US1922793A - Reworking of die-rolled articles - Google Patents

Description

Aug 15, 1933. P. L. COYLE REWORKING 0F DIE ROLLED ARTICLES 2 Sheets-Sheet 1 Filed Dec. 23, 1929 INVENTOR M f JUL- @W, M {M Aug. 15, 1933. P. 1.. COYLE REWORKING OF DIE ROLLED ARTICLES 2 Sheets-Sheet 2 Filed Dec. 25, 1929 I Patented Aug. 15, 1933 REWORKING OF DIE-ROLLED ARTICLES Paul L. Coyle, Coraopolis, Pa., assignor to Republic Steel Corporation, Youngstown, Ohio, a Corporation of New Jersey Application December 23, 1929 Serial No. 415,959

16 Claims.

My invention relates to the reworking of dierolled articles, and particularly to a forging treatment to which die-rolled blanks are subjected.

According to previous methods of forging dierolled blanks, as explained in the patent to Witherow No. 1,572,343, the integral flash formed on the blanks during the rolling process is removed from the blank, and frequently the flash zone is ground smooth to avoid laps, before the performance of any forging operations thereupon. The blank is then subjected to forging between dies which give the blank the proper shape and dimensions. During this operation, the excess metal which it is necessary to provide in the blank to insure that the forging dies are properly filled, is forced into the space between the dies and forms a second flash. After the forging operation is completed, it is necessary to remove this second flash by duplicating the trimming and grinding operation to which the rolled blank was first subjected. This duplication of the flash trimming and grinding increases the cost of the forged articles and requires a greater length of time for their production.

In order to obviate the disadvantages characterizing the previous method, I have invented a novel method of forging die-rolled blanks with the flash thereon. I take the blanks as they come from the shears which cut the string of blanks into lengths and then put them through the steps of a novel forging process without removing the flash. The blanks are first given an edging or are forged on their edges to which the flash adheres. The purpose of the edging is to give the blank the desired longitudinal camber.

The edging is accomplished by placing the blanks edgewise in dies formed to receive them and having grooves for engaging the flash and giving the blank the required edging blows. The grooves have a depth slightly less than the width of the flash so that the edging blow, which is first blow of the forging operation, is applied partly to the flash. The blank is thus given the desired longitudinal camber without caving in the unsupported flanges of the forging blank.

After edging, the portions of the blank which require forging are placed within a suitably formed forging die and the forging operation is completed. The forging and edging dies may be integral. As the forging continues additional flash is formed as previously explained, but the forging dies are so designed that this additional flash lies in the same plane as the original flash formed during the die rolling. The result of forging-treatment on the flash, therefore, is to increase its width, with the formation of a slight amount of flash at portions of the blank where no flash formerly appeared, for example, at the end of the blank where adjacent sections are sheared. After forging, the flash is trimmed in one operation and the duplication of the trimming step is avoided with the result that production is speeded up and costs cut down.

The rolling flash is distinctly advantageous in the forging process since it opposes the extrusion of forging flash and thereby insuresthat -the latter is reduced to a minimum and that the forging dies are properly filled.

For a complete explanation of my invention, reference is made to the accompanying drawings in connection with the following description. In the drawings,

Figure 1 is a plan or edge view of a forging blank from which a front axle for a motor car is to be formed;

Figure 2 is a side elevation of the blank shown in Figure 1 as it comes from the shears after being formed in die rolls;

Figure 3 is a View similar to Figure 2, showing the condition of the blank after it has been subjected to the edging for producing the desired. longitudinal camber;

Figure 4 is another view similar to Figure 2 except that it shows the condition of the blank after the forging has been completed and the blank is ready to have the flash removed therefrom;

Figure 5 is a plan view of one of the dies employed in the edging and forging of the blank;

Figure 6, is a side elevation of the forging dies, and

Figure 7 is a transverse section through the dies, along the line VII-VII of Figure 5.

Referring in detail to the drawings, and specially to Figures 1 and 2, there is illustrated a forging blank 10 for the production of a front axle for motor cars. The blank 10 is produced by known die-rolling processes which result in the formation of integral flash 11 at the edges of the blank. According to known methods, the blanks 10 are produced in strings. The blanks are sheared from the string as indicated at 12 and are then ready for the forging treatment.

The forging treatment is administered by placing the blank between forging dies ,15 and 16 as shown in Figures 6 and '7. Figure 5 shows a plan view of the lower die 16. Edging impres- I ing impressions.

sions 17 and 18 are provided at one side of the dies for producing a slight angularity in the ends of the blank which gives the desired longitudinal camber to the finished article. The edging impressions have grooves 19 and 20 which receive the flash which is formed on the blank during the rolling. These grooves have a depth approximating the width of the flash so that the first forging blow, which effects the edging, is received partly by the flash, and is not applied directly to the flanges of the blank which, being unsupported, would be caved in unless the edging blow were partly taken up by the flash. The edge forging of the blanks may thus be effected without materially deforming the flash, or causing laps.

In addition to the edging impressions 17 and 18, the forging dies 15 and 16 are provided with finishing impressions 21 and 22.

After edging the blank has the appearance of that illustrated in Figure 3. The flash 11 is undeformed as are all portions of the blank with the exception that a slight angularity has been imparted to the end portions thereof. When the blank has been placed in the impression 21 and given the finishing blows, there results a blank shown in Figure 4. The flash 11 is increased in width and a new flash area 23 is formed adjacent the end of the blank.

During the forging, of course, they shape and dimensions of the various portions of the blank are reduced to the proper requirements. The flash formed during the forging is actually but an extension of that originally formed during the rolling process except at the end of the blank where the new flash area 23 appears. In both cases the final flash lies in the same plane as that occupied by the original flash with respect to the section of the rolled blank. The rolling flash tends to oppose the growth of the forging flash and thus makes for properly filling the forg- The impressions 21 and 22 are provided with flash grooves 24 which permit the original flash to spread during the forging treatment to accommodate the excess metal forced out of the dies by the forging. The forging operation is carried out by the use of an automatic forging hammer such as those in common use, the dies 15 and 16 being secured, respectively, to the moving and stationary portions thereof.

After the completion of the forging operation, the blanks are placed in trimming dies and all flash simultaneously removed therefrom. I thus eliminate the duplicate flash trimming operations of the prior art and produce a finished article in less time and with less labor than was possible heretofore.

Another advantage of forging the blanks before removing the flash therefrom lies in the fact that the flash adhering to the blanks makes it easier to position the blanks properly in the dies since the flash serves as a guide as it engages the dies and thus definitely alines the blank with the forging impression.

Although I have described the invention as applied to the production of front axles for motor cars, it is obvious that the same method may be applied to forged articles of other types and dimensions. The specific details of the method shown and described, therefore, are not intended as a lim'itationupon the invention since the latter may be practiced in other forms. Any changes in the method or apparatus that fall within the scope of the appended claims may be made without departing from the spirit of the invention.

steps including die-rolling a forging blank with I claim:

1. In a method of forging metalshapes, the steps including providing a forging blank having flash, edge-forging the blank to give the desired camber thereto, forging the blank to the required shape and size and removing the original flash and that formed by the forging simultaneously. 2

2. Ina method of making metal shapes, the

flash, edge-forging the blank to give it the desired camberjforging it to shape and size, thereby producing additional flash co-planar with the original flash, and removing all said flash simultaneously.

3. In a method of forging metal shapes, the steps including providing a die-rolled forging blank having flash, forging the blank to the required shape and size and removing the original flash and that formed by the forging simultane- 9 ously.

4. In a'method of making metal shapes, the steps including die-rolling a forging blank with flash, forging it to shape and size, thereby producing additional flash co-planar with the original flash, and removing all said flash simultaneously.

5. In a method of making metal articles, the steps including providing a die-rolled blank having flash, forging the blank with the flash thereon, whereby additional flash is formed in the plane of the original flash and simultaneously removing all of said flash.

6. In a method of making metal articles, the steps including providing a die-rolled blank having flash and forging the blank with the flash thereon.

'7. In a method of forging metal articles, the steps including forming a forging blank having flash on its edges and forging said blank on its edges to give it the desired camber without deforming said flash.

8. In a method of making metal articles, the steps including die-rolling a blank with flash on its edges, and forging said edges while preserving the flash in substantially its original coridition.

9. In a method of making metal articles, the steps including die-rolling a blank with flash thereon and forging said blank before removing the flash.

10. A metal shape forgedfrom a die rolled blank having flash, the flash formed by the forging lying in the same plane as the original flash.

11. A metal article forged from a blank having rolled flash integral therewith, said article having forging flash in addition to said rolled flash.

12. The method of forming metal articles comprising passing a leader between die rolls adapted to form a string of connected blanks, forming accurately spaced portions along the string adapted for reforging, permitting excess metal to flow sidewise in a substantially unrestricted manner to form flash integral with the blanks, separating the blanks, reheating and forging at least certain portions of the blanks whereby additional flash is formed, and simultaneously trimming both the rolling flash and the forging flash.

13. The method of forming metal articles comprising passing a leader between die rolls adapted to form a string of connected blanks, forming accurately spaced portions along the string adapted for a subsequent operation, permiting ne ates excess metal to flow sidewise n a substantially unrestricted manner to form flash integral with the h1anks,'sepaiating the blanks, operating on the blanks to produce a flow of metal in at least certain portions of the blanks whereby ad ditiOllSl flash is formed, and simultaneously trimmine; all the flash.

it. The method of forming metal articles eomprising passing a leader between die rolls adapt eel to form a string of connected blanks, forming accurately spaced portiom along the string adapted for rewerking', permit-Aug excess metal to flow sidewise in substan' ially unrestricted maimer to form flash integra? with the blanks,

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