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Title: Dies and die making
Author: J. L. Lucas
Release date: November 7, 2026 [eBook #79940]
Language: English
Original publication: Providence: Journal of Commerce Co., 1897
Other information and formats: www.gutenberg.org/ebooks/79940
Credits: deaurider and the Online Distributed Proofreading Team at https://www.pgdp.net (This file was produced from images generously made available by The Internet Archive)
*** START OF THE PROJECT GUTENBERG EBOOK DIES AND DIE MAKING ***
[Illustration: A PRESS OF THE FUTURE. DRAWING UP BOILER SHELLS.]
DIES
AND
DIE MAKING.
BY
J. L. LUCAS.
_FIRST EDITION._
1897.
COPYRIGHT, 1897,
BY
J. L. LUCAS.
PRINTED BY JOURNAL OF COMMERCE CO., PROVIDENCE, R. I.
TO
ELISHA T. JENKS,
WHOSE EARNEST EFFORTS TO INSTIL A FEW MECHANICAL IDEAS
INTO THE BRAIN OF THE AUTHOR WERE MET WITH
BUT INDIFFERENT SUCCESS, THIS BOOK
IS RESPECTFULLY DEDICATED.
PREFACE.
In putting this work before the public, the author is well aware that
it will meet with criticism from those who are better informed on the
subject than he; but a careful search in the bookstores and through
the catalogues of the largest publishing firms failing to show a work
of this kind, has led him to take up the task; and, although better
fitted by experience for the file than the pen, has done the best that
he could. It is essentially a shop book, written by a shopman, and
intended for shop use.
Many of the dies shown were made by him personally, others were made
from sketches, and under his personal supervision, while others were
made and used in various pressrooms of which he had an intimate
knowledge; and the rest, especially those on bicycle tools, are from
the columns of the _American Machinist_ and other papers devoted to
mechanics.
Certain parts of these articles have been published in the columns
of the _American Machinist_; also a few pages can be found in the
catalogue of the Mossberg & Granville Manuf’g Co., which were
contributed by the writer.
Trusting this work may prove a help to the great army of die-makers now
pushing their way to the front, is the wish of
THE AUTHOR.
PROVIDENCE, R. I.,
_September 30, 1897_.
THE ORIGIN OF DIES.
The origin of dies is, without doubt, very obscure. Perhaps the
frontispiece in Mr. Oberlin Smith’s excellent work on “The Press
Working of Metals” will give as good a likeness of the original
die-maker as we shall ever find. A search in some of the best libraries
and museums has failed to reveal any information that is at all
ancient, and that can be relied upon. The samples of old coins that
have been handed down to us, show that the art of die-sinking was known
to the ancient Greeks at least eight hundred years before the Christian
era, but they do not show that the use of punches and dies was equally
well known.
The first record of punches and dies used in a machine or press (having
guides or ways to ensure the punch entering the die correctly) is
in the fifteenth century, when they were used in the manufacture of
hinges, by a German locksmith. Later on, in the sixteenth century, we
find them in use both in Germany and France; and as early as the year
1796 a patent was granted to one “De Vere,” of France, for dies for
punching and drawing of sheet metal.
In 1827, M. Gagalott took out a patent for press and tools for drawing
up cartridge shells from sheet copper. These were nearly the same shape
as those in use at the present time, and the dies were probably of the
same design.
In the article on “Drawing Presses,” on page 22, will be found a
history of the first drawing press made in this country, used for
drawing up kitchen utensils,--the facts of which can be vouched for,
and were related to the writer by one of the workmen employed, Mr.
J. L. Kirby, now superintendent of the Dover Stamping Co. The facts
relating to the use of drop presses for “striking up” sheet metal were
also obtained from the same source.
The author would be pleased to learn any facts relating to the use of
dies prior to that time, and would like to hear from any of his readers
on this subject.
PROPER SELECTION OF STEEL FOR DIES.
Steel intended for punches and dies should in all cases when possible
be ordered directly from the mill, giving all the information possible
as to the use to which it is to be put, and the class of work it is
intended to punch. The steel should be annealed at the mill, as the
extra cost is more than offset by the ease with which it is worked, and
the certainty with which it can be hardened.
Much of the trouble now experienced with die steel could be avoided by
this method, except that caused by improper heating by the smith in
hardening. Steel for dies should be free from seams and flaws and of
even color, not to be high in carbon (from .007 to .009 per cent. is
a good proportion) and capable of being hardened without shrinking or
changing its shape to any great extent, except in the case of drawing
dies, where this fault is a desirable one, as the die can be (when
worn) reduced to size by being re-hardened, thus increasing the amount
of work the die will perform.
When you have once found a grade of steel that you know to be suited to
your work, “stick to it” (and don’t be induced by a smart agent with
a box of cigars to give him an order even if he claims that he has a
brand that will not shrink or change in the least, and would stand any
degree of heat without injury). If you find that it is impossible to
get any one grade that will fill the bill for all kinds of dies, mark
each brand so that you or your men can tell at a glance what kind of
stock it is. A good way is to paint a stripe the whole length of the
bar, and a different color for each make or brand of stock. The stripe
the whole length of the bar, indicates the make no matter how short the
piece may be, and as shellac is usually the most abundant paint in the
shop, use red, black, and white shellac, and but three grades of steel.
For drop-press work for cold dropping, use a steel that is a little
high in carbon, and give the dies plenty of stock to avoid breakage.
For very large dies for drop-press work and where they are to be used
on thin stock, as tin or sheet iron, a die made of a steel casting and
case hardened will give good results. Where a large amount of labor is
necessary to produce the die as in the case of watch or clock dies, get
the best steel that can be found, as it is a poor policy to try and use
a poor grade of steel for intricate work.
MAKING A PLAIN PUNCH AND DIE.
Having found a brand of steel that is suitable for the work to be
punched it should first be machined to the proper size and shape, which
will depend on the class of work it is to do, and the style of die-shoe
it is intended to be used in. A good way, and one that is adapted to a
large class of work, is to bevel the edge of the bar to an angle of 10
degrees, leaving the ends as they come from the forge or saw. To get
out these blanks cheaply, cut the steel up into two or three lengths,
plane up and bevel the edges to the proper angle, and then saw off as
wanted to the required lengths.
This style of die can be held by a key or set-screws, whichever the
practice may be.
The upper surface of the die should be finished on the surface grinder
if there is one, or by hand with the use of the file and scraper, as
the time thus spent is saved in the laying out of the die, and the work
can be laid out better, and more distinctly than on the rough machined
surface of the blank.
The surface of the die is now covered with what the die-maker calls
“blueing,” but what is really sulphate of copper, and is made by
dissolving sulphate of copper or blue vitriol in water (a proportion
of ten parts of water and one of crystals makes a good solution), this
leaves a thin deposit of copper on the surface of the steel, leaving an
excellent surface for laying out the die. The outline of the piece to
be punched should now be traced on the upper surface of the die; care
should be taken in laying out to avoid waste of metal, also that the
grain of the stock to be punched runs in the proper direction so that
it can be easily prepared for punching. A margin equal to the thickness
of the metal to be punched must be allowed between the blanks, and if
the stock is ¹⁄₁₆″ or less, it is better to increase this proportion.
The die being neatly laid out from either drawing or template, all
round corners should be drilled with a drill of the proper diameter to
leave the corner the shape, and then reamed with a reamer of the proper
taper to give the die the clearance wanted; the rest of the stock is
now removed by drilling. Every die-maker has a way of his own for this
part of the work; one will drill so that the holes will cut into each
other and thus avoid broaching, while the next man will drill holes so
that there will be ¹⁄₃₂″ or more between them, and then cut out the
stock with a flat, square-ended tool called a “broach.” This is the
best and quickest way. The bulk of the stock being removed, if there
is a die-sinker in the shop, the die can be partially finished on it,
and by using a mill of the proper taper, the necessary clearance can be
given; this will vary from ¹⁄₄ to 3°. Excessive clearance is given when
it is essential that the blank should drop from the die before the next
piece is punched.
[Illustration: Fig. 2.]
The die being worked out as far as the machine will do it, is now
finished with the file, using the die square (Fig. 2) to give it the
proper clearance, and if the shape is an intricate one that must be
closely followed, a template made of thin sheet metal and soldered to
the end of a bent wire will be found a help in making the required
shape.
If the die is for a press room using a large number of dies, it should
be marked with a shelf and rack number, so that it can be quickly found
by the die-setter; the die is now ready to harden.
The die being finished, the blank for the punch, which, if the shape of
the die demands it, should be a forged one (but if possible, should be
cut from the annealed bar), should be machined on both ends, and one
end finished, then clamped firmly on to the face of the die, using a
die clamp (Fig. 3); now scribe through the die, and mark the outline
of the punch on the finished end of the blank. This should be nicely
marked with a centre punch. The stock can best be removed by the use of
a milling machine, as a base or shoulder, of the same shape but of a
larger area, can be more easily left with this tool than the shaper.
The object of this base is to give the punch better support, and
increase the length of time it can be used.
The stock having been removed close to the lines, the punch should
be placed over the die and then forced into it ¹⁄₁₆″, thus giving a
“witness” mark to file to. This is called “shearing in,” and is the
method usually employed in this country. The reverse of this operation,
known as the “French” way, consists of finishing and hardening the
punch, and then broaching out the die with it. The results obtained
by this practice are not as accurate as those by the first process
described, as the die will change to a greater extent in hardening,
than the punch, and it is not so easily finished. The punch should now
be carefully filed to the lines formed by the “shearing in” process,
and if the work requires it, should be hardened; but should in all
cases be left softer than the die. When possible, the punch and shank
should be in one piece, but if not, care should be taken to see that it
has a good bearing on the punch back, and is held firmly to it.
[Illustration: Fig. 3.]
[Illustration: Fig. 4.]
Fig. 4 shows a plain die for blanking out a tool that all are familiar
with. No stripper is shown, but the two holes at the back are intended
to hold one on.
The letter “C” denotes the brand of steel that the die is made of, and
is very useful in keeping a record of the results obtained from the
different brands of steel.
BLANKING DIES.
A set of blanking dies consist of a male die, or punch, and the lower
or female die; they are made in almost every form and size for cutting
out flat blanks from steel, iron, paper, mica, etc.
Usually both punch and die are hardened and tempered; sometimes the
punch is left soft, and as it gets worn, is set out and refitted by
being forced or shoved into the die; sometimes it is best to reverse
this operation, as in punching paper, playing cards, etc., and harden
the punch and leave the die soft.
A shear is usually given to the punch or die, determined by the work
it has to do; when it is intended to use the blanks, or pieces punched
out, the shear should be given to the die, as less distortion is
given to the metal by this method, but where the hole is the object
sought,--as in rivet holes in boiler plates, etc.,--the shear should be
given to the punch.
Cutting or blanking dies are usually held in a shoe or die holder, or
if a large die, it is fastened to the bed of the press direct, but as
a rule the fewer pieces intervening between the press and the die the
better results will be obtained.
Very large blanking dies are usually made in one of two ways; either as
rings set in a cast-iron holder, or by welding the rings directly on to
a wrought-iron holder or die plate; the latter method is the best in
making plain dies, but cannot be used in compound dies. The welding of
the steel rings together, and then on to the wrought-iron plate, calls
for good work on the part of the smith. Some of the finest work of this
kind we have ever seen is done at the works of the E. W. Bliss Co., at
Brooklyn, N. Y., large steel rings, both round and square, being welded
to wrought-iron beds or die-plates, and the joints so perfect they
could scarcely be detected.
In the former method the rings are first welded and then turned,
hardened, and ground true in the universal grinder, then set in a
groove turned in the holder as shown in the sketch (Fig. 9, page
20), and held there by being bolted from the back of the holder. The
distortion of these rings, caused by long use of the die, is something
that is hard to account for, the lower or die ring often being dished
to such an extent as to close in the top or cutting edge of the die so
much that it is necessary to grind it out and refit it to the punch,
a ring of 20″ diameter, and made of 2″ square steel, being out over
¹⁄₈″ on the bottom or lower edge; this is caused, it is thought, by
the strain left in the ring in hardening, and which is released by the
grinding of the die.
In making dies for hot work (as the blanking out of nuts and other
thick work from red-hot metal), a die made of chilled cast-iron, with a
good clearance, will give good results, as the temper is not affected
by the heat of the stock punched, the punch being made of steel and
fitting the die loosely (in very thick stock a difference of ¹⁄₁₆″ or
more in the diameter of the punch and die is not too much), and if a
nice job is wanted, the work can be shaved, or re-punched, as it is
called, by forcing it through a second die that is a trifle smaller
than the first, leaving a true and smooth surface.
In the re-punching of brass and copper, the use of buttermilk as a
lubricant will give a better result than any oil or soap water that
we have yet found. Dies for re-punching or finishing work are not in
general use to the extent that they would be if the saving that could
be effected by this method were well known. Many jobs now performed on
the milling machine could be re-punched, and better results obtained at
less cost than by the former method.
The power required to blank out a piece of metal depends largely on the
shape of the blank and the number of cutting inches in the die; a long,
narrow blank requiring more power than a round blank of the same area,
the shear of the dies being equal. If the work will admit of the face
of the punch being slightly rounding, less pressure will be required
than with a flat-ended punch.
The first thing to be considered to determine whether a punch and die
should be used to produce work, is the number of pieces wanted. If it
is standard work, and the demand is 100 or more per week, it is both
desirable and economical to have a die made, for after the die is once
made the work can be produced at a very low cost. Oftentimes when a
large number of pieces are wanted, and a power feed is used, the cost
will not exceed two cents per 1,000 blanks.
BENDING DIES.
[Illustration: Fig. 5.]
Bending sheet iron or wire can be done to good advantage in either drop
or power presses, and a few styles of dies suitable for this class
of work are shown. The one shown in Fig. 5 is intended for bending
any ordinary thickness of sheet metal or wire where a square bend is
wanted. It is known as a Universal bending die, and will be found very
useful, from the fact that it will do a very large range of bent work.
The different steps are for bending an angle near the end of a strip,
and for making bends of different depths.
[Illustration: Fig. 6. COMPOUND BENDING DIE.]
The second die shown is for bending up a loop in a wire shown by the
small sample at one side of the die. It will be found very effective in
making looped wire for armature connections, switchboard work or other
places where a looped wire is required. The wire is placed in the die
by hand, against a stop,--not shown in the illustration,--and as the
punch descends, the loop is bent down by the same, and as the end of
the punch strikes the bottom of the die the spring gives way and allows
the side benders,--to be forced in by the inclined wedges (formed on
the lower end of the two pins,)--to force the wire solidly against the
center punch, and as the punch rises the side bending jaws are carried
back by the wire itself which is removed from the punch by hand, the
end of the punch being ball-shaped to facilitate the removal of the
same. The loop just formed acts as a guide for forming the next loop,
the wire being moved along and the loop held against the stop (not
shown) while the second loop is being formed; and then this operation
is repeated indefinitely, according to the length of wire desired. This
is a very successful style of die, as it does in one stroke of the
press what would otherwise require a second operation.
[Illustration: Fig. 7.]
The third die, Fig. 7, is for bending the piece on the right-hand side
of the punch. This is blanked out by a previous operation placed in
the die by hand, and is bent as shown by the finished piece on the
left-hand side, which does not show it so clearly as it should. The
two sides of the blank are bent down, and the long one on the right
is curved around the punch shown, and the ring on the end is twisted
around to a right angle to the rest of the arm.
The punch is made from a single block of steel which is planed up to
fit the press, and then machined out as shown in the cut. The twister,
which is for turning the ring at right angles to the rest of the arm,
is counter-bored in and held in place by the quarter-inch pin driven
into the side, and which is held up by the spiral spring seen at the
upper right-hand corner of the sketch.
The die is self-contained as is used in an ordinary single-stroke
press, and requires no extra attachments to enable it to do the
work. This same principle can be used in many cases, and the bending
performed in one operation which would otherwise require two or more
strokes of the press.
COMPOUND DIES.
[Illustration: Fig. 8.]
A compound die is, as the word indicates, a compound of a die and
punch, or to speak more clearly, the upper half consists of a punch
set inside of a die, and the lower or bottom half of a die set into a
punch, the punch cutting the outside diameter of the blank, which is at
the same time pierced in the centre by the upper punch, thus finishing
a blank at one stroke of the press, that would otherwise require two or
more operations if done on plain dies.
The work from a die of this class is far better than when done by the
ordinary gang or double die, as the accuracy of the work depends on the
care with which the die is made, and not on the skill of the operator.
They are especially efficient when used on mica, paper and other
substances that do not admit of the use of a gang die; also on work
that must be practically perfect, for example--the blanks for watch and
clock movements, sheet-iron disks for electric armatures, and other
work where the relation of the centre or other holes to the outside
diameter must be perfect.
The invention of the compound die, and the adaptation of the same to
the finer grades of work, as watch and clock movements, is due to A. L.
Dennison, of Waltham, Mass., and was used in connection with the sub
press, also designed by him.
Though originally designed for the smallest work, the idea has been
extended, and it is now used for dies of the largest size, for both
light and heavy work. The die shown in Fig. 8 is a washer die,
intended for cutting washers out of scrap mica, the centre punch (A)
piercing the hole at the same time the outside is being cut by the die,
and as a perfect washer is punched out of scrap mica at each stroke of
the press, its advantages can be easily seen.
[Illustration: Fig. 9.]
The above illustration shows a method of making plain compound dies for
electrical work that will be found very serviceable--dies that can be
easily made and kept in order. The upper and lower cutting rings are
forged up and welded, finished in a lathe, and ground to size after
being hardened.
The centre punches are made from solid stock in the same manner. Both
inside and outside strippers are shown, for removing the scrap, and
are made from machine steel; the whole die is seated into a cast-iron
holder. The illustration shows the construction of the die so plainly
that further description is unnecessary.
[Illustration: Fig. 10.]
Fig. 10 is a sketch of the largest compound round die of which we have
any knowledge, but should any of the readers of this book know to the
contrary, we should be pleased to hear from them.
There are many dies containing more cutting surface, but in actual
diameter, we think this exceeds them; it is used for blanking
sheet-iron disks for the armatures of large electric railway generators
for street car service:
Outside diameter 45 in.
Inside diameter 25 in.
Weight of Punch 1,200 lbs.
Weight of die 1,100 lbs.
Cutting surface 290 in.
In work where the stock is too heavy to admit of the use of springs,
the press is fitted with a “knock-out” for the lower and upper dies,
thus doing away with the springs. The pressure required to strip a
complicated piece of work from the dies is very great; and a test made
with a die of 16″ diameter, and containing 274″ of cutting edge, the
force required was between 3,500 and 4,000 lbs.; thickness of stock,
.025″ sheet iron.
DRAWING PRESSES.
The use of presses for shaping or “drawing up” sheet metal is of
comparatively recent origin, and although it was not original with the
French mechanics, it was improved, perfected and first put to practical
use by them, for while evidence can be found of their being in use in
Germany in the sixteenth century, there are no details that are worth
publishing.
In 1796 a patent was granted to one DeVere, for a press and dies for
working sheet metal, and in 1827 M. Gazalott took out a patent for a
cartridge shell drawn up from sheet copper. These were nearly the same
shape as those in use at the present time, and probably the drawing
tools were of the same design as those now made.
In the early ’60’s, two French workmen came to this country bringing
with them a wooden model of a drawing press. This had been made from
drawings taken from a press upon which they had been employed in
France. This wooden press was secreted in a barn near the city of
Wilmington, Del., and was finally shown to Henry Marchand, who was a
brother-in-law of one of the men. Marchand, who was a mechanic of fine
ability, saw at once the value of the invention, and, as he afterward
expressed it, “would rather have seen the press than had five hundred
dollars in gold.”
Mr. Marchand at once started to raise funds to build and operate the
press, and after many delays a company was formed, known as the Higgins
& Marchand Co. Work was commenced on the press at Philadelphia, but Mr.
Marchand soon discovered that they were secretly copying each part of
the press as fast as it was made, and the parts of the half finished
press were taken to Wilmington, and finished at what was afterward
known as the Higgins & Marchand shop. It was set up in one corner of
the shop, which was boarded in, and only three men were allowed in
the room, to one of whom, Mr. J. L. Kirby, now Superintendent of the
Dover Stamping Co., Cambridge, Mass., the author is indebted for this
information. The press was a single-action cam press, the cam being
used to force the drawing punch through the die, the blank holder being
held down to the work with a 3,000 lb. weight which was worked by a
long 16′ lever, extending through the wall. The first piece of work
drawn up was a wash basin, made from a 14″ blank, and was probably the
first piece of drawn work ever made in America.
The second press was a great improvement over the first, the long
lever and weight being discarded, and side cams for the blank holder
substituted in its place. This press is still in use in the shops of
the Dover Stamping Co. The blank holder has been removed, and the top
hamper taken off; the press is now used for a few special jobs. No
punching was done on the press, as it was used for drawing only. It
had been in constant operation for nearly forty years, when it was
displaced by one of E. W. Bliss’s latest presses, about a year ago.
This is an authentic, if not an exhaustive, account of the origin of
the drawing press in this country.
There is one thing about drawing up a long shell out of a round blank
that is a puzzle. That is, if you draw up a long tube 1″ in diameter,
out of, say, a 12″ round blank, where does the edge of the blank go?
It is 36″ around that piece of metal when you start to work on it, and
only 3″ when you get through. Where has the 33″ of edge gone? “It is,”
as one of the boys said one day, “all crumpled up and drawn out into
the shell.”
DRAWING DIES.
Drawing dies may be divided into three kinds, plain drawing, or “push
through” dies, solid bottoms or “knock-out,” and combination dies.
These last named may be subdivided into single, double or triple
action, or the number of operations may be extended as far as the
ingenuity of the die-maker will carry him. In the private press room of
the Plume & Atwood shops at Waterbury, Conn., seven distinct operations
are performed on one piece of work before it leaves the press, the
stock being fed in automatically, and the work carried from one set of
dies to the next in the same manner. Such presses are only possible
when the work is to be done in large quantities, and the cost of the
press and dies is very great, three of the presses spoken of costing
nearly $30,000.00.
PLAIN DRAWING DIES.
[Illustration: Fig. 11.]
In sketch Fig. 11, we show a plain “push through” drawing punch and
die, the blank being punched out to fit the “set edge” and then “drawn
up,” or rather, it is pushed through the die by the punch, and as
the punch rises, the work is stripped from the punch by the “pull
off,” which is made very sharp for that purpose. A “draw” of about
one-quarter to one-half of a degree is given the die, making it that
much larger on the upper side or face, and the upper edge is rounded
over and left very smooth, and as hard as fire and water will make it.
“Don’t draw a drawing die.” The lower end of the punch is rounded and
left in the same shape; often the die will work better if the finish is
changed from a circular to a lateral polish. The diameter of the punch
is equal to that of the die, minus double the thickness of the stock to
be drawn. A die of this kind can only be used on shallow work, or in
redrawing or reducing the diameter of the work that has been previously
drawn up; if used on deep drawing it will pucker or crimp around the
edge. To avoid this, we must have a blank holder to hold the stock
firmly while it is being drawn.
SINGLE ACTION COMBINATION DIES.
[Illustration: Fig. 12.]
Fig. 12 shows a single-action cutting and drawing die, better known
as a single-action combination die. A combination die is, as the name
indicates, a combination of a drawing die and cutting die in one;
it punches the blank, and at the same stroke of the press, draws it
up into a cup or shell. The die shown is intended to be used in an
ordinary single-stroke power press, and will draw up work not over one
or two inches deep.
SOLID BOTTOM DIES.
[Illustration: Fig. 13.]
The die shown in Fig. 13 is the same general design as the previous
one, except that it is a “push back” or “solid bottom” die, and is used
for taper and flared work that could not be done in a “push through”
die, such as thimbles, taper ferules and lamp burner parts. The action
is the same as the “push through” style, except that the work is pushed
back by a “follow plate” worked by a “knock-out” attached to the press,
and so arranged, that, as the drawing punch rises from the work, the
“knock-out” strikes the plate pin and pushes the work from the die, and
is removed either by a swinging arm, or by the use of an inclined press.
DOUBLE ACTION DIES.
[Illustration: Fig. 14.]
A double-action die is a modification of a single-action die, to be
used in a double stroke press; it can be used on work that is too deep
for single-action dies. The one shown in the sketch, Fig. 14, is known
as a “push through” die. It is somewhat like the single-action die,
except that the shell is cut by the punch (B), and is carried to the
drawing die (D), and the lower surface of the die acting as a blank
holder is held there while the drawing punch (A) forces it through the
drawing die, and as the punch withdraws, the shell is removed by the
lower edge of the die, which is ground very sharp for that purpose, and
is known as the “pull off.” The drawing die is held in place by the
cutting die being clamped upon it by the ring (G).
This style of die has this advantage; the cutting and drawing dies are
independent of each other, and can be changed for a longer or shorter
shell, or either die can be repaired or replaced without changing the
other.
TRIPLE ACTION DIES.
[Illustration: Fig. 15.]
Triple-action dies are intended to punch, draw and stamp the work at
the same stroke of the press. The construction is the same as the
double-action, except that the die block (E) is cut away to allow the
stamping die (F) to be set in place, and the shell is carried down to
the stamping die and “struck up” between that and the matrix formed on
the end of the drawing punch; as the punch rises, the work is stripped
from the punch by the “pull off,” and is removed from the dies by
the use of an inclined press, or by a swinging arm attached to, and
operated by the press, that catches the work as it falls from the punch.
This style of die is largely used on blacking box covers, lard pail
lids, or other work where a stamped or embossed cover is wanted. A die
of this class should always be used in an arched press, as the strain
of the stamping process is very severe on the “open back” style press,
and is apt to crack the body of the press. In making a drawing die, use
a steel that is high in carbon, and if it shrinks a little in hardening
so much the better. There is on the market at least one grade of steel
which will stand three successive hardenings, and will shrink each time
so that the die as it wears out, can be “shrunk up” and then ground out
to size again.
Various modifications of a drawing die are necessary in order to
successfully draw up the different metals. Zinc works better when
the soap suds, or whatever lubricant may be employed, is used hot as
possible, as that metal works much better at a heat of about 125°.
In drawing up very delicate work where the nature of the metal is such
that the die is inclined to clog, or as the press hand calls it “copper
up,” the use of buttermilk will be found very effective.
In drawing very thick work the drawing die can be made bell mouthed, as
the thickness of the metal will reduce the tendency to crimp or pucker.
The same method of making the die is followed when it is desired to
draw a shell that is very short in proportion to its diameter.
The possibilities of what can be done by this method of forming up
sheet metal are almost unlimited, and the press of the future as shown
by the frontispiece, is not an exaggeration of what will be performed
at no distant day, as trunks, wheelbarrows, sinks and the copper boiler
for hot water service are every-day productions at the present time.
The great secret of drawing up work is to have good metal, and to
properly adjust the blank holder, so as to hold the metal just hard
enough to prevent it from puckering. In drawing up metal, always keep
one thing in mind, that is, that metal has some of the properties of
water, and it will flow where it can go the easiest. A grade of steel
which will harden good, a little knowledge of tool making, and a good
deal of experience are what is needed to make a good drawing die.
DROP PRESS DRAWING DIES.
[Illustration: Fig. 16.]
The use of drop presses for stamping and forming work is very ancient.
The first information of the drop press being used in this country was
in 1833, when the Dover Stamping Company was founded by Mr. Horace
Whitney, at Dover, N. H. They were used for making tinware, which
previous to that time had been formed up by hand. In 1847, Mr. Whitney
started manufacturing, using a number of tools of this kind, some
of which are still in existence at the works of the Dover Stamping
Company, now at Cambridgeport, Mass.
These presses are used where the nature of the work demands that it
shall receive a blow or force to enable it to retain the shape given it
by the dies, and which cannot be readily given in a power press. They
are also used for drawing up shells or cups in place of the ordinary
press, as the work can be done cheaper than by the use of the power
press, unless furnished with a roll or automatic feed. In the die
shown, Fig. 16, the blank is held in place by the “set edge,” and as
the punch comes down, the blank holder strikes the work and prevents
it from crimping while the punch compressing the rubber spring draws
the blank down into the die, and give it the shape desired. Drop dies
are also used for striking up work that has been previously drawn up in
the drawing press; also the bending and forming of both sheet metal and
wire. For important improvement in this class of tools see page 88.
JACK DIES.
[Illustration: Figs. 17 and 18.]
The illustrations show two methods of holding the upper die, or as it
is sometimes known in shop language, the “jack” or “pick-up” die; the
die being held by a taper shank which fits into the hammer of the drop,
or by the dovetail which is keyed into the slot.
The former method is best adapted to hammers of 100 lbs. weight or
less, and the latter to large dies or pick-ups. The under or face side
of the jack is scored across with two or more slots at right angles to
each other, and the face hardened. The lower die is made and finished,
and the blank for the upper die or force is heated to a cherry red,
and placed under the hammer which is brought down with all the force
that can be applied, driving the hot metal both into the slots in the
pick-up, and into the lower die, forming the punch or force, and at the
same operation attaching it to the hammer.
This seems to be a crude method of holding what is often a nice piece
of work, but careful search proves it to be the one universally
practiced in all sections of this country.
ARMATURE DIES.
[Illustration: Fig. 19.]
The phenomenal growth of the electrical industry in the last few years,
and especially in the use of notched or slotted sheet-iron disks for
the armature cores, has stimulated the invention and use of compound
dies of large diameter and complicated designs.
The modern armature resembles somewhat a gear that is built up of thin
sheet-iron plates or disks, usually about .010″ to .040″ thick, and
from 12″ to 100″ diameter. These are, in the best of armatures, punched
from sheet iron, with centre holes, keyway and the teeth, or, as they
are called, “the winding slots,” at one stroke of the press; the
smaller ones in a complete disk, the larger sizes in as large sections
as it is possible to procure the iron; and as some of the styles are
very intricate, the ingenuity of the die-maker has been taxed to the
utmost to produce what is wanted.
The method first adopted was to blank out the plain sheets, and then
put in the centre hole and keyway with a separate die. The sheets were
assembled on the shaft and turned to size on the lathe; the slots for
the winding coils were then cut in a milling machine, and the core was
ready to wind. It was soon found that the contact of the sheets caused
by the milling process was detrimental to the electrical efficiency
of the armature, and the use of a dial-feed press was adopted for
punching the slots before the sheets were assembled on the shaft.
This gave better results, except that irregularities of the punched
sheets required a good deal of filling to correct them, the effect of
which was the same as that caused by the milling process, except to a
less extent. This led to the development of compound dies that would
punch sheets so perfectly that they could be assembled on the shaft or
spider, and the armature wound without any further labor expended on it.
[Illustration: Fig. 20.]
Fig. 20 shows one of the latest designs of these dies, adapted for
use in an E. W. Bliss, No. 95 press, which comes nearer meeting the
requirements called for, than any other in the market. This press is
fitted with a “knock-out” capable of exerting a force of 5,000 lbs.,
thus obviating the use of springs in the lower stripper. The upper
stripper is also worked by a stationary “knock-out” attached to the
body of the press.
This die is a sectional one, is set into a steel casting, instead of
cast-iron, as is generally done. The rings “A,” “B” and “C” are of tool
steel hardened and ground to size, and the rest of the rings are left
soft.
These dies are invariably sub-pressed, as the utility of the die is
greatly increased by this process.
A die of this kind, well made, and run at a speed of 55 revolutions per
minute, operated by two men, will produce 4,000 to 6,000 20″ sheets per
day of ten hours, using 10,000 to 15,000 lbs. of iron.
The cost of these dies varies from $100.00 to $800.00 each, according
to design of the armature, and they weigh from 1,000 to 2,000 lbs. each.
[Illustration: Fig. 21.]
The above illustration shows a die for a small armature blank for fan
motor work; also a punching from the same. The die is a compound one,
sub-pressed by the use of four pins, two of which are shown in the
illustration.
The difficulties of making the die were such that, at first, it was
deemed impracticable; but the urgent necessity of getting out the work,
which was being done by the use of a dial-feed press, made it advisable
to make a trial of this method of punching.
The lower die was made precisely as shown by the punched blank, of a
piece of Styrian steel, which was carefully annealed, turned to the
required shape, drilled for the thirty-seven holes, and then slotted on
a milling machine and left soft.
The upper punch, or, as it really is, the die, was made in two pieces;
the inner punch hardened and ground and forced into place in the upper
casting, and the outer cutting die made in the same manner and seated
in a recess machined out concentric with the centre punch.
The knock-outs or strippers were made, the lower one in two pieces,
and then held together by the outer ring shown, which was forced
on, holding them firmly together. This knock-out was fitted with
thirty-seven pins of the same diameter as the holes in the disk, so
arranged that as the punch was withdrawn the scrap was forced from the
holes by the action of the spring shown in the illustration.
The upper knock-out, for removing the blank itself, was actuated by a
knock-out attached to the body of the press, and so arranged that when
the press reached the highest point of the stroke it was forced against
the plate shown in the centre of the upper part of the die.
The die was a success, and was run continuously, day and night,
producing several million sheets before being replaced by a new one.
NEEDLE DIES.
[Illustration: Fig. 22.]
The illustration, Fig. 22, shows a small die and holder which
is largely used in needle factories for punching the eyes of
sewing-machine needles, and is intended to be used in a press adapted
to that class of work. The die is a sectional one, made in three
pieces, the centre one projecting up above the surface of the two sides
and into the groove of the needle, thus supporting the latter while it
is being punched. This centre piece is cut out with a U-shaped slot,
the width of the slot being equal to the length of the eye of the
needle, the two blocks forming the sides of the die, and the whole held
firmly together by a set-screw not shown.
The press is so arranged that the needle is first clamped (not shown)
and then punched, the speed of the punch at the moment it enters the
die being very slow. The punches are made of Stubb’s wire about .080
diameter, milled down to a diameter equal to the length of the punch,
and are then hardened and the sides are ground in a special grinder. A
punch of .004 diameter is used on the finest needles, and a punch of
.008 to .010 is a common size in every-day use.
FLUID PUNCHES.
[Illustration: Fig. 23.]
The well known fact that water cannot be compressed to any great
extent, has led to the use of fluid punches for shaping and expanding
work that would otherwise be impossible to do in a press, and may be
used as a medium for conveying force, as in the case of a hydraulic
press, or the fluid may be applied directly to the work with or without
the use of a packing ring.
The illustration shows a die designed for shaping ice pitchers, and
intended for use in a heavy drop press, the die being made in two parts.
The pitcher is placed in the die, which is then closed and placed in
the clamp ring, force being applied by the plunger swelling out the
work to the shape of the die. A special preparation of wax is often
used in place of water or oil in connection with dies of this kind.
In presses used for the manufacture of hats, 800 lbs. pressure to the
square inch is applied to the work. The lower die which is of cast-iron
or spelter, is placed on the bed of the press and then brought up to
the water cylinder and locked. The water is then turned on and a bag
of thin rubber is expanded, filling the entire inside of the hat and
allowing the whole pressure of the water to come upon the material,
remaining some ten seconds, when it is removed the press unlocked and
the hat removed. When the water is applied directly to the work, it
is usually done in a drop press as the pressure can be applied very
quickly and but little packing is required. This method of press work
is also followed in the manufacture of silverware, or where it is
desired to swell the centre of the work to a diameter larger than the
end of the same.
RIVETING DIES.
[Illustration: Fig. 24.]
Where a large amount of riveting has to be done, the work can be
produced better on a riveting machine arranged to spread the head of
the rivet by a revolving heading tool than it can on a press, but
ofttimes it is desirable to do a limited amount on a press, and the die
shown will be found a very good one for the purpose. The illustration
is so plain that it explains itself. It is intended for bicycle chain
work, the upper and lower dies are made convex, and the rivets headed
by rapid reciprocating blows of the same. A stiff short stroke press is
necessary for riveting.
When a large number of holes are required to be riveted, and the work
is of a nature that it can be done at one blow, the drop press will be
found preferable. In a shop engaged in the manufacture of wrenches,
seven to ten rivets are headed at a single blow of the drop. On page 47
will be found an illustration of a die for imitation rivets, which, as
it is not really a riveting operation, is shown separately, that it may
not be confounded with the one just described.
GANG DIES.
[Illustration: Fig. 25.]
Fig. 25 shows a die intended for punching out a diamond shaped piece
pierced with four round and four triangular holes, and a square hole in
the centre. The die being a small one is made in one piece of steel.
Laying out of work of this kind required skill on the part of the
die-maker. Proper allowance must be made for the “creeping” of the
stock, also for the margin between the pieces punched. The large punch
should be fitted with a centre pin projecting into the square hole
which has been previously punched by the centre gang punch; the pin,
however, is not shown in the cut.
When the die is a large one, and especially if the holes or work is
round, it is preferable to make the dies separately, and then set them
into a cast-iron holder.
Gang dies are also used very extensively when a large number of blanks
of the same kind are wanted, also in punching rivet holes in tank or
boiler work, and making perforations in gas or lamp burners, as high
as 1,500 holes often being pierced at one stroke of the press. In work
of this kind it will be found advisable to have the stripper fit the
punches very tightly, so that it will act as a guide, and support the
punches while they are entering the stock. A good illustration of a
stripper of this kind is found on page 64.
SECTIONAL DIES.
[Illustration: Fig. 26.]
Dies of large sizes or of a difficult shape, can usually be made to
better advantage in sections, for in the former class the dies can be
separately made and tempered, and set in place in the holder, thus
forming a complete die, requiring less stock. Should a part be spoiled
in making or hardening, it can be easily replaced; whereas, in a solid
die, the whole would be spoiled.
Fig. 26 shows a method of making a small compound die in sections that
was adopted because it was found impossible to produce work that would
meet the requirements of the case, with the best solid die that could
be made. The pieces wanted were simply flat blanks of .014″ thin sheet
iron 2″ × 4″ in size, with ³⁄₈″ centre hole. A limit of .002″ was all
that could be given on the dimensions. A large number of these was
wanted, requiring the use of dies that must not vary over .002″ from
each other.
After many trials with solid dies, which failed on account of the
contraction caused by hardening, also by the changing of the die as it
wore out, on account of the clearance given, a die was made like the
sketch, the sides and ends of the die were made in separate pieces,
hardened and ground to size, and held in place by the shrink ring,
the centre punch “B” perforating the blank at the same time that the
outside is cut. No clearance was given to the die, as the work was
removed by a spring stripper, thus rendering the clearance unnecessary,
and enabling the die to hold its size until worn out. This style of die
gave such good satisfaction that it was used exclusively for this class
of work, and the extra cost of the die was more than offset by the
decreased cost of the work produced.
[Illustration: Fig. 27.]
Fig. 27 illustrates a large punch and die that was made sectional, from
the fact that it was impossible to get steel of the proper size for the
die, as soon as wanted. The punch and die were both made in sections,
and ground to a perfect fit after being hardened. The dotted lines show
the manner in which the joint was made. The results obtained from the
die, in cutting qualities and shape, were better than had it been made
solid. The size of the die was about 18″ × 20″, and the stock punched
was thin sheet iron. The labor cost of the work, though somewhat more
than it would have been for a solid die, was more than offset by the
saving in the amount of stock used. The die was set in a cast-iron
holder having eight lugs which were fitted with set-screws, forcing it
firmly together and making a solid die.
[Illustration: Fig. 28.]
Dies for armature sheets are almost invariably made in sections,
so arranged that each piece may be taken out and replaced without
disturbing the rest of the die. Fig. 28 shows some of the shapes made
in this style.
No. 1--A square sheet-iron disk with centre hole, also cut across the
side.
No. 2--A washer with a section cut out.
No. 3--A transformer sheet.
No. 4--A clock wheel blank.
No. 5 and 6--Armature sheets, punched at one stroke of the press, the
dies made in sections.
BURNISHING DIES.
[Illustration: Fig. 29.]
When a nicely finished piece of punched work is wanted, the piece is
first blanked out a little larger than the finished size and then
pushed through a die that is slightly tapered, that is, it is made
larger at the top or upper side. The cutting edge of the die is a
little smaller than the blank so that a shaving is taken off around the
edge, and then it is forced through the die, which is made very smooth
on the upper part. This leaves a finely finished surface on the edge,
and is used on work that would otherwise require milling or buffing,
such as bicycle chain links, and the large and small sprockets, for
finishing operations. The die shown is intended for finishing bicycle
links by the use of a dial feed. The centre hole is punched at the same
time the link is blanked, and is centered on the burnishing die by the
use of a pin that enters the hole and holds the links firmly while
passing through the die.
It is important that the inside of the die is made smooth, well
finished after being hardened. This style of die will, when made and
properly used, save a large amount of milling and buffing, and will
produce work that is uniformly accurate.
WASHER DIES.
[Illustration: Fig. 30.]
These illustrations show three distinct methods of producing washers,
each of which has its advantages according to the material used.
The compound washer die in Fig. 30 is used for thin work, and where an
accurate cutting die is wanted, for punching paper, mica, thin sheet
iron or brass. The illustration shows so plainly the method of making
the die that little explanation is necessary. The spring stripper
is used on the lower die, as it is called--which is in reality a
punch--and a spring shedder or knock-out for ejecting the blank from
the upper die. The advantage of a die of this kind is that the material
is pressed flat and smooth by the spring stripper before being cut,
thus giving a more perfect washer than can be made by any other method.
REVERSED WASHER DIE.
[Illustration: Fig. 31.]
The die shown in Fig. 31 is intended for thick washers, the punch being
made with an outlet through the shank of the same for the scrap from
the centre of the washer, the blank remaining in the die until it is
ejected by the shedder which is actuated by a knock-out motion applied
to the press. This die can be used for washers ¹⁄₄″ and ³⁄₈″ thick,
and will produce perfect work even when using scrap stock, which is
a difficult thing to do when using the gang washer die shown on the
following page. It is especially adapted to collars and ball cups for
bicycle work.
GANG WASHER DIE.
[Illustration: Fig. 32.]
This illustration shows a gang washer die intended for punching washers
of any description, and is the style ordinarily used. It is necessary
in using a die of this kind that one edge of the stock be straight, in
order that in feeding it may be kept firmly against the back gauge so
as to ensure its being properly fed.
Another method of producing washers may be described, and consists of
first cutting out the blank with a gang of punches, the press being
fitted with a roll feed, and punching 25,000 washers per hour, or from
one to two tons per day. These are then put through a second operation
for piercing holes in the same, the press being fitted with two dies
which are fed by tubes, the washer being carried to the bottom of the
tube and deposited under the centre of the punch which pierces about
200 washers per minute, or about one-half ton per day.
TRIPLE DIES.
[Illustration: Fig. 33.]
This illustration shows a die intended for slotting the ends of tubes
or other shell work, and is intended to be used in any ordinary power
press.
The dies are held by a hollow stud which fits the inside of the tube or
shell to be punched, the scrap passing into the cavity (A) and dropping
through the outlet below, left for that purpose; the punches being held
in the side carriers (B), which are driven by the inclined studs (C)
secured by the punch holder (D).
The die is self-contained, and can be removed from the press and set in
the die rack in the usual manner. The punches are straight pieces of
steel wire of the proper shape to fit the die, and are held in the same
manner as shown on page 51, Fig. 39, and not by the set-screws as shown
in the illustration.
The advantage of a die of this kind is the reduced cost of the work,
and the better results obtained, as it is impossible to get out
imperfect work if the die is properly made and used.
IMITATION RIVET DIES.
[Illustration: Fig. 34.]
The above illustration shows a die for imitation rivets intended to be
used on thin sheet-iron work, such as hoops for tubs and water pails,
tinware, attaching hinges to stove ovens, or other work of a similar
character.
The advantage of the die is, that no stock is removed from the parts
to be joined, and no rivets are required. The punch is driven through
the double thickness of stock on the first set of punches, and then
finished on the second set. The only object of the second set of
punches is to avoid turning the work over, as the operation could be
performed equally well on a single set.
It is not really a riveting operation, being more of the nature of an
eyelet than a rivet, but is described as such from the fact that it is
often used in place of solid riveting, especially on thin work, such as
pail hoops, band iron, and in putting handles on the cheaper grades of
tinware. The operation can be rapidly performed, and applied to many
classes of work not specified.
FOLLOW DIES.
[Illustration: Fig. 35.]
Follow dies, so called when two or more operations follow each other,
that is, the piece is first stamped, pierced and then blanked out.
Sometimes this order of operation is reversed and the piece is stamped
and cut off at the same time, the holes having been punched at a former
stroke of the press.
The illustration shows a die for making a clip, used for holding
armature binding wires, and will be recognized by many of our readers.
The stock is first stripped the proper width and fed into the dies by
hand and the finished clip is knocked off the die in the same manner.
The same idea can be used for a large variety of work. Slots or holes
can be punched in either or both ends of the blank, and any style of
bend can be made that does not exceed an angle of ninety degrees, and
where the depth of the bend is not more than three-eighths or one-half
inch.
The difficulty of making a long bend is that the cutting punch must do
the work before the bending die comes into use, and must necessarily
pass down into the die whatever the depth of the bend may be. The work
should be entirely cut off by the punch just at the moment it is struck
by the bending die, otherwise it will be apt to be moved from its
proper place, resulting in imperfect work.
ARMATURE LEAD DIE.
[Illustration: Fig. 36.]
The illustration, Fig. 36, shows a die intended for cutting and forming
a half-round piece, or, as it is called, a _lead_, which was formerly
in great demand for armature work. The stock is fed from the left of
the die, covering the small die shown in the bottom holder, and as the
upper die comes down the stock is trimmed on both edges and bent to the
shape shown, as the press reaches the full length of the stroke.
The piece shown at the right of the die is a gauge, and is supported on
pointed screws, held up by the springs in the centre, so that as the
upper knives come down it is depressed out of the way, but rises to its
place again as soon as the punch returns.
This idea can be used for a large class of die work, and requires no
attachments of any kind applied to the press.
TUBE BENDING DIES.
[Illustration: Fig. 37.]
[Illustration: Fig. 38.]
The illustrations show two methods of forming up a tube at one stroke
of the press, doing the work with a single operation.
The first of these, shown in Fig. 37, is published by permission of Mr.
C. H. Hardinge of Chicago, who gives the origin of the same as follows:
That he obtained the same from a die-maker of his acquaintance who
learned the trick from a tramping journeyman.
The second sketch is for the same purpose; the action of the dies are
the same; the method of construction being changed to obviate the
necessity of cutting out the deep slot shown in the first die.
These sketches are taken from the columns of the _American Machinist_,
and not having seen the same in practical operation, it is impossible
to state whether satisfaction equal to that obtained by the use of two
sets of dies can be had by their use.
HOLDING SMALL PUNCHES.
[Illustration: Fig. 39.]
Small punches always give more or less trouble from breaking and then
sticking in the punch back or holder. The method shown in Fig. 39 is
designed to overcome this difficulty. The punches which are straight
pieces of Stubb’s steel wire, are cut off and headed on the upper end
and hardened. The chuck, which is made with a removable collar, is
split in the centre, one side of which can be removed by loosening the
set-screw. The ease with which this can be done makes it unnecessary to
send the job out of the press room. The punches can be made and kept
in stock and renewed, and the punch replaced without the necessity of
removing the die from the press.
Small punches are broken, not in punching the work, but in the
withdrawal of the same. The cross section of the stripper in the centre
of the cut shows how it should be made so as to prevent this trouble,
the stripper being machined off on each side so as to have a bearing
on the work to be punched, close up to the punch. When possible, the
stripper should be bolted on to both sides of the die.
Out of many methods and plans devised for holding punches, this one
gives the best satisfaction, on account of the ease of making and
removing the punches.
SUB PRESS DIES.
[Illustration: Fig. 40.]
[Illustration: Fig. 41.]
A sub press, is, as the name indicates, a press set under a press, and
was designed by Mr. A. L. Dennison of Waltham, Mass., for the making of
watch movements, and at first consisted of two pins acting as guides
for the moving part of the sub press, which being quite a distance from
the punch, served to make it enter the die correctly.
A very interesting article on the origin of the sub press, as well
as the illustration and description of the first die thus made, by
Mr. Dennison, can be found in the _American Machinist_ of March 5th,
1891, and will repay anyone for looking it up who is interested in this
subject.
For regular sub-pressed die work, the form shown in Figs. 40 and 41
will be found a good style to use. The inside of the casting, shown in
cross section, is made tapering, and bored out true with the plunger,
and a heavy nut is fitted to the top, as shown in the illustration,
so that the babbitt with which the sub press is filled is kept tight
by screwing down the nut and forcing the babbitt into the taper and
against the plunger.
In making a die for the sub press, it is made and fitted in the usual
manner and set in its place. The punch is then carefully set, and the
space around the plunger is filled with the best quality of babbitt
metal. The plunger has three parallel grooves milled to prevent the
liability of its turning in use, and the upper half or arch of the
press is shouldered on to the base and then held to the same by screws,
shown in the cross section Fig. 41. The plunger is driven by the slot
shown at the top, and is attached loosely to the gate of the press. No
dependence whatever is placed on the ways of the press, but the stiffer
the press in which the die is run the better the results obtained, as
it is considered good practice that the punch should never enter the
die, but should come down and punch out the work without the edges
coming in contact.
The illustration on page 34, shows how a die may be fitted up when the
height of the die space in the press will not admit of a regular sub
press casting being used. The punch and die are made in the regular
way, and after being finished the punch is entered into the die about
¹⁄₁₆″ and is kept in position by parallels being placed between the
two. They are firmly clamped together, and while thus clamped the holes
are drilled, reamed and the four pins, only two of which are shown in
the illustration (which are hardened and ground), are fitted in the
holes in the bed of the lower die, then the clamps and the parallels
are removed and the die is ready for use.
These pins insure the punch entering the die perfectly, and do not
depend on the ways of the press or the skill of the operator in setting
the same.
The advantage of having a die sub-pressed, especially if it is a
complicated one, can hardly be overestimated, as a die which before
being sub-pressed would cut but two to four thousand blanks with the
ways of the press as carefully adjusted as it was possible cut twelve
to forty thousand after it had been thus arranged, and the work was of
a superior quality.
SOFT PUNCHES AND DIES.
When punching thin stock, sheet iron, or soft metal such as copper,
brass, etc., a soft punch will give equally good results to a hardened
one, for when worn it can be taken out and upset and then “sheared in”
by putting it in the press and forcing it through the die. When the
blank or the piece punched out is the object sought, as in playing
cards or cards for photograph work, the reverse of this plan is
followed. The punch is made straight, hardened, the die is left soft as
it gets worn, is set in with a peen of the hammer and the punch forced
through it, thus practically making a new die, also keeping it exact
to the size wanted for the work. Where the stock is very thin, machine
steel will be found equal if not better than tool steel, and the
operation of upsetting the punch will harden it, so that it will become
very tough.
A punch of this kind well fitted will run off eight to sixteen thousand
blanks from soft metal, and with less injury to the die than though a
hard punch was used. For forming up sheet tin or other kitchen ware,
cast-iron dies and a lead force are often used; the die being set in
the press and a punch shank is secured in the hammer and then the
melted lead poured around the shank, filling the die and forming a
lead force. This is an ancient practice and is seldom followed in an
up-to-date shop.
In exceptional cases the punch and dies can both be left soft to good
advantage. This is particularly the case when the work to be punched
is very thin or soft metal, or an intricate pattern that would be
liable to crack or change in hardening; or if they are to be used on
paper, which if cut in thin sheets is a very easy material to work, but
when large numbers are punched at the same time it is one of the most
obstinate of substances, on account of the toughness of the same.
A most interesting article on the punching of paper or fibre, which is
practically the same thing, appeared some months ago in the columns
of the _American Machinist_, by Mr. Oberlin Smith, who has made some
most interesting tests on the power and tools required. Although not
classed as soft punches, fluid punches are often used in expanding or
distending work described on page 36.
A SET OF DIES.
[Illustration: Fig. 42.]
The illustration shows a set of dies designed for blanking, forming and
piercing a set of springs and holders intended for holding cartridges
in rapid firing army rifles.
The second and third dies are plain gang dies designed for blanking and
piercing the clip.
The large die shown at the right is for bending up one of the clips
at one operation, and is constructed on the same principle as the one
shown on page 46, the side benders completing the springs at one stroke
of the press.
The fourth and fifth dies, and the three punches over them, are for
bending the second spring, three operations being required.
The fourth and last dies are for bending and piercing the springs, one
of which requires three operations, and the other but one, the whole
being shown to illustrate the number of tools often required for very
small articles.
An attempt has been made by the photographer to illustrate the work
done, by placing a spring in front of each die, with, however, but
partial success.
CHUCK FOR MAKING PUNCHES.
[Illustration: Fig. 43.]
The advantage of having a chuck for turning out punches from solid
stock, capable of taking a heavy chip without springing and still run
perfectly true, is well known.
The illustration shown, represents one which will fill all wants in
that direction. It is simple, and can be made in the shop, no special
tools being required. The boys in the shop used to call it a “Pratt &
Whitney” chuck, because a part of the tool, at least, is similar to one
which is largely used by that firm, but the split cone is, I think,
original. The base or internal portion of the chuck is screwed on to
the mandrel of the lathe in the usual manner, and the split cone, which
is provided with bushings to accommodate all sizes of steel, from one
inch down, is gripped by the outer shell, which is worked by a spanner
similar to the ordinary chuck.
For those who have much of this class of work to do, they will be well
repaid for the trouble and expense required to make them, for made in
the shop, the cost will not exceed $15.00 each. If some enterprising
firm would take hold of the matter, they probably could be produced for
half this sum.
SPRING DIES.
[Illustration: Figs. 44 and 45.]
The half-tones show a combination punch and die for cutting and bending
a sheet metal spring, the stock being fed in with a roll feed, and then
removed by the use of an inclined press, shown on the opposite page.
Any length of spring, up to the length of the die, is made by simply
changing the length of feed. The stock is cut off and fed by gravity to
the bending die, and after being bent, is removed in the same manner,
the bending up of the ends of the spring allowing it to pass freely
from the die.
Considerable trouble was experienced in getting the die to work nicely,
but it was accomplished, finally, by the use of kerosene as a lubricant
on the under die.
The press shown is what is known as a “Style B” Press, and the
illustration is loaned by the courtesy of the Mossberg & Granville
Mfg. Co., by whom the dies shown were made. The same style of press
is largely used on can, pail, and other tinware, in connection with a
single-action die shown on page 25.
INCLINED POWER PRESS.
[Illustration: Fig. 46.]
The advantage of a press of this kind is that single-action combination
dies, shown on page 25, can be used either in connection with a roll
feed or without, and the work removed without any special attachment;
the operation of the die being that, as the punch rises, the work is
raised to the top of the die and removed by gravity. The expense of the
die is greater, but a larger amount of work can be accomplished than
with the “Push Through” double-action die shown on page 27.
The greatest disadvantage of the inclined press is the inconvenient
position of the press for die setting. This is avoided in the style
shown, which can be instantly changed to the upright position.
DIE HOLDERS AND BOLSTERS.
[Illustration: Fig. 47.]
Die holders and bolsters are used for holding dies to the bed of the
press, the holder often being used to support some part of the die that
would otherwise be unable to stand the strain of punching. They are
usually made of cast-iron, except for heavy work, when steel casting
will be found preferable, as steel does not crack under any strain, and
will stand more abuse than the cast-iron holder.
The holder shown in Fig. 47 is a good style, and is adapted to a large
variety of work. It can be set either way in the press, and with either
keys or set-screws for holding the dies. If screws are used, the dies
should be made of standard width, as 2″, 4″ and 6″, and thus avoid a
large variety of holders. Dies for drop presses are usually held in a
round block, as they can be more readily set in the drop, and are held
by four or six screws, known as “poppets,” as shown in Fig. 82 on page
84. This manner of holding a die will give good results, and it is
suitable for all drop-press work, except drop forgings, for which the
dovetail slot in both hammer and anvil will be found preferable.
[Illustration: Fig. 48.]
[Illustration: Fig. 49.]
The four holders shown in Fig. 48, are intended for taking a uniform
range of dies, and the shoe is so designed that it may be removed and
replaced by simply loosening the bolt, as it is not necessary to remove
the nut, the slot being so designed that the holders may be pulled
forward, and then sideways, and thus removed from the press.
[Illustration: Fig. 50.]
The bolster plate, Fig. 50, is intended to be placed on the bed of the
press, and the die holder fastened by the use of two cap screws or stud
bolts, which are not shown in the illustration. The die holder and
bolster are used as shown on the press on page 59.
A GANG PRESS.
[Illustration: Fig. 51.]
[Illustration: Fig. 52.]
Fig. 51, shows a gang of foot presses; Fig. 52, one of the dies used in
the same, and intended for notching and mitering skylight bars. They
are made with three, four or six presses on one table, and intended to
be used in consecutive order, each press being fitted with dies for
performing a certain operation on the bar.
The die and punch, which are shown with the stripper removed, are so
arranged that the back of the die acts as a guide and prevents the
punches from sheering and being forced away from the die when cutting.
The press is made by the West Manufacturing Company of Buffalo, N. Y.,
through whose courtesy the illustration of the same is shown.
CAM STRIPPERS.
[Illustration: Fig. 53.]
Figs. 53 and 54 show a die having a cam-actuated stripper, also press
specially adapted to the use of the same, illustrations of which are
loaned through the courtesy of the E. W. Bliss Co.
The great advantage of a stripper of this kind is less liability of
breaking the punches, and the thicker stock that can be punched on
account of the decreased length of punches that can be used, which are
made very short, and are held in a punch back. The stripper plate is
fitted with bushings, which guide the punches and support them while
piercing the metal.
Fig. 53 shows the details of the die and punches, the punches being
held in the punch block which is fitted with a backing plate of
hardened steel; the stripper plate is attached to four vertical rods
which receive their motion from two cams on the main shaft. When the
stripper is up, a free space is left between punch and die, enabling
the operator to manipulate his work quickly and accurately. The
stripper comes down on the blank, straightening it and clamping it
tight before the punches enter, and holds it while the punching and
stripping is done, and the work comes out perfectly straight and true.
As the stripper moves up and down with the punches, they may be made
shorter than a stationary stripper would permit, and the punches used
are therefore more rigid and lasting. This also enables the punching of
smaller holes in proportion to the thickness of the stock, the stripper
acting as a guide for the punches up to the moment when they enter the
metal.
[Illustration: Fig. 54. CAM-ACTUATED STRIPPER PRESS.
The press shown has a 6″ crank shaft, weighs about 15,000 pounds, and
is geared 7¹⁄₂ to 1, and is one of the latest productions of the E. W.
Bliss Co.]
U. S. STANDARD PUNCHES AND DIES.
[Illustration: Fig. 55.]
The following illustrations are loaned through the courtesy of Mr. I.
P. Richards, the well known inventor of the only standard for round
punches and dies, and the best method for holding the same. The shank
which is shown in Fig. 57 is fitted to the press, and the punches are
held in place by the coupling. The punches being a standard length,
can be easily renewed when worn, or exchanged for a larger or smaller
size without disturbing the adjustment of the press. They are made in
all sizes from ¹⁄₈″ to 4″ diameter, and adapted to almost all classes
of round work, but more especially for punching out holes for boiler,
tank, and other work which is secured by riveting.
[Illustration: Fig. 56.]
[Illustration: Fig. 57.]
[Illustration: Fig. 58.]
The punch shown in Fig. 58 is ground shearing thus reducing the power
required for operating the same. These punches are furnished by the
inventor, Mr. Richards, at a less cost than they can be made by
consumers, although the patent on the same having expired, they are
open to the public, and are extensively copied by other manufacturers,
often, we are sorry to say, without giving Mr. Richards the credit
which is due for the invention and his efforts to introduce and
maintain a standard punch.
While we have no data of the power required to operate these punches,
we have reason to believe the statement that 40% is saved by their use.
PUNCHES AND DIES FOR NUT WORK.
[Illustration: Fig. 59.]
[Illustration: Figs. 60 to 63]
In the manufacture of nuts it is customary to make each operation a
separate one; that is, the bar is first cut up into short lengths, and
then the holes punched the entire length of the bar; the nut is then
roughly blanked out, and put through, or rather under, a crowning punch
which presses the corners, and leaves the circle on the top, shown in
Fig. 62. The nut is then put through one, two, or three shaving dies,
each of which takes off a thin shaving, and leaves the side of the
nut very smooth. The greater the number of operations the nut passes
through, the better the finish obtained.
Various attempts have been made to reduce the number of operations
required in this work, and thus produce a nut at a less cost. These
attempts have met with more or less success. Perhaps the nearest
approach in this direction has been made by the Port Chester Nut Co.,
who punch a blank and shave a nut at each stroke of the press. This is
a patented process, and for that reason is not shown here.
The Figs. 59, 60, 61, 62 and 63 show the first, second, third, fourth
and fifth processes. The curvature of the bar is caused by the first
punching, as the metal invariably stretches more on the under side;
this however is but of little consequence as it does not show in the
finished nut.
FORGING BICYCLE SPROCKETS.
[Illustration: Fig. 64.]
Fig. 64 illustrates a method of making bicycle sprockets that is both
better and cheaper than that usually followed, and one that is not in
general use. It is the invention of Mr. L. B. Munger,--who is well
known for his improved methods of manufacturing bicycle parts,--and has
been copied to some extent by his competitors.
The sprocket is blanked out in the usual manner, and the cross area
of the stock that is left to form the spoke is carefully calculated,
so that after the sprocket has been through the forging die, no fin
is left around the edges of either spoke or hub. This calls for good
judgment as well as accurate measurement on the part of the die-maker,
as it has proved a failure in several cases where an attempt has been
made to adopt Mr. Munger’s method.
The tail shown on the blank is intended to be grasped in the tongs
while heating, and in placing the blank upon the forging dies, and cut
off after that operation.
This same method is followed by Mr. Munger in all kinds of forgings the
work being first punched out to the proper size, leaving the required
amount of stock necessary to fill the die, and is then forged, leaving
little or no fin, and avoiding the trimming process after the work has
been forged.
This method has been jealously guarded by Mr. Munger, and is here
published for the first time with his full permission.
[Illustration: Fig. 65. A GROUP OF ARMATURE PUNCHINGS.]
Illustration Fig. 65 shows a group of armature punchings, all of
which are blanked out by means of compound dies, the largest of the
group being 36″ diameter, and the smallest one, which is shown in the
centre, 1¹⁄₈″ diameter; the others being respectively 4″, 6¹⁄₄″ and 20″
diameter.
A detailed description of the dies for producing this work is given
on page 32. The methods of constructing the dies are so varied that
it is impossible to give a plan which will fit all styles of armature
sheets. Plans or sketches for dies for any work of this character will
be furnished on request.
[Illustration: Fig. 66. A GROUP OF SMALL PUNCHINGS.]
The above illustration shows a large variety of different articles
which are produced wholly, or in part, by press work.
The four corner illustrations will be recognized by those interested in
bicycle manufacture, being punchings of sprocket wheels made by four of
the leading manufacturers. The figures 14, 15, 19, 21, 31 and 35, are
also parts for bicycles; and numbers 32, 42, 44 and 47 represent the
pieces used in the construction of the well known bicycle whistle.
SPEED OF PRESSES.
The speed at which a press can be operated depends upon the nature and
thickness of the stock being punched, the quality of the steel of which
the tools are made, and the material used for lubricating the same.
In punching a soft material, such as paper, cloth or very thin sheet
metal, a speed of 200 to 350 revolutions per minute is practical, as
the fiber of the metal does not require to be broken, as is the case
when operating on thick or hard material.
The old-fashioned rule that a punch will penetrate metal equal in
thickness to the diameter of itself, is fast being exploded, as it is
a well known fact that a ¹⁄₂″ punch can be put through a 2″ bar of
iron, provided the tools are properly made, and a speed of not over one
stroke in two and one-half minutes be given to the same; breaking the
punch being the result of an increase of this speed.
In ordinary punching sheet metal, .014″ to .04″ thick, 125 to 150
revolutions per minute has been found as high a speed as it is
practical to run; in blanking out large sheet-iron armature disks,
.025″ thick, and 20″ diameter, more work is produced at 60 revolutions
than at 90, as the dies will stand up to the work and run off a larger
number of sheets without being ground, than when used at higher speed.
The speed of drawing punches depends largely on the work done, and the
material used for the same, as a slow speed will often enable work
to be produced that would rupture at a high speed. On large and deep
shells, a speed of two to four revolutions is often necessary, while
small and shallow work will stand a speed of 150 to 200 strokes per
minute.
The stroke of the press is an important factor which must be taken into
consideration when estimating the speed at which work may be punched,
the idea being that the tools must have time to break or rupture the
grain of the metal, and this can be facilitated by giving the proper
amount of clearance to the punch, as well as the usual clearance to the
die; also care being taken when punching a thick metal that the punch
and die do not fit too closely. Probably more trouble is caused by this
one defect in tool making than any other. It is hard to convince a good
die-maker that the punch and die must not fit nicely when used on thick
work; often a difference of ¹⁄₃₂″ to ¹⁄₁₆″ should be given on work ³⁄₈″
in thickness or over. On thin sheet metal the tools must fit nicely in
order to produce the work without burr, and the speed of the same can
be greatly increased; 90,000 to 100,000 per day being the usual output
of a press running at 200 revolutions per minute, the stock being fed
with either roll or ratchet feed.
DIE SETTING.
Setting punches and dies in the press is often done without due regard
for the tools,--that they are properly set and adjusted for the work
they have to do. From a mistaken idea of economy, this work is often
put into the hands of an operator who has little idea of the value of
the tools which he is adjusting, and to whom any accident caused by
improper setting is a small matter.
To set a punch and die in the press, remove the belt from the wheel,
unless the press is provided,--as all presses should be,--with a
countershaft. Place the die and holder, (into which the die can be
keyed to better advantage on the bench), on the bolster plate, and
enter the punch carefully by hand; now bring the gate or slide of
the press down until the bottom of the slide strikes the shoulder of
the punch and prevents it from being moved out of the die; next ease
up slightly on the slide, so that the punch, die and holder can be
moved along by hand into their proper places in the press. The punch,
if secured in the head block or chuck of the press, is pushed to the
left-hand side of the dovetailed slot in the slide, and the key driven
in. The bolt or stud holding down the die holder should now be slightly
tightened, and a few raps with the hammer be given to the die; this
causes it to find its proper place on the bolster; the holder is now
secured to the bolster plate, and the punch withdrawn from the die and
then entered again, to be sure that the operation of setting has been
properly performed.
No specified distance can be given as to the distance the punch should
enter the die. In sub press dies for watch work, the punch should
come to the surface of the die and enter the least possible amount;
while in rough crude dies used for thick sheet iron or boiler plates,
the removal of the scrap or the piece punched out will be greatly
facilitated if the punch enter ³⁄₈″ or more.
The above method will not meet with the approval of many, but a
large experience in different methods of die setting has led to the
description just given.
There is one good rule which, if followed, would practically prevent
the accidents now so common in large press rooms, and that is: never
allow the hand or fingers to be placed under the punch while the press
is in motion. Many of the accidents which occur are caused by gross
carelessness on the part of the operator who is induced to take the
chances of accidents because of the larger amount of work which can be
produced.
BROACHING.
[Illustration: Fig. 67.]
Although not usually classed with punches and dies, the operation of
broaching is analogous with punching, and for that reason is properly
entitled to description here. The broach is really a punch, the cored
or drilled hole in the work broached forming a die for the same. It is
used for finishing holes which may be either punched, cored or drilled
in brass, iron or steel, and which may be round, square or any other
desired shape. The operation is best performed in a press designed
for the purpose, having an adjustable stroke of 1″ to 12″. The broach
shown is intended for finishing a cored hole, and is 2¹⁄₂″ × ¹⁄₂″
rectangular section, about 8″ in length. The teeth being very coarse
on the lower end, are intended for taking out the bulk of the stock,
until the centre of the broach is reached, when they are sheared in
opposite directions, thus breaking the chip off, and then the teeth
decrease in size until the upper end of the broach is reached, when the
same is left perfectly straight for about 2″, forming a sizer, keeping
the finished hole a standard size. The broach is best driven when
operated on by a V block secured in the press in the same manner that
the punch is usually held, and as the plunger comes down, the broach
will find its own centre with less liability of breaking or making an
imperfect hole. Broaching of almost any length can be done in a press
having a short stroke, by using a successive number of blocks, the
broach being inserted in the hole, and driven down the full stroke of
the press. A block of the same thickness as the stroke of the press
is then inserted, and the operation can be repeated until the desired
length of drive is obtained. The results obtained are not equal to a
continuous stroke broaching press, as the stopping of the broach when
partly through the work, gives the metal an opportunity to settle into
the teeth of the broach, thus increasing the liability of breakage.
There are on the market several machines designed expressly for this
work, several of which perform the operation by pulling the broach
through the hole, which is an improvement over the method just
described, but as it does not come under the jurisdiction of this work,
the description of this machine is omitted here.
REVOLUTION COUNTERS FOR PRESS USE.
[Illustration: Fig. 68.]
The use of a revolution counter or indicator for keeping account of
the work produced by a press, is preferable to the ordinary manner
of weighing up or trusting to the intelligence of the operator to
determine the amount of work done. This fact has led it to be adopted
by several of the largest press rooms in the country, and with
satisfactory results.
The above illustration shows a style which is adapted to all makes of
presses, as it can be connected either directly to the shaft itself,
or to the centre, or can be located in front, on the upper part of the
press, and then connected by a lever from the slide, and will give
an accurate record of the revolutions made. It is simple, having no
springs or gears, and can be furnished with either four, five or six
dials. The five figure indicator shown in the illustration will count
up to 99,999, and then repeat automatically. A dial can be set to zero,
or the counter can be had without the thumbscrews for re-setting.
In using the counter in connection with gang punches, that is, in work
that requires one or more strokes of the press to properly start the
strip of metal used in feeding, there is a loss of six to nine per
cent. from the number actually indicated. This fact being thoroughly
understood, the proper amount of work can be produced, making the
necessary allowance for the false strokes.
BALL CHUCK.
[Illustration: Fig. 69.]
The illustration Fig. 69 shows a chuck for bench use, which is adapted
for “working out” punches and dies or any work which can be done more
conveniently by placing it at an angle, so as to use a hammer and
chisel to good advantage. The chuck was originally designed for and is
usually used in die-sinking, but the advantages mentioned has led to
its use in the die room, and once introduced, it will be found to be a
good tool.
A base provided with a cavity of the same radius as the bottom of
the ball is intended to be used in connection with the chuck, and is
usually made by coiling up an old belt, and then striking the chuck
firmly down into the same. The die is held in the slot, secured by the
two set-screws.
The advantages obtained from the use of this chuck will be appreciated
by those who have experienced the difficulties of chipping out an
odd-shaped die.
FINISHING PRESS WORK.
[Illustration: Fig. 70.]
Perhaps a few words on finishing punched work may be of interest to
those who have the good or bad fortune to have charge of that kind of
work, and the barrel shown is specially adapted to work of this kind;
being a modification of the ordinary tumbling barrel, so arranged that
the incline may be varied, giving a greater or less effect on the work
as may be wanted.
All punched work as it comes from the press is in an unfinished
condition, owing to the soap, oil or other substance which is used
for lubricating the dies, and the advantage of tumbling cannot be
overestimated. Burrs can be removed with practically no expense, and
work put in a salable condition which would otherwise be consigned to
the scrap.
For abrasive materials to be used in tumbling the work, there is
nothing better than broken emery wheels for rough tumbling or taking
off heavy burrs, and for finishing light, delicate work, leather chips
and sawdust will give good results. For polishing buttons of hard
rubber or papier mache, old woolen rags will be found to give a high
polish without marring the work.
For tumbling shells which have been drawn, but are to be put through a
second operation, a solution of strong soap water, either hot or cold,
will be found to give a good polish and also leave the work in good
condition for the second drawing.
BELTING UP PRESSES.
To belt up a power press properly, set it in line with the countershaft
or main shafting, and fasten securely to the floor, taking care that
it is properly leveled, and that each leg has an equal bearing on the
floor. The better the foundation, the better results will be obtained.
Take double the distance from the centre of counter or main shaft to
centre of crank shaft on the press, and add one-half the circumference
of both pulley and balance wheel, and the result will be the length of
belt required. If the press is an inclined one, and it is to be used
in an upright position also, set the press on an incline and cut the
belt to the proper length; then set it upright and set a piece of belt
of the proper length to be used when the press is in that position.
Put on a belt the full width of the wheel. Do not put a 2″ belt on a
4″ balance wheel, and then expect the momentum of the wheel to do the
rest. Do not set the press directly under the main or countershaft when
it is possible to avoid it. Set it at least 2 ft. away, even if you
have to sacrifice floor space to do so. Run the belt with the grain
side next to the pulley. A long belt is preferable to a short one, as
the adhesion caused by the weight of the belt is more desirable than
that obtained by tight lacing, and the belt will wear longer and give
better results.
FEEDING PRESSES.
[Illustration: Fig. 71.]
Feeding by hand is the oldest and most common method of feeding press
work, and a few words on this subject may be of interest.
When work is to be punched from short stock, as most sheet tin stock
comes, or where irregular stock is used, an automatic feed is of
doubtful utility, for the operation of keeping the feed supplied is
certainly as troublesome as feeding the press itself. In cases of this
kind it is best to feed by hand as a skillful operator moves his hands
with the press and will produce work rapidly, but if the work will
admit of it, a power feed should be used.
We describe a few of the many kinds in use: roll, finger, slide, double
roll, reel, tube, grip, ratchet and friction dial feeds, combination
feeds and knock-outs.
When large quantities of the same general class of work are wanted,
and the stock can be procured in long strips or rolls, fit the press
with a plain roll feed, Fig. 72, as they are easily applied, and can be
quickly adjusted and changed from one class of work to another. They
are made in several styles, to feed from front to back, left to right,
or the reverse, single or double and with ratchet, friction, or “pinch”
adjustments of rolls. The amount that can be fed is usually regulated
by the diameter of the rolls except in special cases where a rack and
pinion, giving any amount of feed wanted, can be used.
[Illustration: Fig. 72.]
A finger feed is an adjustable “finger” fitted to and worked by the
slide of the press, so adjusted that it is raised at each stroke just
enough to allow the stock to pass under, and then catches in the hole
punched by the preceding stroke. It is inexpensive, and is not in the
way when not in use. When fitted with a power reel to wind up the
scrap, it becomes one of the most useful feeds known, and can be used
equally well on both single and double acting presses.
Tube feeds are used for feeding work that has been previously punched
out by a plain die. It is best adapted for coining, swagging, etc. The
work is caught in a tube as it falls from the blanking die, and is then
transferred into a second tube placed on the press. An automatic moving
slide delivers the lowest piece in the tube to the dies at the proper
time. This feed is largely used on coins, medals, buttons, etc.
An automatic slide feed consists of a mechanical hand which grips
the work and then slides it to the proper place on the dies, and is
specially adapted to a fragile material, as cardboard, paper, etc., and
is also one of the most accurate style of feed in use.
A grip or claw feed is so arranged as to enter the first hole in the
stock just punched, and then draw it ahead the proper distance for the
next blank. It is easy to adjust, and can be run at a very rapid speed.
Dial feeds, Fig. 71, are used to hold a blank on which it is desired to
perform a second operation, as armature blanks, or to act as a carrier
to present the blank in successive rotation to the punch, and in some
cases to remove the work after the punch has performed its duty. They
may be belt, ratchet, or friction driven, and may be a smooth disk as
used for cartridge work, or fitted with sockets to hold and carry the
work.
A combination feed is two or more feeds in one, as they are usually
adapted for special operations, and can not be changed with the same
ease as the roll or finger feed.
Knockouts are fitted to many presses to assist in removing the work
from the dies. They are applied to either the slide or body of the
press, and in the latter case are connected by a pitman to the end of
the crank shaft, so that as the punch rises from the die, the work is
forced out.
HARDENING DIES.
So much has been said on the subject of hardening steel that we are
disposed to let it alone, but feeling that a work of this kind would
not be complete without it, will give the results of our experience.
For heat we prefer a gas furnace of any good make, but this not
available, a clean charcoal fire is nearly as good.
Fill all holes in the die that you do not wish to have a cutting edge,
such as the stripper holes, with fire clay; use plenty of good hard
wood charcoal, heat slowly but steadily to an even red. Dip the die
entirely below the surface in salt water, for while there are baths
that are good for special work, steel that will not harden in clean
salted water is not fit to make a die of, keep it in the water until
it is entirely cold, then put it on the fire again and warm it until
the heat is as great as the hand can bear, then cool off and polish and
draw to a light straw. The object of the second heating is to lessen
the liability of fire cracking.
For large dies it is indispensable to have a tank properly arranged for
cooling the steel quickly. This is best arranged by having two rods
fixed across the tank about 10″ below the surface of the water; the
water supply is led down below the surface nearly to the bottom of the
tank. The end is bent up so that as the die is plunged into the tub
the valve is opened and a circulation of water is created in the tank.
This method will prevent the soft spots often met with in hardening.
Fig. 73 shows the arrangement so clearly that no further explanation is
required.
[Illustration: Fig. 73.]
[Illustration: Fig. 74. AN ANCIENT TRIP HAMMER.]
Although not properly classed as a punch and die, and yet clearly the
result of the laws of evolution, the above illustrated tool is entitled
to be represented here; and shows the trip hammer in its most primitive
form. It is taken from a German illustration, loaned through the
kindness of the Bradley Co., of Syracuse, N. Y., for insertion here.
The mode of operating the hammer is clearly shown in the illustration,
the water-wheel attached to one end of the revolving drum carries the
collar and dog for raising the hammer.
The method of keying the lower die in the anvil shown, is identical
with that practiced at the present time, the force of the blow being
controlled by the in-flow of water actuated by the knotted rope which
hangs within easy reach of the smith. The swinging seat, however,
would not be tolerated with the methods of operating the hammers now
practiced.
The exact antiquity of the sketch could not be ascertained, but it is
not far from the 16th century.
BROWN & SHARPE MFG. CO., Providence, R. I.
TOOLS FOR DIE WORK.
[Illustration: Fig. 75.
1-2″ Micrometer.]
[Illustration: Fig. 76.
Micrometer Calipers.
Made to measure from ¹⁄₂″ to 24″, and to read to .0001″.]
[Illustration: Fig. 77.
Height Gauge.]
Attachments used with Brown & Sharpe Universal Milling Machine for die
work.
[Illustration: Fig. 78.
Vertical Spindle Milling Attachments.]
[Illustration: Figs. 79 and 80.
High Speed Milling Attachment and Driving Fixture.]
[Illustration: Fig. 81.
Universal Vise.]
PAWTUCKET MFG. CO., Pawtucket, R. I.
[Illustration: Fig. 82.
Press for Blanking, Champering and Trimming Nuts.]
MOSSBERG & GRANVILLE MFG. CO., Providence, R. I.
[Illustration: Automatic Drop Press.
Designed for all classes of stamping and bending operations and can
be operated by inexperienced labor without danger of injury.
]
[Illustration: Single Acting Power Press.
Fitted with instantaneous clutch and stop motion. Designed for all
classes of punching operations, and can be fitted with roll, finger
or dial feeds.
]
E. W. BLISS CO., Brooklyn, N. Y.
PRESSES, DIES, SHEARS, DROP HAMMERS, DOUBLE SEAMERS, TRIMMERS.
[Illustration: Toggle Drawing Press.
The toggle drawing press as shown in above cut is used in the
manufacture of wash bowls, milk and pudding pans, tea kettle bodies
and breasts, sauce pans, bucket and pot covers, small scoops,
cuspidors, coal hod bottoms, trays, dust pans, brass and copper goods.
This press is fitted with an automatic friction clutch; it can be
stopped and started at any point of the stroke, by operating hand
lever not shown.
The toggle movement as applied to this press has greatly increased
the durability and smoothness of action, insuring a more perfect
“dwell” of the blank holder than can be maintained in presses of any
other design.]
EMBOSSING PRESSES, SHEET METAL WORKING MACHINERY, SPECIAL MACHINES.
[Illustration: Armature Disk Cutting Press.
The press shown in above cut is specially designed for cutting the
outside and inside of armature disks simultaneously, insuring exact
concentric of outside and inside circumference.
This press is fitted with a positive knock-out device.
The same general style of presses also supplied in larger and smaller
patterns.
]
NEW DOTY MFG. CO., Janesville, Wis., U. S. A.
[Illustration:
Above cut represents a combined punches and shears in which the knives
for flat and round iron are independent of each other and of the punch;
and both sets of knives as well as punch are at all times ready for use
without any change. While it is a single end, it has all the advantages
of a double end machine, and is much less expensive.]
E. S. STILES PRESS CO., Watertown, N. Y., U. S. A.
METAL CUTTING, SHAPING and FORMING TOOLS, PRESSES, DIES, DROP HAMMERS
and SPECIAL MACHINERY.
[Illustration: No. 19 Adjustable Incline Press.]
[Illustration: No. 3 Punching Press.]
WATSON AND STILLMAN, New York, N. Y.
[Illustration: Hydraulic Open Jaw Die Sinking Press.
A very small press with short motion, on which small medals may be
struck without the annoying shock of the drop hammer, and is an
adaptation of their improved hydraulic punch, strengthened in the jaw
to avoid spring.
The body is steel, and from its method of construction irregular dies
may be used. The lower lever can, if desired, be made self raising by
weighting it at the rear.
Power, 60 to 125 tons pressure.]
[Illustration: Heavy Hydraulic Die Press.
Adapted for hubbing up very heavy dies.]
HILLES AND JONES, Wilmington, Delaware.
[Illustration: No. 4 Horizontal Power Press for Very Heavy Work.
For punching boiler heads, crooked furnace plates, bent, angle or tee
iron, boiler legs and all close or crooked work.]
G. A. CROSBY & CO., 176 So. Clinton St., Chicago, Ill., U. S. A.
Manufacturers of presses, dies, and designers and builders of
patent automatic machinery for making cans. Write for catalogue and
information.
[Illustration: No. 2 Power Punching Press.]
THE WATERBURY FARREL FOUNDRY & MACHINE CO., Waterbury, Conn.
[Illustration: 300 Ton Knuckle-Jointed Embossing Press.
These presses are constructed upon an improved plan which permits a
powerful machine to be made in more compact form than formerly. The
main frame is made very rigid and as short as possible (by allowing the
guides for the crosshead to be placed in front of the knuckle-joints)
thereby reducing the spring or elasticity of the frame to a minimum.
A specialty is made of designing and building machinery for specific
requirements. Some of our standard machines are as follows: automatic
rivet machines, automatic nut blanking machines, thread rolling
machines, machinery for making hinges and butts from sheet steel and
brass, machinery for making shot-shell and ball cartridges. Patent
hydraulic presses, pumps and accumulators.]
FERRACUTE MACHINE CO., Bridgeton, N. J.
[Illustration: Power Punching Press P4.
This press is for heavy cutting, punching, shearing and forming.
12 sizes of this style of press, and a great variety of other designs.]
INDEX.
A Press of the Future, _Frontispiece_
Armature Dies, 32
Armature Punchings, 70
A Group of Small Punchings, 71
Automatic Drop Press, 88
Burnishing Dies, 42
Bending Dies, 16
Blanking Dies, 14
Broaching Tools, 74
Belting up Presses, 79
Ball Chuck, 77
Blanking Press, 91
Chuck for Punch Work, 57
Combination Dies, 25
Cam Stripper, 64
Compound Dies, 19
Compound Bending Dies, 17
Double Action Dies, 27
Die Shoes, 60
Drop Press Dies, 30
Drawing Presses, 22, 90
Drawing Dies, 23
Embossing Presses, 98
Finishing Press Work, 78
Fluid Punches, 36
Follow Dies, 48
Forging Bicycle Sprockets, 69
Feeding Presses, 80
Gang Dies, 38
Gang Washer Dies, 45
Gang Press, 62
Hydraulic Presses, 94, 95
Hardening Dies, 82
Holding Small Punches, 51
Imitation Rivet Dies, 47
Inclined Presses, 59
Jack Dies, 31
Largest Dies, 21
Making a Punch and Die, 11
Milling Attachments for Die Making, 86
Needle Dies, 35
Nut Press, 87
Origin of Dies, 9
Power Presses, 89, 93, 99
Punches and Dies for Nut Work, 68
Plain Drawing Die, 24
Proper Selection of Steel for Dies, 10
Revolution Counters, 76
Reversed Washer Dies, 44
Riveting Dies, 37
Set of Dies, A, 56
Sectional Dies, 39
Spring Dies, 58
Sub-Pressed Dies, 52
Setting Dies, 73
Soft Punches and Dies, 55
Speed of Presses, 72
Standard Punches and Dies, 66
Solid Bottom Dies, 26
Shearing Presses, 92
Triple Dies, 46
Triple Action Dies, 28
Trip Hammer, 84
Tools for Die Work, 85
Tube Dies, 50
Washer Dies, 43
Transcriber’s Notes.
Italic text is indicated with _underscores_, bold text with =equals=.
Small/mixed capitals have been replaced with ALL CAPITALS.
Evident typographical and punctuation errors have been corrected
silently. Inconsistent spelling/hyphenation has been normalised.
References to Gazalott and Gagalott are the author's. Possibly a
misreading for Gévelot (Joseph-Marin), a French ammunition manufacturer.
Half-titles and reiterations of chapter titles have been discarded.
To improve text flow, some illustrations have been relocated. Where
necessary, references in the text have been modified to reflect this.
Cover art created for this eBook is granted to the public domain.
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