Abstract: A process for manufacturing a bicycle chain drive which utilizes a crank which is cold formed as a single piece with integral splines for engaging a sprocket wheel when the sprocket wheel is mounted in driving relationship with the crank. A cold forming process which can be used for producing the crank includes several stages of upsetting to form the journals, the splined sprocket flange, and an adjoining collar for aligning the sprocket. After those elements have been formed the pedal receiving ends are formed by another upsetting process after which they are drilled and tapped. Then the arms are bent to form the finished crank which is assembled to the sprocket.

Abstract: An axially elongated expansion sleeve is formed from an extruded cylindrically shaped blank with a blind hole in one end. An axially extending part of the blank from the other end is deformed into a U-shaped section of uniform thickness. The U-shaped section is upset so that it increases in thickness toward the other end. The upset U-shaped section is shaped to provide it with a cylindrically shaped outside surface with the inside base of the section sloping toward the axis of the sleeve in the direction toward the other end.

Abstract: A camshaft for an internal combustion engine or the like is formed of an expandable steel tube and individual preferably hardenable cam and journal elements fixed together by a mechanical expansion of the tube by a mandrel or other device. Material selection and processes for low cost manufacture are disclosed.

Abstract: The disclosed method features an automatic high production process of forming a socket wrench and other elongated hollow parts such as a nutdriver from a tubular metal workpiece. The method of making a nutdriver includes extruding a workpiece through a tapered female die to reduce both the inside and outside diameters at one end of the workpiece and along a predetermined portion of its length from that one end of the workpiece. A recess of non-circular cross section is formed at the other end of the workpiece. In the method of making a socket wrench, an additional step is included in forming another recess of non-circular cross section at the reduced end of the workpiece.

Abstract: A method of forging a crank shaft at least including: a first step of forming a pair of fitting grooves in an outer periphery of a crank throw portion of a billet at an axially central portion of the billet, said grooves extending perpendicular to an axis of the crank throw portion as well as to a diametral line thereof; a second step of subjecting said billet to rough forging by using a rough forging mold which comprises upper and lower molds having respective recesses which are adapted to determine the position of the billet in cooperation with the fitting grooves of the crank throw portion and a journal portion, in which step, an outflow of burr is restricted by means of an inclined offset surface disposed opposite to the outflow direction of said burr while the crank throw portion is forced to move towards a crank pin position; and a third step of subjecting said billet to finish forging by using a finish forging mold which comprises upper and lower molds having respective recesses formed corresponding to

Abstract: A brake shoe resizer characterized as a hydraulically operated die which includes a groove presenting a shape corresponding to the area of the ribs surrounding the openings for the brake shoe anchor pin. Guide and/or stop means are provided for positioning and/or checking purposes during the reworking operation. The latter includes introduction of a guide pin into the openings for the anchor pin and the successive reshaping of each such openings after the selective heating of the areas around the anchor pin openings prior to die or reforming action. The overall assembly further includes structure for reshaping the curvature of the brake shoe, if necessary, and, as well, the spacing between the ribs presented on the brake shoe.

Abstract: A method of manufacture of a magnetic rotor core member for a rotating-field dynamoelectric machine, particularly a small alternator, including the steps of: hot forging a segment of steel bar stock into a core blank approximating the external configuration desired for the rotor core member; de-burring the core blank; coining the core blank into closer conformation to the desired core member configuration; cooling the core blank; cold punching a shaft aperture through the central part of the core blank and simultaneously cold-compressing the core blank into closer conformity with the required dimensions for the finished rotor (or rough machining of a shaft aperture and rough machining of some elements of the blank); and, finally, cold-compressing the core blank to finished form as a rotor core member.

Abstract: A cold metal working process gradually changes the cross-section of a copper band to a wider band having one or more sections of reduced thickness. A hammering tool having a chevron-like protrusion, formed by two convergent elongate ridges with long and narrow flat crests, performs a succession of elemental hammered compressions on the band. The metal band, between blows of the hammering tool, is advanced toward the wider part of the chevron-like protrusion and enables the reduced thickness section to be progressively widened by hammering, with the long flat crests of the two ridges, on narrow strips of the portions of the band adjacent to the reduced thickness section. The material displaced from the hammered indentation at each elemental compression of the narrow strip is displaced substantially laterally and results in a widening of the band without an appreciable increase in the initial thickness of the other portions of the band's cross-section.

Abstract: A structure and method of manufacture of a sleeve for an anchor bolt which has a wedge held in its bolt hole, not separate from the sleeve body. The wedge is formed by striking the sleeve from the side opposite to the bolt hole on an area smaller than the cross-sectional area of the bolt hole.

Abstract: In a method of manufacturing a rack for a variable ratio rack and pinion steering gear, having a preforming process for preparing a rack blank having a plurality of teeth which are formed to a shape corresponding approximately to the shape desired in the finished rack and a finishing process for converting the teeth to the finished shape by cold forming in a die having a shape which is the exact counterpart of the finished shape, the preformed rack teeth are shaped to have top lands which are level with those in the finished shape and bottom lands that are deeper than those of same. The rack teeth in the preformed shape are all wider at the top areas than in the finished shape, and the ratio of the widths at the root areas of the rack teeth in the preformed shape to those in the finished shape varies in proportion to the variation of the steering ratio such that a rack tooth for a higher steering ratio is given the above-mentioned ratio that is larger.

Abstract: A hip prosthesis comprises a one piece element including a head, a plate portion, a neck interconnecting the head and plate portion, and a flexible femoral rod which includes thin longitudinal elements extending away from the head in opposition to one another. The longitudinal elements are obtained by providing at least a longitudinal cutting in the rod which extends to its end opposite the head. A slot in each end coincident with the cutting houses a linking part for holding the elements together in one plane while permitting their relative movements in a second substantially orthogonal plane. The elements are made in one piece with the head, the neck and the plate of the prosthesis, with the rod itself being forged from a single piece.

Abstract: A method is provided for making single crank throws for built-up crankshafts. The method includes heating an elongated workpiece having a saddle-shaped central area on one surface thereof and forming the workpiece into V-shape by pushing it with a punch into a first-forming die having legs angled between 35 and 65 degrees. The punch is V-shape with opposed surfaces inclined at substantially the same angle as the first-forming die. The workpiece is then reheated and pushed with a punch into a second-forming die having inwardly converging surfaces at an outer portion of the cavity and parallel sidewalls joining the inner end of the outer die surfaces. The apparatus includes a bottom die having a long generally rectangular cavity and top die punch rotatably mounted about a vertical axis on the underside of the press crosshead and a motor drive for rotating the top die punch to alternate positions for forging opposite halves of the workpiece in the lengthwise direction.

Abstract: The invention relates to a method of manufacturing solid metallic materials having a circular cross section by employing a rotary mill. A three or four roll cross-type rotary mill is employed, with cross and feed angle setting selected so as to meet specific conditions. The method permits efficient production of metallic materials without internal cracks or internal fracture initiated from porosity. In one version of the method the material being worked is rotated. In another version the material is not rotated and the roll housing is rotated around the former. Where the latter version is employed, it is possible to work the material as produced by a continuous casting machine and without cutting.

Abstract: There are disclosed a shoe which is interposed between a swash plate and a piston of a swash plate type compressor and which converts rotary movement of the swash plate into reciprocal movement of the piston, and a method for manufacturing the same. According to the method of the invention, a columnar element is compressed in the axial direction for plastic deformation in such a manner that one end of the columnar element is deformed along the inner surface of a hemispherical recess of a die while the other end is urged against the flat end surface of another die. A shoe can be easily manufactured with this method, which has a flank between the hemispherical part which is in slidable contact with the surface of the piston defining the hemispherical recess and the bottom end face of the swash plate which is in slidable contact with the swash plate.

Abstract: An anchor for a cutting tooth of a suction dredge comprises a unitary body to be welded onto the periphery of a suction head, this body having a base with a crenellated rim surrounding a tapering head designed to penetrate into a cavity of the cutting tooth. The head has a throughgoing slot alignable with similar cutouts of two lobes of the tooth receivable between crenellations of the body to accommodate a key for retaining the tooth on the head. The body consists of high-strength ductile steel, preferably alloyed with manganese and vanadium, and is formed by forging with the grains of its structure running from the base toward the tip of the head while bending around the slot thereof, the latter being produced by hot forming without chip removal.

Abstract: A metal workpiece, such as a gear blank, is forged in a press. The workpiece is first heated and then placed in a working chamber above the press. Force is applied against opposite sides of the workpiece to press the metal of the workpiece outwardly against a sidewall formed by a ring die and inwardly against a side surface of a removable center section. After the workpiece has been shaped, the workpiece and the center section are removed from the working chamber of the press with the center section firmly gripped by the workpiece. The workpiece is then allowed to cool and the center section is separated from the workpiece.

Abstract: Meshing radially serrated annular pads projecting from the meeting surfaces of two members of a belt drive tensioning device to provide locked incremental angular adjustment of the members are formed by depressing an annular indentation in each member in the side thereof opposite its meeting side so as to cold flow metal to the meeting side thereof and in coining a serrated annulus in the metal thus transferred.

Abstract: There is disclosed a method of making a fork for a fork lift vehicle, which fork is formed with an integral head, created by forging the same, into a hooked shape form, the rest of the fork being of generally conventional configuration, the fork further including a mechanism to effect latching of the same in position for use made possible by the method and ultimate form of the fork head and to make positive the positioning and release of the fork for movement into various transverse positions with respect to the vehicle.

Abstract: Seamless well drill tubes are formed by extruding seamed tube blanks through a die throat by pushing the tube blank through the die throat with a pusher rod having a portion located internally of the tube and die throat. The pusher rod has a narrow lead portion so that as the lead end of the tube length is forced through the die throat, its material flows inwardly to form an inwardly thickened annulus and therefore, the remainder of the pusher rod is located within the die throat and blank so that the blank material flows into the desired wall thickness. Before the tube is completely pushed through the die throat, the pusher rod is removed and the second tube blank is inserted in end to end contact with the trailing end of the first blank.

Abstract: A tool holder for a mining tool bit is disclosed; it comprises a unitary steel body with a cylindrical shank for supporting the tool holder and a conical head for holding a tool bit. The shank includes a retaining neck constructed of a roll-formed portion of the shank. A cylindrical section between the shank and the head includes an extracting neck which is constructed of a roll-formed portion of the section.

Abstract: A method for increasing strength and/or hardness of a sintered powder metal specimen containing tungsten by cold working is disclosed. Compressive force is applied to the specimen slowly so that the yield strength of the specimen progressively increases and the specimen exhibits squirming instability as its diameter increases.

Abstract: A universal coupling comprising an outer element integral with a first shaft having a spherical cavity inside which are formed grooves, an inner element integral with a second shaft and having an external surface in which grooves are also formed whose bottom has a section through a plane passing through the axis of the inner element formed by an arc of a curve, rolling means being disposed between the pairs of grooves, these rolling means being held in the windows of a cage. The inner element has on its outer surface a cylindrical surface portion situated substantially in the median region in the axial direction and extending at least substantially as far as the plane orthogonal to the axis containing the points of the bottoms the furthest from the axis, this portion being extended on each side by spherical surface portions intended to mate with the inner surface of the cage.

Abstract: A method for making replacement grouser bars particularly contoured to fit rock worn grouser shoes from blanks cut from inexpensive sheet metal. The blank has a straight lower edge and a curved upper edge such that the bar is thicker at the ends than in the middle. The straight lower edge is easily double beveled and the blank is reverse forged to obtain a finished grouser bar having a straight upper edge and a curved lower edge, the bar still being thicker at the ends than in the middle.

Abstract: A disc-like or annular workpiece within a set of closed dies undergoes lateral flow in a first direction (e.g., radially outward or inward, depending upon the geometry of the die cavity) as the upper die is forced against the lower, with the workpiece being now restrained from flowing in other directions. Toward the end of forging, when the metal offers a rapid increase in resistance to flowing, the workpiece is set free of the restraint from flowing in a second direction, generally opposite to the first direction, as by creating a bore centrally therein or by cutting off its peripheral portion. Then, upon resumption of forging, the workpiece flows in both first and second directions, completing the desired flow in the first direction with no greater forging force than before.

Abstract: Method and apparatus for making certain types of parts which are stepped in one plane and curved in other planes transverse to the planes in which they are stepped. The invention uses a specially shaped billet which is formed into the part in a closed flashless die set at warm forging temperatures.

Abstract: A method and apparatus for forming an electrical connector having a first hollow cylindrical portion of a first outside diameter and a second hollow cylindrical portion of a second outside diameter which is less than the first outside diameter, are provided in which two successive extrusion operations are performed. In the first extrusion operation, a billet of ductile metal is placed in a first die and an intermediate billet is formed by back extruding the first portion of the connector over a punch while forward extruding a part of the billet in the die to form a portion of reduced diameter approximately equal to the second outside diameter of the electrical connector. In the second extrusion operation, the intermediate billet is placed in a movable die section and the intermediate billet and the movable die section are moved downward from an initial position by means of a finish punch. The finish punch contacts the intermediate billet and is received within a first cylindrical recess defined by the billet.

Abstract: A method for cold forming a metallic billet into an article having divergent members with a single hit comprises depositing the billet centrally within a die cavity between a first member and a second member. The first and second members are hydraulically urged toward one another at an equivalent velocity until the divergent portions of the die cavity are filled. The forming velocity is between about 30 percent and about 60 percent of the normal forming velocity for the material comprising the billet.

Abstract: A socket of yieldable semi-rigid plastic material is formed with an external circumferential groove for receiving the periphery of an opening in a linkage member. The periphery of the opening is deformed out of the plane of the surface of the linkage to produce an effective thickness approximately the thickness of the groove, providing a method to assure a secure fit in cases where the thickness of the linkage material is either greater than or less than the width of the groove.

Abstract: The hollow stabilizer is made from a single pipe and has a torsion section coupled to a vehicle, curved sections each integrally extending from each end of the torsion section, and arm sections each integrally extending from each of the curved sections. All these sections have the same outer diameter, and the curved sections have an increased thickness compared to the rest of the stabilizer.

Abstract: The invention is well adapted to the manufacture of water-cooled mandrels for use in a piercing mill. The method of the invention consists in that a cone-shaped cavity is formed in a blank by hot piercing, whereupon the blank thus formed is subjected to hot upset forging whereby it is reduced until its outer diameter at the end of the fitting section is in the range of from 0.9 to 1.02 times the diameter of the mandrel sizing band, the outer diameter of the mandrel working section and that of its nose being 0.9 to 1 times the diameters of the respective sections of the mandrel, the wall thickness in the area of the fitting section and that of the sizing band being from 0.7 to 1 times the thickness of the mandrel wall. Then, the fitting section is subjected to reduction effected concurrently with upset forging of the working section, this followed by final sizing of the mandrel setting cavity.

Abstract: A method of manufacturing a hollow spark plug body having a cylindrical central portion (28), a first end portion (10) of smaller circular radial cross-section and a second end portion of non-circular radial cross-section, e.g. hexagonal, and of smaller maximum diameter than the central portion by cold extruding the both end portions. The second end portion is extruded in two stages, the first involving the formation of a recess in one end of a cylindrical blank, the second involving extrusion the blank between a die (19) and a mandrel (21) which moves with the blank during extrusion.

Abstract: A wiper arm includes a wiper rod which is directly formed from wire rod.

Abstract: An apparatus for reverse redrawing of a cup is provided with an annular ring surrounding the upper end periphery of body portion of a die ring, provided concentrically with the die ring, a slightly larger clearance than the wall thickness of the cup to be redrawn being provided between the inside surface of the annular ring and the outside surface of the die ring.

Abstract: Forging of a camshaft which is formed integrally with plane cams arranged longitudinally thereof. A blank for the camshaft has its cam-forming portion heated to different temperatures with the heating temperature decreasing from the axially central position towards the opposite ends. Pressure is applied to the preheated blank at the opposite ends to thereby form cams on the cam-forming portion of the blank in sequence, starting first with the axially central position of the cam-forming portion towards the opposite ends. The camshaft forged using this method has a forged fibre flow with no substantial breaks and has sufficiently high mechanical strength.

Abstract: The disclosed method features an automatic high production cold working process of forming socket wrenches from coiled alloy steel wire stock. The wire is cut to length, its ends are squared to form a workpiece blank which is then located in a die station and a recess of circular cross-section is cold formed at one end of the workpiece by impacting a round punch into the workpiece which thereafter is transferred to and inserted into a downstream die in a longitudinally reversed orientation whereupon a second punch forms a square socket on an end of the workpiece opposite the end wherein the circular recess is formed. Additional steps of the process include extruding an end of the workpiece surrounding the circular recess to reduce its outside diameter, broaching a hex socket into the necked-down end of the workpiece and piercing an axial through-hole between sockets at opposite ends of the workpiece.

Abstract: A method of manufacturing gear forms comprising cold forming metal stock to produce a workpiece having a protruding hub portion with a central opening, impressing indentations in the hub portion by means of appropriate dies, boring and counterboring the region around the hub portion, and modifying the central opening according to the configuration of a shaft to be received thereby.

Abstract: A method is provided for the formation of high precision metal slugs by cold forming. A metal column starting material is subjected to a preforming step in which the starting material is cold forged with a pair of upper and lower metal dies provided with concave recesses to produce a primary product having a barrel shape having a high degree of parallelism on the ends. The resultant primary product is subjected to an upsetting step in which the barrel shape is crushed while maintaining parallelism to obtain a secondary product. The resultant secondary product is then subjected to an ironing step in which the outer diameter of the secondary product is reduced to obtain a high precision slug having an outer diameter which is substantially the same as the outer diameter of the desired final product for which the slug will be utilized.

Abstract: A method and apparatus for forming cup-shaped metal containers from a metal blank by drawing and then redrawing the blank to its finished configuration is disclosed. The method and apparatus is intended for use in a double acting press having inner and outer rams which operate in relatively timed relationship. The means for performing the drawing operation are operatively associated with the outer ram and the means for performing the redrawing operation are carried by the inner ram. The drawing means are pneumatically activated and the redrawing means on the inner ram are telescopically received within the drawing means of the outer ram and carry peripheral radially extending shoulders thereon for engagement with the drawing means so that, for at least a portion of the travel of the inner ram, travel of the drawing means is retarded thereby controlling the timing of the actuation of the drawing means and reducing the stroke of the press required to accomplish the triple action drawing and redrawing function.

Abstract: A planar material to be press-formed is confined in a space having a contour corresponding to the outer contour of the flange part of an article to be produced and is pressed between a punch member having a through hole corresponding to the outer contour of the hollow main part of the article and another die member holding slidably a mandrel having an outer contour corresponding to the inner contour of the internal bore of the hollow article, the mandrel being simultaneously projected into the through hole of the first member. By the pressing action, the peripheral part of the material is formed into the flange part of the article while an inward flow of the material is caused, thereby elevating the surface of the material in the through hole of the punch member and forming a recess in the opposite side surface of the material. The mandrel is projected simultaneously with said pressing action, whereby topless hat-shaped product is easily formed by one step.

Abstract: A method for the production of a toothed belt pulley made of metal without machining which is provided at lateral sides with annular flanges which protrude above the height of the teeth comprising initially shaping one of the two flanges as an axially extending collar with an outside diameter equal to or less than the diameter of the pitch circle of the teeth and then radially flanging the said collar to the outside to form the second annular flange and the pulley formed thereby.STATE OF THE ARTToothed belt pulleys are known and are used, for example, for the camshaft drive in internal combustion engines but the known pulleys have a rather complicated construction. One known pulley consists of a solid massive hub or nave which is produced on a metal lathe to which are connected three sheet metal parts forming the outer circle track with flanges on either side as well as the area connecting the circle track with the nave.

Abstract: A method and apparatus are provided for producing a cross-slotted die for forming cross-slotted screw heads. One end face of a cylindrical blank is turned to form a cone having a cone angle of between 124.degree. and 140.degree.. The cross shape is produced in this face by a single cold forming stage while preserving the outer diameter of the blank. The blank is held in a cylindrical holder having a bore with an internal diameter corresponding to the diameter of the cylindrical blank. An ejection mandrel engages in the bore to form the base of the holder. A platen carries a punch for insertion into the bore to deform the end face of the blank.

Abstract: Solar parabolic reflecting troughs are formed from long strips of sheet metal by applying equal bending moments to each long edge of the strip to draw the metal into a parabolic shape. While maintaining the metal in parabolic form, the trough is stress relieved by heating.

Abstract: Sheet metal is processed by providing one or more corrugations longitudinally along the sheet in a position spaced from both lateral edges of the sheet while the lateral edges are maintained in fixed relationship to each other, thereby causing the sheet metal portion containing the corrugations to be stretched. The corrugated portion is subsequently rolled or otherwise pressed to flatten out the corrugations either partially or completely, resulting in a sheet which is wider than the original, but which still has certain areas having the original thickness. The sheet metal thus processed may be utilized to form structural members such as channels or studs which are less expensive for a given size than conventional structural members, but which still exhibit sufficient supportive strength by virtue of the portions thereof which retain their original thickness.

Abstract: A one piece, integrated steering shaft and flange for vehicles and the method of making it is disclosed. One end of a solid or hollow linear shaft is heated and placed in a die. A series of blows to the heated end shapes the flange by an upset forging method.

Abstract: A machine and method whereby a metallic stick is pressed into a mold which is moved along two axes substantially perpendicularly to the stick so as to make the end of the stick follow the mold while it is softened by heat produced by passage of an electric current between the mold and the stick, the stick only being moved in its axial direction while the mold is only moved in the two substantially perpendicular directions to this axial direction.

Abstract: A method of manufacturing a spherical bearing rod end having an outer race member, an intermediate member of yieldable material within and supported by said outer race member and an inner race operationally supported by said intermediate member comprising preforming a rod end blank having a cylindrically shaped head section at one end thereof, flattening the cylindrical section to cold form two enlarged faces, forming a bore through said faces thereby leaving a uniformly cold formed annular area to serve as the outer member, inserting in said bore said intermediate member and said inner race member, interlocking with mechanical interlocking means said intermediate member and inner race member within said bore to effect the bearing support of said inner race member within said intermediate member.

Abstract: A draw bead made integral with the die plate or as an insert and having alternating pressure applying surfaces and grooves which will thicken the metals drawn across it minutely at the grooves and will distribute the metal evenly at the pressure surfaces. The draw bead is preferably placed close to the draw radius of the die cavity, and it can have various shapes to compliment the shape of the die cavity. Substantially less blank holder pressure is required because the draw bead restrains the flow of metal and better distributes the metal as it is drawn into the die cavity, and since the draw bead is close to the draw radius, a smaller blank holder is possible. The draw bead can be used to form a portion of the drawn part thereby eliminating a secondary forming operation if the part requires a flat flange about its trim line.

Abstract: The invention relates to the cold extrusion of a part having a polygonal interior and a cylindrical exterior. Instead of the usual process of forcing a polygonal punch into a billet in a single extrusion step, the new method employs a plurality of extrusion steps, first forming a lobed preparatory blank and then in a second extrusion step providing a punch and die combination whereby the external lobes of the intermediate part are forced radially inwardly. In the second extrusion step a polygonal punch is used to provide the proper polygonal interior surface. A cooperating die is provided with an upper lobed cavity for receiving the lobed preparatory blank and this die is oriented with respect to the polygonal punch so that the interior lobes of the die are exactly opposite the flats of the polygonal punch.

Abstract: This invention relates to a method of determining the sequence of die sizes to be used in a multi-die/block drawing machine to draw metal from any given input stock size to any given final wire size to give optimum efficiency and proposes nomograms for achieving the sequence quickly and easily.

Abstract: An improved method is disclosed for making spur gears having teeth with axially crowned working faces. A sintered powdered metal compact is formed in the shape of the desired gear, but slightly oversized and preferably with gear teeth having working faces that are uncrowned in the direction parallel to axis of rotation of the gear. The compact is forced into a smooth circular die cavity having a diameter slightly less than the outer diameter of the compact. Only the tips of the gear teeth engage the die wall. While the compact is constrained within the die, axial compressing forces are applied to it and gear teeth having axially crowned working faces are produced. At the same time, the gear is finish sized to desired dimensions.