Fig. 2912Fig. 2912.
Fig. 2912.
Fig. 2913Fig. 2913.
Fig. 2913.
Fig. 2914Fig. 2914.
Fig. 2914.
Fig. 2915Fig. 2915.
Fig. 2915.
Fig. 2916Fig. 2916.
Fig. 2916.
To forge a turn buckle, such as inFig. 2912, we bend two rings, such as inFig. 2913, and weld into the open ends a piece as shown inFig. 2914, on the opposite side a recessa,Fig. 2915, is cut out to receive a second piece, which being welded in the work appears as inFig. 2916, and the end may be drawn taper. Two such pieces welded together obviously complete the job.
Fig. 2917represents a yoke for the slide valve of a steam engine or a locomotive, which may be forged by either of the following methods:
Fig. 2918represents a stemawelded into the barb, which may be bent to the required rectangle and welded at the ends.
A second method is to jump the stemdand split it open as in the side view inFig. 2919. The bareis forged with a projecting piece to go in the split ofd, and after the weld is made, bareis drawn to size as shown, leaving the two projectionsxwhere the corners are to come, which is necessary in order to have sufficient stock to bring the corners up square. The ends ofeare split open as in the end view atf, and a piecegis then welded tof.
In a third method the end of the stem is rounded for the weld, as shown inFig. 2920. The ends of the barjare then split open and piecekwelded on.
It is to be observed with reference to the two last methods that in hammering to forge the weld the frame is closed, so that after welding the swaging to finish may be carried on until the frame is brought to square, and any superfluous metal may be cut away; whereas if the kind of weld is such as to stretch the sides, it may happen that to get a sound weld will stretch the side welded too long and throw the frame out of shape.
Suppose, for example, that a scarf weld were made on the side of the yoke opposite to the stem, and if, in welding, the scarf is hammered too much, it would draw it out too much and throw the whole frame out of shape, as inFig. 2921, so that the welded side would require to be jumped to bring it back to the proper length again.
A fourth method is to take a piece of iron and punch a hole in it, and then split it open up to the hole, as inFig. 2922, and by opening out the split form the stem and part of the frame out of the solid, forging the remainder of the frame by the plan described for either the second or third methods.
A fifth method is to make the weld of the stem as inFig. 2923, then forge out the barb, leaving projectionsx xto bring the cornersy yup square, and after bending to shape and squaring up to weld in a piecec.
A sixth method is to form the band first as inFig. 2924, form the stem as inFig. 2925, and weld as inFig. 2926.
Fig. 2927Fig. 2927.
Fig. 2927.
Fig. 2928Fig. 2928.
Fig. 2928.
Fig. 2929Fig. 2929.
Fig. 2929.
Figs. 2927,2928, and2929represent a method of forging a fifth wheel for a vehicle. A rectangular piece of Norway iron is fullered to form the recess atcinFig. 2927. Holes are then punched athand splits are made to the dotted lines shown in the figure. The ends are then opened out, forming a piece such as inFig. 2928. The letterarepresents the same face of the work in all the figures, being the edge inFig. 2927, and the top face after the ends are opened out. The four arms may then be dressed to shape, the two lower ones being drawn out and threaded before being finally closed to shape. A piece may then be welded on one end, as atb, to complete the circle.
Fig. 2930Fig. 2930.
Fig. 2930.
Fig. 2930Fig. 2931.
Fig. 2931.
Fig. 2932Fig. 2932.
Fig. 2932.
To forge a double eye, such as inFig. 2930, we may take a piece of sufficient size and fuller ata a,Fig. 2931; a hole is then punched atb, and it is then split through to the dotted line inFig. 2931, and opened out as inFig. 2932, and then forged to shape.
Fig. 2933Fig. 2933.
Fig. 2933.
Bending.—Fig. 2933represents a tool for bending pieces of small diameter to a short curve, either when cold or heated. In bending hot iron it is advantageous to confine the heat as closely as possible to the part to be bent, as a more true bend may then be obtained.
Fig. 2934Fig. 2934.
Fig. 2934.
Fig. 2935Fig. 2935.
Fig. 2935.
Fig. 2936Fig. 2936.
Fig. 2936.
As an example in bending, let it be required to bend a straight shaft into a crank shaft, and the following method (from “The Blacksmith and Wheelwright”) is pursued. The shaft is first bent as inFig. 2934. The piece is next bent as inFig. 2935, and finally as inFig. 2936, the cornersa aandb bcorresponding in all the figures.
Fig. 2937Fig. 2937.
Fig. 2937.
Blacksmith’s Bending Blocks.—In cases where a great number of pieces of the same size and shape are required to be bent during the forging process, a great deal of time may be saved and greater accuracy secured in the work by the employment of bending devices. Thus, inFig. 2937is shown ataa clip requiring to be bent to the shape atb. A pair of tongs is provided with a hole atcto receive the stem of the clip, and the jawdis made of the necessary width to close the ends of the forging upon. It is obvious that the holecbeing in the middle of the width of the tong jaw, the wings will be equidistant from the pin.
Figs. from2938to2943represent bending devices.
Fig. 2938Fig. 2938.
Fig. 2938.
Fig. 2939Fig. 2939.
Fig. 2939.
Fig. 2940Fig. 2940.
Fig. 2940.
Fig. 2941Fig. 2941.
Fig. 2941.
Figs. 2938,2939, and2940, represent a “former” for a stake pocket for freight cars.ais a cast-iron plate having a projectionb, around which the stake pocketcis bent.dis fast upona, and affords a pivoted joint for the bending leverse f. The work is placed in the former as shown inFig. 2939, and leverse fare swung around to the position shown inFig. 2938. To enable the work to be put in and taken out rapidly and yet keep it firmly against the end ofb, a hand-piecegis used as inFig. 2940, its form being more clearly shown in the enlargedFig. 2941. Sufficient room is allowed betweenbanddto admit the work, and the end of the pieceg, which is pressed in the direction denoted by the arrow inFig. 2940, forcing the work againstb. A number of the pieces are piled on the fire so as to heat them sufficiently fast to keep the former at work, and the bottom piece is the one taken out.
The corners of the work are by this process brought up square and the faces are kept out of wind. The surfaceaforms a level bed. These advantages will be readily appreciated by all smiths who have had comparatively thin work to bend to a right angle in the ordinary way.
Fig. 2942Fig. 2942.
Fig. 2942.
Fig. 2943Fig. 2943.
Fig. 2943.
Figs. 2942and2943represent a similar former for the step irons of freight cars. InFig. 2942the piece is thrown in place ready to be bent, its ends being fair with the linesj kon the bending leverse f. InFig. 2943the levers are shown closed and the workctherefore bent to shape. The bed platesaare mounted on a suitable frame to raise them to a convenient height for the blacksmith.
Forging a Stable-fork.—In the manufactories where stable and hay forks are made, the whole process of forging is done under the trip hammer, and is conducted asfollows:—
Fig. 2944Fig. 2944.
Fig. 2944.
Fig. 2945Fig. 2945.
Fig. 2945.
Fig. 2946Fig. 2946.
Fig. 2946.
Fig. 2947Fig. 2947.
Fig. 2947.
Fig. 2948Fig. 2948.
Fig. 2948.
Fig. 2949Fig. 2949.
Fig. 2949.
To forge a four-tined fork, such as inFig. 2944, a blank piece of steel is employed, its dimensions being 53⁄4inches long, 73⁄4inches wide, and1⁄2inch thick. The first operation is to swage down one end, as atainFig. 2945. A split is then cut down as atbinFig. 2946. The split is then opened out as inFig. 2947, and is fullered and drawn out atc. Two more splits are then made atd d, and the ends are bent open as inFig. 2948, when the four tinese eandf fare drawn out and shaped out. The stem,a,Fig. 2945, is then finished for the handle.
Fig. 2950Fig. 2950.
Fig. 2950.
Fig. 2951Fig. 2951.
Fig. 2951.
Fig. 2952Fig. 2952.
Fig. 2952.
Fig. 2953Fig. 2953.
Fig. 2953.
Fig. 2954Fig. 2954.
Fig. 2954.
The following example of forging under the hammer is derived fromThe Engineer, of London, England.Fig. 2950shows thepiece to be forged. A block of iron,Fig. 2951, is drawn out as in the figure, the dimensions ofaandbbeing considerably above the finished ones. A forked toolt,Fig. 2952, may be used to nick the two grooves shown inFig. 2953, which marks the locations for the hub and forms a starting guide for the two fullering tools shown inFig. 2954, one of which is held by the blacksmith and the other by the helper. After this fullering the forging will appear as inFig. 2955. The endse,fmay then be drawn out, having the shape as inFig. 2956. To shape the curve between the side of the hub and the body of the stem, grooves are formed as inFigs. 2957and2958,yandbbeing top and bottom half-round fullers, and these two grooves are subsequently made into one by means of larger half-round fullers, as inFig. 2959. The object of making two small fullered grooves and then making them into one is to prevent the fullering from spreading the body of the stem by lessening the strain due to using a large fuller at once. The piece now appears as inFig. 2960.
Fig. 2955Fig. 2955.
Fig. 2955.
Fig. 2956Fig. 2956.
Fig. 2956.
Fig. 2957Fig. 2957.
Fig. 2957.
Fig. 2958Fig. 2958.
Fig. 2958.
Fig. 2959Fig. 2959.
Fig. 2959.
Fig. 2960Fig. 2960.
Fig. 2960.
The next operation is to cut or punch away the metal between the ends of the hub and the body of the piece, which is accomplished as follows:
Fig. 2961Fig. 2961.
Fig. 2961.
Fig. 2962Fig. 2962.
Fig. 2962.
A top and bottom die and block are made to contain the work, as inFig. 2961,aandbbeing the work ends. Through these dies are two holes for two punches which are driven through together as marked; the dies are held fair, one with the other, by four holes in the lower and four pins in the upper one, a section and top view of the dies being shown inFig. 2962.
Fig. 2963Fig. 2963.
Fig. 2963.
The piece is at this stage roughed out to shape all over, and may be finished between the pair of finishing dies shown inFig. 2963, which also represents a plan and sectional view,a,b,c,dbeing the holes to receive guide pins in the upper die.
An excellent example of forgings in Siemens Martin steel is givenin the following figures, being the rope sockets for the Brooklyn Bridge.
Fig. 2964Fig. 2964.
Fig. 2964.
Fig. 2965Fig. 2965.
Fig. 2965.
Fig. 2964represents two views of the forgings, and it will be readily perceived that they are very difficult to make on account of the taper hole, which is shown in dotted lines. The first operation was to take a bar of steel 61⁄2inches square and punch a hole, as ataFig. 2965.
Fig. 2966Fig. 2966.
Fig. 2966.
Fig. 2967Fig. 2967.
Fig. 2967.
Fig. 2968Fig. 2968.
Fig. 2968.
Next the piece was fullered atb,cby the fullera,Fig. 2966, and cut partly off as atd. The fullering atbwas then extended by a spreading fuller, shaped as atb, and the endewas drawn out. Then the piece was cut off atd. Next the spreading fuller was applied toc, and the forging appeared as inFig. 2967. The endfwas then drawn out, and the appearance was as inFig. 2968.
Fig. 2969Fig. 2969.
Fig. 2969.
The next operation was to enlarge the holea,Fig. 2965, by drawing taper mandrels through it, the mandrels being about 7 in. long, having1⁄2-in. tapes on them, and being successively larger. With the last of these mandrels in the hole the hub was drawn out to length and diameter, leaving the forging roughly shaped, but having the form shown inFig. 2969.
Fig. 2970Fig. 2970.
Fig. 2970.
To finish the hole the forging was then placed in a block such as shown atg, inFig. 2970, a finishing punch being shown athin the figure.
Fig. 2971Fig. 2971.
Fig. 2971.
The next operation was to let the steam hammer down upon the face of the punch and bring up the wingse fparallel, but not more than parallel, as then the mandrel could not be got out; the forging then appearing as inFig. 2971.
Fig. 2972Fig. 2972.
Fig. 2972.
The next process was to put in a bar mandrel such as shown inFig. 2972ati, the piecesj,kfitting on their sides to the mandrel and being curved outside to the circular and taper shape of the hole. The wingse fmay then be closed on the mandrel to their proper width and the whole hub end being trimmed by hand, all the previous work having been done under the steam hammer. Thehub being finished the keymmay be taken out and the washerltaken off, whenican be pulled out, leavingj kto be taken out separately. A pair of tongs are then put through the finished hub end, while the wings are punched and trimmed under the steam hammer, and subsequently finished by hand.
Fig. 2973Fig. 2973.
Fig. 2973.
Fig. 2974Fig. 2974.
Fig. 2974.
The forging of wrought-iron wheels for locomotives is an excellent example. The spokes are first forged in two pieces, as 1 and 2 inFig. 2973, and then welded to form the complete spoke. Piece 1 is first forged in dies under the steam hammer to the form shown inFig. 2974, the dimensions being correct when the faces of the dies meet. The studc dis then drawn out to the required length and dimensions.
Fig. 2975Fig. 2975.
Fig. 2975.
Fig. 2976Fig. 2976.
Fig. 2976.
Fig. 2977Fig. 2977.
Fig. 2977.
Fig. 2978Fig. 2978.
Fig. 2978.
The upper half of the spoke is first blocked out under dies to the shape shown inFig. 2975, and the blockbspread so as to form a section of the wheel rim, as shown inFig. 2976, in whichdis a die,la movable piece wedged up by the wedgesw w, and removable to enable the extraction of the forging, andfis an end view of the fuller, the use of which is necessary to cause the metal to spread sufficiently in the direction of the dotted lines. The corners of the rim are then cut off, as shown inFig. 2973, and the rim is bent in a block having its top face of the necessary curve, as inFig. 2977,abeing the block, andba piece movable, to allow the extraction of the work, and fastened in place by the key or keysc. The two pieces are then welded together, their lengths, &c., being gauged by a sheet-iron template, formed as inFig. 2978. The welding is usually performed with sledge-hammers, but as soon as the pieces will hold well together, the drawing down is done under a steam hammer.
Fig. 2979Fig. 2979.
Fig. 2979.
The spokes thus forged are then put together, as inFig. 2979,brepresenting a wrought-iron band, encircling the rim of the wheel and closed upon the same by the bolt and nut atn.
Fig. 2980Fig. 2980.
Fig. 2980.
Two washers are then forged, to be placed and welded in as atw w, inFig. 2980.
The welding together of the spokes and of the washers to the spokes proceeds simultaneously. The washers are heated to come to a welding heat at the same time as the wheel hub is at a welding heat, and the two are welded together under a steam hammer. During the heating of the wheel hub, however, the bandb,Fig. 2979, is tightened up with the screw to bring the spokes into closer contact when heated to the welding point.
Fig. 2981Fig. 2981.
Fig. 2981.
The seams between the spokes at the circumference of the hub are welded with bars as shown inFig. 2981, in whichr rare two bars of iron which are operated by hand as rams. The wedge shape of the washers on their inside faces performs important duty in spreading the metal as well as simply compressing it,giving a much more sound weld than a flat washer or plain dish would.
The rim of the wheel is welded up as follows:
Fig. 2982Fig. 2982.
Fig. 2982.
InFig. 2982are shown four spokes of the rim as they appear after the hub is welded. Into theVspaces, asa,b,c,d; wedges of metal, of the form shown ate, are welded, after which the surplus metal ofeis cut away, and the rim is solid as atf. In this process, however, it is necessary to weld all the pieces on one side of the wheel, as ata b, &c., except one, which must be left unwelded until all the pieces save one on the other side are welded, and the wheel must be allowed to become quite cool before these last two pieces are welded. Otherwise the strain induced by the contraction of the wheel rim while cooling will often cause the rim to break with a report as loud as that of a rifle. In those cases in which this breakage does not occur the wheel will be very apt to break at some part of the rim, when subjected to heavy shocks or jars.
TheFigs. 2983to2999(which are taken fromMechanics), illustrate the method employed to forge the rudder frame of the steamshipPilgrim.
Fig. 2983Fig. 2983.
Fig. 2983.
A side elevation of the rudder frame is shown inFig. 2983.
The forging is made in eight separate pieces, which are so united as to make three pieces. These three pieces are finally joined by five welds. The whole length being 29 feet 113⁄4inches, and the weight 6,500 pounds.
Fig. 2984Fig. 2984.
Fig. 2984.
Fig. 2985Fig. 2985.
Fig. 2985.
Fig. 2986Fig. 2986.
Fig. 2986.
Fig. 2987Fig. 2987.
Fig. 2987.
Fig. 2988Fig. 2988.
Fig. 2988.
Fig. 2989Fig. 2989.
Fig. 2989.
The work is commenced by piling and welding on the porter-bar at the point in the shaft markeda. The stubsbandchaving been previously prepared, the pile on the porter-bar is heated and welded up and drawn, shown inFig. 2984, and scarfed as shown inFig. 2985; the piece, shown inFig. 2986, is then laid in the scarf and welded; then the part frombtoais finished to size, the finished forging of the post being shown inFig. 2984. The surplus stock to the right ofb,Fig. 2984, is worked down into the poste, and the distance frombtofis thus made correct without loss of stock or time. The curve atd,Fig. 2983, was worked down somewhere near, and then another pile and weld carries the job tog. Here the same operations as at first are repeated, and the armcis welded in. There is left a good lump of stock in front ofc, and by another pile and weld enough is added to make the job toi, as shown inFig. 2987. Holes are then punched atjandl, and the piece of stockmcut entirely out. A cut is made tolwith a hack opening out the piecenfrom the shaft. A taper punch, with a 3-inch point and a 4-inch head, is then driven atl; to throw the piecenout into the position shown atn1,Fig. 2983;n1is then finished, and the post fromltojbrought to forging size; then, by the ordinary process of piling, welding and drawing, the shaft is finished fromitoo. Next the porter-bar is cut off, so as to leave stock enough to make the lower part of the shaft, as shown inFig. 2988. A hole was punched atq, and the stubs drawn out, as shown inFig. 2989, which gives the post complete.
Fig. 2990Fig. 2990.
Fig. 2990.
Fig. 2991Fig. 2991.
Fig. 2991.
Fig. 2992Fig. 2992.
Fig. 2992.
Fig. 2993Fig. 2993.
Fig. 2993.
Fig. 2994Fig. 2994.
Fig. 2994.
The piecessandt, and the tillerv, having been forged, as showninFig. 2991, the upper member of the frame is started on the porter-bar atw,Fig. 2983, and filed, welded and drawn to make the job as far asx1. Wooden templates, such as inFig. 2992, are provided for the pieces of the frame, the first extending fromwtox1andx, and the second including the part fromx1tox2andx3. Afterw,x1has been drawn out with lumps left where the tiller and the armsare to be joined, the scarf is made for the tiller and that is welded in, and the job finished to pieces. The scarf forsis then made, andswelded in. This makes the upper member of the frame. The lower member is made in the same way, starting atx3. These two members are shown complete inFig. 2993. The post,Fig. 2989, was sent to the machine shop, and was turned, planed, bored, and slotted, as shown inFig. 2990. The frame was now ready to be pieced up, by welds atw,x,x1,x2, andx3,Fig. 2983.