l^resenUb to ®t|£ |Stfararg of % ^ntUersttg of ©arnnto The Office of the Late Dr. H.A. Gates / Digitized by the Internet Archive in 2007 with funding from IVIicrosoft Corporation http://www.archive.org/details/dropforgingdiesiOOwooduoft FIVE GOOD PRACTICAL BOOKS By JOSEPH V. WOODWORTH These are practical shop books for all interested in accurate tool and die making, steel treatment, drop fora;inp, die sinking-, power presses and modem shop practice In the production of duplicate metal parts. Dies: Their Construction and Use for Modem Working of Sheet Metals. This is the only practical, authoritative book for the die maker and power press user. - - - - - - - Price $3.00. Hardening, Tempering, Annealing and Forging of Steel. The most up-to-date book on steel treatment for the practical steel worker and the user of tempered steel cutting tools. - - Price $2.50. American Toolmaking and Interchangeable Manufacturing. A 20th century shop reference l>ook on the very latest toolmaking practice. Interchangeable manufacturing and machining of duplicate metal parts. Price $4.00. Punches, Tools and Dies for Manufacturing in Presses. A cyclopedia of die making practice, sheet metal formation in presses, and use of punches and dies. - - Price $4.00. Drop Forging, Die Sinking and Machine Forming of SteeL The only book published on these great branches of mechanical art and modern shop practice. A mine of practical information for the drop-forger, die sinker and steel parts manufacturer. ... Price $2.50. Power Presses : Their Feeds, Attachments and Safety Devices. If interested in this book, send us your name and we will send a descriptive circular of it, on publication. {In preparation.) S^^^y^iny of the above books sent prepaid on receipt of the price The Norman W. Heiiley Publishing Company 132 Nassau Street NEW YORK Drop Forging, Die Sinking and Machine Forming of Steel MODERN SHOP PRACTICE, PROCESSES, METHODS, MACHINES, TOOLS AND DETAILS A Practical Treatise on The Hot and Cold Machine-Fonuino of Steel and Iron into Finished Shapes: Together with Tools, Dies and Machinery Involved in the Manufacture of Duplicate Forgings and Interchangeable Hot and Cold Pressed Parts from Bar and Sheet Metal Comprising Die Sinking and Drop Forging Practice and Design for Modem Forging, Pressing and Stamping of Duplicate Parts . Die Sinking Methods, Processes, Macliines and Tools . , Drop Forging Dies: Their Design, Construction and Use in Drop Hammer and Forging Machine . Press Forming of Heavy Hot and Cold Stock in Dies . Drop Forging and Hardening Plants: Their Designs, Fundamental Conditions,and theEquip- ment Involved in Their Attainment . Steel and Iron: Their Treat- ment for Twisting, Reducing, Forging and Working in Drop Dies . Hot Pressed Steel and Iron Parts: Their Manufacture and Assembling into Finished Products . Drop Hammers: Their Development, Use, Weights, Foundations and Dies . Forging Machine, Steam Hammer, Bulldozer and Swaging Machine Methods and Processes . Machine Forging, with Examples of Modern Practice and Tools Involved. By JOSEPH V. WOODWORTH " Author of Dies: Their Construction and Use" etc. CONTAINING 300 ILLUSTRATIONS NEW YORK THE NORMAN W. HENLEY PUBLISHING CO. 132 NASSAU STREET 1911 Copyrighted, 1911, by The Norman W. Ilenley Publishing Co. 5745';0 ^3. a. S^ PREFACE In this work I have endeavored to produce a practical mechanical book, treating subjects comprehensively and thor- oughly, which until now have been strangely ignored by writers and compilers of practical works on the mechanical arts. Although I searched carefully, I was unable to locate any work of value, published in any language, which treated practically and understandingly the arts of Die-Sinking and Drop and Hydraulic Forging. Only in the mechanical pub- lications American Machinist and Machinery dad I find articles and illustrations on the subjects which appeared to me to be of sufficient value to live; and I here acknowledge my great obligation to both these journals for the valuable matter which I secured from their columns and have now embodied in the contents of this volume. I believe that the extensive development of the Die-Sink- ing art and the wide adaptation of Machine-Forging processes by all metal parts manufacturers, together with the meager- ness of published information on the practise involved, make a work of this kind necessary, timely, and valuable. The text of the treatise is concise; technical and ambigu- ous terms have been replaced by practical and familiar shop words; and all the illustrations and descriptions are plain and simple to understand. Thus, a -thorough comprehension of the information and data contained in this treatise by the greatest number is assured. The description of every subject and method involved has been boiled down to the simplest and fewest possible words; so that the **meat" of all may be arrived at and digested in the shortest time by the busy men of metals who will consult the pages following. 1 Z PREFACE The hot and cold shaping, squeezing, forming, and bend- ing of duplicate metal parts and high-speed steel cutting tools by forging in drop-dies, drop-hammers, steam-ham- mers, hydraulic presses, and forging-machines, are becoming more appreciated by the most adv-anced manufacturers and mechanics; but, until the publication of this work, to the average mechanic familiarity with the advanced shop prac- tise, tools, and processes has been denied, because of the al- most total lack of descriptive practical literature, and also the conservatism of manufacturers and experts in publishing their shop-practise and knowledge evolution. Therefore, to make possible among mechanics a broad and comprehensive knowledge of these arts I present this book, hoping it will find a valuable and permanent place in its field. Joseph V. Woodworth. Brooklyn, N. Y., January, 1911. —— CONTENTS Introductory Pages 7 to 10 CHAPTER 1 DIE-SINKING AND DROP-FORGING PRACTISE AND DESIGN FOR MODERN FORGING, PRESSING, AND STAMPING OF DUPLICATE METAL PARTS Drop-Forge Work—Materials for, and Life of, Drop-Forging Dies —Automobile Shop Drop-Forging Practise—Making a Die Tools Employed in Making Dies—The Lead Casting or Proof —Staking Tools Used for Repairing Dies—Examples of Drop- Forging Dies—Trimming Dies—Heating Furnaces—Harden- ing Drop-Forging Dies—Die Practise for Accurate Forging Method of Sinking a Drop-Forge Die—Micrometrical Forgings — Drop-Forging a Ratchet Drill Handle—Vanadium Forging Dies—Die-Sinking and Shop Practise in the Making of Cut- ting Tool-Holders for Machine Tools—Drop-Forgings on the Pacific Coast—Machining a Deep Forming Die—Dies for Finishing Bossed Levers—Sectional Dies—Materials Used for Dies—Principles of Drop-Forging and Stamping Large Parts Removal of Fin Produced in Drop-Forging—Difference Be- tween Treatment of Steel and Wrought Iron—Work with Holes P'langed Through It—Methods of Applying Impact or Pressure on Dies—Methods Used for Making Dies—Marking and Working Out Dies—Typing or Hubbing Process. Pages 11 to 61 CHAPTER II DIE-SINKING AND EMBOSSING PRACTISE METHODS, PROCESSES, MACHINES, AND TOOLS Making Forces for Embossed Work—Properly Made Forces—Dif- ferent Shaped Forces—Steel Forces for Flat Work—Copper and Brass Forces—Cutting the Impression in Die-Sinking—Riffles and Their Use—Drilling Out the Stock—Using the Breaking- Out Chisel—The Champney Die-Sinking Process—History and Evolution of the Process—Modeling, Casting, and Drop- ping—Driving Model Into the Die—Heating and Hardening of the Dies—Exactness of Size of Dies— Final Development of Champney Process—Die-Sinking Machines —Closed and Open Dies for Forgings—Value of Modern Machinery Prevision and Supervision—Hob for Making Forging Dies. Pages 62 to 93 — CONTENTS CHAPTER III DROP-FORGING DIES, THEIR DESIGN, CONSTRUCTION, AND USE IN DROP-HAMMER, DROP-PRESS, AND FORCING-MACHINE Combination Drop-Dies—Union Between Metal Parts—Die-Blocks and Impression-Blocks—Making Die to Resist Wear— Keying Wide-Seat Dies— First Principles in Holding-Dies— Bolt- Heading Dies—Forging-Press Dies for Making Hammers Saving Unnecessary Movements—Making a Double-Paced Hammer—Tfie Finishing of the Dies—Few Dies Needed for Forging-Press—Set of Tools for Forging a Fulcrum Bracket Forging Dies for "Pin-Ends" — Forging Dies for Round and Square Upsetting—Drop-Forging Dies for Gun-Work—Unusual Job of Drop-Forging—Trimming Wrench Blanks in Dies Trimming Cheap Hardware—A Slab-Truck for Forge-Shop The Possibilities of Planing-Tools for Finishing Forgings Work on Hand-\'ise Forgings—Forging Under Steam-Hammer —Forging Large Pieces—Drop-Hammer Forging—Drop-For- ging or Squeezing—Setting the Dies—Accurate Forgings Forging High-Grade Steels—Effects of Alloying Materials Hydraulic Press Gives Best Results—Heating Too Suddenly. Pages 94 to 138 CHAPTER IV DROP-FORGING AND HARDENING PLANTS: —DESIGNS, FUNDAMENTAL CONDITIONS, AND EQUIPMENT INVOLVED IN THEIR ATTAINMENT The Drop-Forge and Hardening Plant—Drop-Forge and Hardening Departments Under One Roof—Location of Die-Sinking De- partment—Board, Steam, Helve, Trip, and Drop Hammers Plan of Modern Drop-Forge and Hardening Plant—Layout of Hardening Department-—Advantages of Oil Puel— Refitted Coal-Forges and Furnaces for Fuel-Oil—Arrangement of Pi- ping—Finishing Department—Oil-Burning Forges and Heaters —Single and Double Opening Forge Furnaces—Top-Slot and End-Heating Forges—Installation of Forges— Burners—Brazing Furnaces—Heaters Pages 139 to 162 CHAPTER V DROP-HAMMERS: THEIR DEVELOPMENT, WEIGHTS, FOUNDATIONS, AND DIES The Development of the Drop-Hammer—Counterbalanced Treadle —Compound Lever Device for Operating the Lifting or Head Mechanism—Jointed Swinghead Construction—Paper Pulleys — CONTENTS 5 —Method of P'astening Board jn Hammer—Foundations Ratio of Base as Compared with Weight of Hammer—Founda- tions for Drop-Hammers—Drop-Hammer Effects—The Ambler Drop-Hammer — Securing Hammer-Heads — Hammer-Dies Improved and Up-to-Date Drop-Hammer—Capacity of Steam- Hammers and Size of Work— Rules for Finding the Capacity of Steam-Hammers, and the Horse-Power Required for Opera- tion—Development of Steam Drop-Hammers.