end portion, forming a first bore axially from the one end portion of the blank, so as to provide a diameter equal to that of the sleeve acceptor, to an intermediate portion of the blank, drawing the one end portion of the blank so that a portion in which the sleeve acceptor is formed remains, forming a second sliding bore in the blank so as to penetrate from the one end portion to the other end portion of the blank, and forming a window portion in a wall of the sleeve acceptor.

Abstract: A method for manufacturing a flanged shaft from a forging having a shaft and a flange having an inboard side and an outboard side using a first lathe and a second lathe. The method comprises chucking the forging in the first lathe such that at least the outboard side of the forging may be worked on and finishing at least the outboard side of the flange. The forging is then removed from the first lathe and chucked in a second lathe while referencing the forging off the outboard side of the flange such that the remainder of the forging may be worked on. The remainder of the forging is then finished into a flanged shaft.

Abstract: An apparatus for cleaning the welded corners of an assembled window frame is provided. The apparatus has a work surface and a clamping device on the work surface for holding an assembled work piece on the work surface. A cutting tool is provided on the work surface for removing excess weld material from the work piece corner in a specific profile, the cutting tool moveable in an arcuate path around the apex of the corner of the assembled window frame whereby excess material is removed from the corner in a single pass of the cutting tool.

Abstract: A high strength, monolithic shrouded impeller is made from a single blank by a method that includes the following four steps: Turning and boring a rough forging to an impeller profile; Using a three-dimensional CNC milling machine with end mills, removing as much material as possible from what are to be passageways in the impeller, defining leading and trailing edge zones of vanes defining the passageways, by removing material in direct line of sight from the outside diameter or from the eye of the impeller or both; Forming a hole through a central zone of what will be each impeller passageway, and removing the remainder of the material to define the passageways by three dimensional planning controlled by the CNC machine using a non-rotating tool.

Abstract: An overpressure-protected, differential pressure sensor 37 is formed by depositing diaphragm material 24 over a cavity 23 formed and filled with sacrificial material 22 into a front surface of a substrate. The sacrificial material 22 is then removed to create a free diaphragm. The floor of the cavity 23 defines a first pressure stop to limit the deflection of the diaphragm in response to pressure applied to the top of the diaphragm. A port 33 is created to allow pressure to be applied to the bottom side of the diaphragm 24. An optional second pressure stop, which limits the deflection of the diaphragm in response to pressure applied to the bottom side of the diaphragm, is formed by bonding a cap 35 to standoffs 34 placed around the top of the diaphragm. The standoffs are spaced to allow pressure to be applied to the top of the diaphragm.