Abstract: A manually-operated rule bending and notching press producing a ram output mechanical advantage that is substantially than prior art manual rule bending and notching presses. This is accomplished by providing a toggle linkage that drives a crank-and-pivot mechanism. The input handle is able to travel through at least about 100 to 180 degrees of rotation as the ram moves through its full travel, however, the handle still moves through the most usable 90 degrees of rotation while the ram is moving through the most highly loaded final 1/2 to 3/4 inch of its stroke. The crank and pivot mechanism provides a substantially linear force multiplication during this last part of the press ram stroke because the crank does not pass or near the top dead center of either the input or the output linkage. Accordingly, variations in output mechanical advantage may be effected simply by altering the radii of the input and output crank pivots.

Abstract: A ram that is utilized in high speed apparatus for forming elongated one piece metal can bodies from shallow cups is constructed by metallurgically bonding either a nose piece to a body or a tail piece to a body, the body constructed from a single integral piece having an elongated thin walled tube section with either a tail piece section or a nose piece section for connection to a drive means.

Abstract: A novel tool and method for making the tool for bending roofing material having uniformly spaced support ribs. The bending tool has a channel for bending roofing material having uniformly spaced support ribs. The dimensions of the channel height and length are based on properties of the ribs of the roofing material on which the tool is to be used, specifically the height of the ribs and the distance between two consecutive ribs. The tool is made by taking these measurements of the ribs and fabricating a channel based on these measurements. The channel is formed by two flanges attached to a solid upper base. The entire base is attached to a handle.

Abstract: The invention provides a reduced recoil bucking bar and corresponding methods for forming joints with rivets. The bucking bar includes a housing and a driven member movable with respect to the housing. The worker using the bar holds it with the driven member pressed against one end of the rivet. When blows are delivered from the hammer through the rivet to the bar, an appropriate reaction force is generated automatically by mechanisms within the bar. These mechanisms include at least a first pressure chamber and an exhaust port for releasing pressure from the pressure chamber to the atmosphere. By controlling the flow of air through the pressure chamber, the mechanisms within the bucking bar control the forces acting on the driven member during the recoil and rebound motions. Preferred control mechanisms include a second pressure chamber and a movable shuttle. The shuttle is initially biased in a preferred direction by a biasing element in the form of a coil spring.

Abstract: A tool for rounding the end of a tube has an anvil with a cylindrical midsection and a tapered forward end. Extending rearwardly from the rear end of the anvil is an elongate shaft, and around the elongate shaft is a cylindrical hammer which slides axially along the shaft to strike the rear surface of the anvil. The hammer is retained in the shaft by any appropriate means such as a threaded nut or external flange at the distal end thereof.

Abstract: The present invention is a simple machine that permits the concentrated application of a bending moment to a stiff metallic bone plate. The present invention permits bends along three orthogonal torsional axes. The present invention can be scaled so that modest sized operators can bend the most stout bone plates. The bending moments are transmitted to the bone plates through the edges of curved apertures so that the built in transverse curvature of the plate is not crushed with resulting weakening of the plate. Finally, the apertures are rotated and angled to provide comfortable hand clearance and to permit efficient application of muscle force by the operator.

Abstract: A tool for use in aligning a vehicle door. A vehicle typically has a door lock assembly which receives a lock pin on the door frame, or similar article, to secure the vehicle door in a closed position. The tool of the present invention has a comparable lock pin toward one end which can be "locked" into the vehicle lock assembly and, at an opposed end, a portion for engaging the vehicle door frame lock pin. The lock pin engaging portion is structured so that, at least, the door and the door frame are horizontally fixed in a desired ajar relationship. This frees both hands of the tool user to make the desired door adjustment. The tool of the preferred embodiment is used with a standard breaker bar, with extension if necessary.

Abstract: A bender for bending metal rod to form surgical implants in a sterile operating room environment. The bender being made of an autoclavable material having a hardness greater than the maximum hardness of the rod to be bent. The bender includes a capstan, a primary mandrel, a gripping element, and a follower mandrel. The primary mandrel, which rotates with the capstan, includes at least one generally cylindrical portion with a guide channel formed in the periphery thereof. The follower mandrel also includes at least one generally cylindrical portion with a guide channel formed in the periphery thereof. The follower guide channels are disposed in planar alignment with the corresponding guide channel of the primary mandrel to form bending channels therebetween. The gripping member is mounted for rotation with said primary mandrel, and encloses a portion of the primary mandrel guide channel(s) to form a passageway of predetermined configuration.

Abstract: A method for producing a nozzle holder for an injection valve, having a valve closing member comprising an armature and a valve closing body, disposed within a nozzle holder. The nozzle holder has a bore which is provided with at least one guide protrusion on end and that extends at least partway around the bore. The guide protrusion is stamped into a guide segment of the nozzle holder. The injection valve is especially suited for fuel injection systems of mixture-compressing internal combustion engines with externally supplied ignition.

Abstract: A straightener for removing dents from an installed section of pipe. The inventive device includes a tapered body positionable within the pipe. A vibrating assembly within the body removes dents from the pipe as the device is pulled therethrough.

Abstract: A tool for the repair of small dents in the sheet metal surfaces of motor vehicles uses a laser beam assembly as a pointer, instead of a mechanical pointer, and the laser beam produces a sharply focused small dot of light to precisely locate the hidden working head of the tool in exact alignment with the small dent, thereby facilitating efficient removal of the dent.

Abstract: A tool with socket means for connecting the tool to an ordinary ratchet wrench or the like. The tool includes an offset head portion having socket means, the head portion located in the rearward end for attaching the tool to a ratchet wrench or the like. The forward body portion can be a wedge-shaped, two-prong fork means that is used for spreading, prying, pulling and lifting or it can be an elongated telescoping rollerhead that is used to straighten a piece of metal or essentially any other forward body portion. The offset head portion with socket means not only allows attachment to any ordinary ratchet wrench or the like but it also allows the operator to use the tool when attached to the rachet in extremely confining places whereas a tool not disclosed by the invention could not effectively work.

Abstract: A ram (40,50) of a press comprises metal sleeve (41,51), a hollow core (42, 58), a first end piece 42A, 52 attached to one end of the rod and a second end piece 46, 54 attached to the other end 47 of the ram to support a tool, the hollowcore being made of a material lighter than that of the sleeve. The benefit is a ram of reduced weight to minimize inertia forces arising during use.

Abstract: A device for use in the repair of automobiles, trucks, farm equipment and other vehicles having sheet metal bodies capable of deformation from impact accidents, which device includes a main body portion having a first nestable solid section and a second tubular receiving section, the receiving section being constrictedly open at its proximal end being closed on its distal end by a closure which is threaded to receive a work head of varying configurations, each of which is interchangeable with the other for carrying out specific tasks or functions within a specific area of the vehicular body.

Abstract: A stiff lever arm has a tapered end. A slot is located within the tapered end of the lever arm. The slot has dimensions slightly larger than the looped line tie of a lure which allows the line tie to fit within the slot. Once the line tie is engaged within the slot, a manual force applied to the lever arm produces a torque which bends the line tie to the properly tuned position.

Abstract: A tool is presented which includes a shaft portion for insertion into a tubular stake; a head portion for receiving and conveying an applied impact; and a flaring portion intermediate the shaft portion and the head portion for contacting the upper edge of the tubular stake to force it downward during the applied impact and to flare the upper edge thereof.

Abstract: Aluminum automobile wheels are straightened by exerting gentle pressure on the wheel to urge the wheel back to its original shape. If the metal does not move under pressure, the wheel is heated, and pressure again exerted, the process continuing until the wheel becomes round. A C-shaped wheel mount carries a spindle which mounts a hub. The hub rigidly receives the wheel, and the hub is selectively rotatable, and the wheel mount is selectively rotatable about a horizontal axis. The wheel is gently brought back to shape without excess heat or excess working to damage the metal. A final metal spinning step relieves stresses in the metal and brings the wheel to final tolerances.

Abstract: A tool for machining of openings, shafts and the like has a body having concentrical stepped cylindrical working regions, grooves provided between the working regions, and transitional regions arranged between the grooves and the cylindrical working regions. The transitional regions extend substantially tangentially in a machining direction and a deformation process of an outer surface of the workpiece to be machined is performed without material removal by compression.

Abstract: A needle bending device for bending a needle to any desired length without damaging the lumen of the needle and while maintaining sterile conditions, comprise a plastic casing having an open aperture and elongated chamber. The chamber is maintained sterile and the aperture is provided with a curved crown so that the needle can be bent around the crown. Graduated markings on the outer surface of the casing can be used in conjunction with transparent material for the casing, to see the length of needle within the casing and provide a bend of suitable length. Bends having angles of 90.degree., more than 90.degree. or less than 90.degree. can also be provided by bending the needle to any desired extent around the curved crown.

Abstract: An apparatus for connecting a coolant tube (20) and header (22, 24) of a heat exchanger (10) comprises manifolds (12, 14) forming fluid reservoirs (16, 18) and a plurality of coolant tubes (20) in fluid communication with the manifolds (12, 14) . The manifolds (12, 14) comprise a header wall (22, 24) having a plurality of collars (26) forming collar openings (28). The tubes (20) include an axially extending mechanical seam (50) and deformable hollow end portions (52) extending through the collar openings (28). A flaring tool (70) having tapered side surfaces (74) is inserted in the end portion (52) of the tube (20) to expand the tube (20) outwardly against the collar opening (28). The flaring tool (70) includes a groove extending axially along the side surface (74) aligning with and straddling the seam (50) during expansion of the tube (20) and further forces the portions (62, 64) of the tube (20) adjacent the seam (50) outwardly into sealing engagement with the collar opening (28).

Abstract: An instrument for bending a rod, wherein the instrument includes an elongated handle and an angled tip extending therefrom. The tip includes a channel or bore therethrough for receiving the rod. The top side of the tip may include a flat surface thereon. Two such instruments are used to bend a rod by inserting one end of the rod into the channel of one instrument and the other end of the rod into the channel of the other instrument. Force is applied to the instruments to preliminarily bend the rod. The instruments are each then rotated 180 degrees, and further force is then applied to the instruments to further bend the rod. The force may be applied until the flat surface on each instrument abuts each other.

Abstract: The brake piston adjuster mechanism includes an expandable or deformable tube (80) which is attached to the piston (60) and engaged by a deforming member comprising a pin (190) having a threaded end (194) receiving thereon a nut (193) and tube expander (192). The nut (193) biases the tube expander (192) against a chamfered pin shoulder (191). The tube expander (192) has at least one inner diameter chamfer (198) which engages the chamfered pin shoulder (191) in order to impose preload forces upon the chamfered pin shoulder (191) and reduce stresses at a smaller diameter portion (195) of the pin. The (193) nut may be a castellated nut (193) which receives a locking wire or pin (200) extending through an opening (199) in the threaded end (194) of the pin (190).

Abstract: A stud puller comprises a body that can be attached selectively to a hand pulling tool or to a slide hammer for removal of dents. A small bore at the forward end of the tool receives a pulling stud and a slot at the top of the tool at the leading end extends in communication with the stud passageway. An eccentrically mounted wheel in the slot may be turned forward to clear the stud passageway for insertion of a stud and then pulled back to engage the shank of the stud in a firm grip for pulling. The stop prevents the wheel from being turned too far and block the stud passageway until the stud is inserted.

Abstract: A method for connecting a coolant tube (20) and header (22, 24) of a heat exchanger (10) comprises manifolds (12, 14) forming fluid reservoirs (16, 18) and a plurality of coolant tubes (20) in fluid communication with the manifolds (12, 14). The manifolds (12, 14) comprise a header wall (22, 24) having a plurality of collars (26) forming collar openings (28). The tubes (20) include an axially extending mechanical seam (50) and deformable hollow end portions (52) extending through the collar openings (28). A flaring tool (70) having tapered side surfaces (74) is inserted in the end portion (52) of the tube (20) to expand the tube (20) outwardly against the collar opening (28). The flaring tool (70) includes a groove extending axially along the side surface (74) aligning with and straddling the seam (50) during expansion of the tube (20) and further forces the portions (62, 64 ) of the tube (20) adjacent the seam (50) outwardly into sealing engagement with the collar opening (28).

Abstract: A guide for removable attachment to a conventional pneumatic hammer adapts the hammer for use as a Pittsburgh lock hammer. The guide includes a hollow, open-ended tubular element which defines a fragmentary cylindrical wall, and an adjustable fastener is attached to the exterior surface of the wall for removably attaching the element to the pneumatic hammer.

Abstract: A metal forming tool attachment includes a body assembly having a front part and a rear part. A rotary forming element journalled on the rear part is driven by an input shaft which projects from the rear part for coupling engagement with the output shaft of an associated power tool. Another rotary forming element journalled for free rotation on the front part cooperates with the driven rotary forming element to form a nip region therebetween. An adjustment lever mounted on the rear part cooperates with a threaded member mounted in fixed position on the front part to move the front part generally toward and away from the rear part whereby the nip region between the forming rolls may be adjusted. A pair of spaced apart rotary forming elements carried by a mounting plate pivotally supported on the front part may be substituted for the single rotary forming element carried by the front part to adapt the tool attachment to perform a radial bending operating.

Abstract: A pair of hand held tools with one having a handle (10), and shaft (12) to provide a means of control and safe working distance. The body of this tool features a flange lip groove (18) which keeps the tool on the area being worked, a leverage rack (22) that provides a guide for the leverage pick and a means of pulling the panel flange lip away from the panel frame. A second hand held tool, the leverage pick and featuring a handler (32) and shaft (36) with a flared, flattened, angled tooth (36) for prying.

Abstract: A process for straightening a crossbar of an anode to correct the suspension of the anode while the anode remain in an electrolytic cell. The process has an elongated shaft having a lower portion and an upper portion. A transverse slot extends longitudinally upward into the lower portion of the shaft. The slot has sufficient width to receive an upper portion of the crossbar. A handle is attached to the upper portion of the shaft. The handle extends laterally outward from the shaft. The handle is for twisting the shaft to cause the slot to straighten twisted crossbars within the slot.

Abstract: An apparatus for form-locking torsion prevention in screw connections includes a bolt with a standard bolt thread and a special nut having a free end and nut threads. A thin-walled sheath is disposed on the free end of the special nut. An integral cross-sectional portion intended for deformation is in the form of a bead supported on the thin-walled sheath. The nut thread extends uninterruptedly through the sheath and the bead. The bolt thread extends through the bead. A thrust pad is pressed axially onto the bead and has a conically narrowing bore formed therein in which the bead is substantially radially plastically deformed and forced inward into the bolt thread.

Abstract: This tool envisions a method for separating clinched together first and second components of a duct, which components have been clinched into interengagement, by the uncrimping of the clinch collar tab of the first component from the second component. The clinched parts are first pried loose by a sharpened point of a tool which is penetrated between the tab and the second component. The prying is continued by virtue of the use of the fulcrum, integral with the tool, so that the tab is moved from its initial 90.degree. dihedral position to its subsequent zero degree dihedral position.

Abstract: A method of joining a tube to a flange or wall member includes the steps of moving a plurality of circumferentially spaced workpiece contact surfaces into controlled pressure contact with the inner surface of a tube and maintaining a force against the inner tube surface sufficient to form an outer surface of the tube to a predetermined shape with respect to an opening surrounding the tube. The apparatus for expanding the tube has a plurality of radially movable segments, each of which have a pair of circumferentially offset and longitudinally spaced workpiece contact surfaces disposed thereon. The method and apparatus advantageously expands a tube by an amount sufficient to form a secure mechanical joint with a flange or wall member irrespective of nominal variations in the tube diameter and wall thickness. Furthermore, the method and apparatus form a uniformly smooth finish on the internal surface of the tube thereby eliminating the need for post-forming treatments to remove undesirable surface particles.

Abstract: A pipe expanding mandrel is disclosed which comprises a set pin having a pipe expanding billet mounted on a front end portion thereof and a stepped portion formed at a site behind the billet, a sleeve slidably fitted on a rear portion of the set pin, a spring interposed between the stepped portion of the set pin and the front end of the sleeve, and a mandrel body. An engagement protuberance formed on a rear end portion of the set pin is brought in engagement with an engagement hole bored in a front end portion of the mandrel body, and then the set pin is turned, so that the set pin and the sleeve are coupled to the mandrel body while being prevented from disengagement therefrom by the action of the spring.

Abstract: An autobody door latch alignment tool comprising a lever arrangement including:a strike pin engaging slot adapted to engage, and be rotatable about a strike pin mounted on a first door post of an autobody opposite a second door post arranged apart from and generally parallel to the first door post;a door latch engaging pin adapted to engage a door latch on a misaligned door that is hung by hinges from the second door post of the autobody, with the door latch engaging pin being arranged in mutually spaced apart relation from the strike pin engaging slot at respective points defining a chord along an arc subtended by an angle of the doors rotation about its hinges; and,a lever arm;with the door latch engaging pin and strike pin engaging slot being interconnected through a connection extending transversely to the chord, and being adapted to be secured in fixed relation with the lever arm, in which arrangement the strike pin engaging slot is operable to act as a fulcrum when securely engaged in rotatable relation

Abstract: A method for replacing an automobile door panel without removing the door from the automobile utilizing a crimping tool is provided. The mirror is removed from the door. An inner section of the damaged door panel is cut out leaving a border around the door frame. The cut out inner section is removed and the handle and lock cylinder on the door are also removed. A plurality of relief cuts are made about the front, bottom and rear surfaces of the border remaining on the door frame. The border is then peeled away from the door frame. A new panel is placed around the front edge of the door frame holding the back end out. The panel is then pushed in and around the remainder of the door frame.

Abstract: A hockey stick bender for bending the blade of a hockey stick. The hockey stick bender includes a paddle member with a handle, and two opposing, curved forming members with a slot therebetween. The blade of the hockey stick is placed into the slot and manipulated between the two curved forming members to form a hockey stick blade.

Abstract: An adjustable crimping tool (10) is provided having a pair of indexable discs (18, 32) each of which carry a plurality of concave die cavities (18A-18F, 32A-32F) spaced about and opening to outer periphery thereof which can be moved into registry (FIG. 1) to define a selected size/shape of crimping cavity (C).

Abstract: A tool for straightening an arched pin into one of a pair of slots orthogonally defined in a screw head including an elongated rod-like member, means mounted on one end of the rod member for applying an axially directed force, an elongated sleeve mounting the rod-like member for reciprocal movement within the sleeve and having an end adapted to seat about the screw head, a tool handle mounted at one end of the sleeve adjacent the force applying means and a pin setting tool bit connected to an opposite end of the rod like member being indexible with one of the slots in the screw head and for delivering an impact force to the arched pin in the other screw head slot.

Abstract: A bowed external spring retaining ring of the E-shaped type includes flats at the leading and trailing ends of the ring. The flats from leading and trailing edges of the ring which are rounded on a concave side of the ring. The ring is formed by a punch which has an end face comprised of a concave portion and straight portions, the latter forming the flats on the ring.

Abstract: A hand-operated rebar bender, bent rebar straightener, and rebar cutting machine which includes a base, a pair of spaced apart bending posts, and a linearly reciprocable slide disposed between the posts and movable reciprocally in directions perpendicular to a line interconnecting the posts. The slide defines first and second grooves, both adapted to receive the rebar, which move with the slide. The grooves are positioned so that the straight rebar to be bent and the inclined legs of bent rebars to be straightened can be positioned tangent to the post. The base includes a guideway for the slide and, in one of its first and second positions, an end of the slide projects past the guideway. A rebar cutter defined by a frame releasably connected to the base includes a pair of rebar cutting discs having aligned, peripherally open grooves, one of the discs being fixed and the other being rotatable relative to the one.

Abstract: A stress coining tool for fatigue life extension of the wall of an aperture in a metallic structural member, in the form of a rigid elongated member having a plurality of annular olive-like protuberances of a progressively larger diameter from one end of the member, and an additional olive-like protuberance of a smaller diameter than the largest protuberance, such additional protuberance located on the opposite side of the largest protuberance from the other protuberances. The diameter of the largest annular protuberance is such that the material forming the wall of the aperture is displaced radially elastically and plastically an amount to provide stress coining and to minimize stress concentration in the wall of the aperture. The additional olive-like protuberance to the rear of the largest protuberance is of a diameter such that the latter protuberance functions as a guide to permit passage of the tool back through the aperture without causing any further plastic deformation of the wall of the aperture.

Abstract: An apparatus for repairing bent mixing vanes in a nuclear reactor fuel assembly is provided, including a unique tool and a related tool handling device. The tool is an elongated tube with a housing containing two sets of opposing, high-strength blades movable between closed and opened positions. The tool is inserted into a fuel cell detected as having a grid with a bent mixing vane to a location below the damaged grid with the blades in the closed position. The blades are then remotely opened and the tool is withdrawn. As the tool is withdrawn, one blade abuts the bent mixing vane and bends it back close to its original position. The blades are then closed and the tool is fully extracted from the fuel cell. Once the tool is fully extracted, the fuel rod can again be reliably inserted into the repaired fuel cell.

Abstract: A tool for removing dents from tubing, particularly dents from curved brass tubing used in musical instruments such as trombones, trumpets and french horns. The tool is designed not only to drive a barrel-shaped dent ball past the dent to raise it, but also to reverse the procedure to remove the tool from the horn in working with tubing that is not open ended. The tool has a series of barrel-shaped force transmitting beads which are pivotally connected to each other and to a tubular handle at one end. At the other end a length of cable extends through a fixed metal driver ball to a metal retainer bead at the end of the cable. A barrel-shaped dent ball is strung on the cable for movement between the driver ball and retainer bead for impacting motion by reciprocation of the handle when the dent ball has been lodged underneath the dent to be removed.

Abstract: A large size barrel-shaped dent ball for removing dents in curved and tapered tubing having a diameter between 21/2 and 41/2 inches such as a tuba. The ball is constructed with a hardwood core and a steel band about the center portion of its length. An axial steel tube is also inserted in the hardwood core to facilitate use and removal of the ball from the tube. This composite structure reduces the overall weight so that the ball can be manipulated during use. A cable tool on which the dent ball can be strung between two metal impact balls is also presented. Reciprocation of the cable provides repeated impact of a metal impact ball against the barrel-shaped dent ball to drive the dent ball under and past the dent in a dent removal and tool retrieval direction.

Abstract: A lock tab wrench for removing lock tabs from the shafts of outboard motors, which lock tab wrench includes a handle, a fulcrum extending from the underside of the handle, a threaded allen screw tip projecting from the fulcrum and a shaped hook pivotally mounted on the end of the handle opposite the fulcrum. The hook is provided with a projecting hook retainer at the extending end, which hook retainer is designed to engage the bent tabs on a lock tab seated on the propeller shaft inside the propeller hub and straighten the tabs in order to facilitate unthreading the shaft nut from the motor shaft.

Abstract: A punch for setting a rivet has features to prevent swelling of the rivet between the two members being secured together. The punch has an elongated, solid blow transmitting member with a blow receiving surface and a shank. A sleeve is slidingly carried by the shank and movable from a position protruding past the lower end of the shank. The sleeve has a sidewall with at least one elongated slot extending therethrough. A pin is secured in the shank and extends laterally outward from the shank into the slot to retain the sleeve. A spring urges the sleeve downwardly.

Abstract: A die particularly adapted to drive a rivet, where the head of the rivet has a relatively steep circumferential side surface. The die engages the rivet head in a manner that initially the middle portion of the die driving surface exerts substantial force into the shank portion of the rivet, after which the die driving surface comes in greater overall driving engagement with the entire rivet head. Further, the die has a circumferential lip which limits lateral movement of the die relative to the rivet head.

Abstract: A method of aligning a spring vehicle door without removing the door from its hinge and door frame comprises opening the vehicle door, positioning a prying tool having a head member for engaging the hinge between the door and door frame, engaging a portion of the hinge in the head member, and rotating the tool in a direction of closure of the door so as to bend one of the hinge and door frame to a predetermined alignment position. A vehicle door aligning tool for carrying out the aforementioned method comprises a specialized form of handle and head member. The handle is arranged to extend laterally behind the vehicle door when the head member is fitted on the hinge. The handle includes an elongated handle portion and a relatively much shorter end portion obtusely angled from the handle portion. The head member is J-shaped to define a channel normal to the handle portion for receiving an exposed margin or flange of a vehicle door hinge mount to rigidly engage the hinge mount.

Abstract: A tool for applying the margins of a metal foil strip which is adhesively bonded to the edge of a glass article onto the broad surfaces of the article comprises a handle having a pair of elongated arms merging into the handle and extending therefrom to straddle the edge of the article. The flanks have guide surfaces inclined to the longitudinal dimension of the tool to ride upon the edge of the article and surfaces which press the marginal portion of the strip onto the broad surfaces of the glass.

Abstract: A broach specifically adapted for use in the final sizing of valve guides having a pilot, broaching surface and shank fabricated from a single piece of tool stock. The radius of the broaching surface, measured along a line perpendicular to both the longitudinal axis of the broach and a tangent to the broaching surface, is between 0.375 and 1.0 inches.

Abstract: A process for preparing a cathode assembly comprising forming a hanger assembly by inserting an electrically conductive metal hanger core having a curved cross section into a metal tube jacket having a rectangular cross section such that the sides of the metal tube are displaced outward by the outer surface of the hanger core, effecting good electrical contact between the hanger core and the metal tube jacket. One edge of a metal sheet is rigidly attached to the metal tube jacket along its length, perpendicular to the tangent of the outer surface of the metal tube jacket. The cathode assembly produced according to this process has utility in a wide variety of electrolytic manufacturing processes, especially in the electrolytic refining of copper.