US2511836A

US2511836A - Tube joining

Info

Publication number: US2511836A
Authority: US
Publication date: 1950-06-20
Anticipated expiration: 1967-06-20

Description

J. J. CULLEN TUBE JOINING June 20,1950

Filed May 3, 1945 FIG.

FIG

ATTORNEY June 20, 1950 Y J. J. CULLEN 2,511,836

TUBE JOINING Filed May 3, 1945 FIG. 8.

'4 Sheets-Sheet 2 IN VENTOR JOHN J. CULLEN ATTORNEY June 20, 1950 J. J. CULLEN 2,511,336

TUBE JOINING Filed May 5, 1945 4 Sheets-Sheet s IO6 9o 98 86 11 7s 89 IOQFIG. 20.

m- INVENTOR JOHN J. CULLEN ATTORNEY June 20, 1950 I J, CULLEN 2,511,836

, wuss JOINING v Filed llay 3. I945 4; l;ee ts-Sh eej; 4

INVENTOR JOHN V J. CULLEN FIG. 36.

ATTORNEY Patented June 20, 1950 UNITED STATES PATENT .OFFICE 2,511,836 .f I TUBE JOINING John J. ouuen, Brighton, Mass. Application May 3, 1945, Serial Nb. 5913 2 Claims. (o1. 29-1482) I (Granted under the act of March 3,1883, as

amended April 30, 1928 370 Q. G. 757) My invention relates to tube joining. More particularly, it relates to the joining of pieces of thin-wall metal tubingin angular relationship to each other. It deals with a method and apparatus for forming the necessary interfitting portions on a main tube and a branch tube for connecting the tubes together in angular relationship.

The method used at present to join thin-wall tubes in angular relationship is a hand method which is both laborious and slow and is, therefore, costly. Furthermore, the hand method necessitates the use of extreme care to attempt to obtain accuracy and often results in non-uniform products.

In joining the tubes, it is the practice to form on the side of the main tube, at the location where the branch tube is to be connected, a suitable boss. On the end of the branch tube which is to be connected to the main tube, a saddle, which is complemental to the boss, is formed. The saddle is fitted over the boss and the main tube and branch tube are suitably secured together, for example, by soldering.

To form the boss on the side of the main tube, it is necessary, with the hand method, to first locate exactly on the side of the main tube, the center of the branch to lead therefrom. The main tube is then held in such a position that the center mark is uppermost and by use of dividers, a circle is scribed on the tube. This circle has a diameter equal to the inside diameter of the branch less the thickness of the metal of the main tube. Then the cup or boss is raised on the main tube. This is accomplished by first drilling a relatively small hole at the center mark which is then filed smooth to prevent cracking during the subsequent metal-working or hammering operation. The drilling operation hardens the surrounding metal, especially if it is copper or copper alloy, and consequently, it is necessary to anneal such metal to facilitate the subsequent metal-Working operation. The end of a metalworking pin or bar is then inserted in the drilled opening and by hammering on the side ofthe pin, the metal is worked upwardly to form a flange around. the hole. While hammering, the

pin is moved around the edge of the hole to attempt to raise the metal uniformly as the hole is enlarged. This operation causes the raised metal and the adjacent metal of the tube to harden, and it is necessary to anneal the tube from time to time to prevent cracking of the raised metal and distortion of the tube itself. Furthermore, it is necessary to file the edge of the holeirequently to prevent cracking of the metal. The cup or boss is raised until it has any outside diameter equal to the inside diameter of the branch which will be indicated by reaching.

a the circle scribed on the main tube.

To form the saddle on the end of the branch tube -to fit over the boss on the main tube, the following steps are necessary with the hand. method. It is first necessary to lay out a template paper pattern for the branch so that it fits the circumference of the main tube. The pattern is then cut out,-wrapped around a tube of a size proper for the branch, and the end of the branch is marked along the curved end of the pattern. With a hammer-and chisel, the branch is out ofi and the burr is filed away. The trimmed branch is placed on the main tube to see that it fits snuglyand further filing may be necessary to make-it fit properly. Using. dividers, an arcuate line parallelto'the arcuate end of the branchis scribed at a-point spaced ashort distance there; from" andis'subsequently used as a guide while turningthe saddle. Since the cutting operation hardens the adjacent metal, especially if it is copper or copper alloy, it is necessary to anneal the trimmed end of the tube. Then using :a bumping hammer or a similar tool, the branch end is worked on the edgeof an anvil. The area from the scribed line to the end of the branch is worked outwardly until the saddle of proper.

shape and size is formed thereon. During the metal-working operation, frequent annealing will be necessary to prevent cracking of the metal. a Before the branch is connectedto the main tube, it is usually necessary to place the saddle over the cup or boss to finally check the fitbetween the saddle and the boss. It is often necessary to further .work, the boss up into the saddle.

mustqbe exercised and it is necessary that the workbe performed by skilled labor.

uniformity.

.Oneofthe objects of my invention is to pro,-; vide a methodfor forming. the desired comple mental portions; on sections; of tubing to join. them;in"zangular relationship, the method being.

Even with such care by qualified labor, the resulting produotis .not always of the desired accuracy and;

portions on sections of tubing to join them in angular relationship which is of such a nature that the complemental portions will be -accurately formed to predetermined dimensions and will be accurately located at predetermined positions.

Still another object of my invention is to provide a method and apparatus bf the type indi cated of such a nature that the complemental portions may be so formed that the sections of tubing can be joined to each other at. various selected angles.

Various other objects will be apparent from the following description.

According to my invention, the branch-receiving boss is formed on the side of the main tube and the complemental saddle is formed on the end of the branch tube by a novel method and apparatus. The complemental portions on the two tube sections will be accurately formed and lo'cated'so thatthe sectionscan then be connected to each other in the desired angular relationship.

The branch-receiving boss is formed on the side of the main tube by first punching an elongated opening in the form of an ellipse in one side of the main tube. This tube is usually larger than the branch tube although'both may be the same size. The opening is disposed at such apoint that its center will be at the desired center of the branch to be joined to the main tube. Also, the opening is so disposed that its longer or transverse axis extends longitudinally'of the tube and is in the same plane as the axis of the tube. The opening is of a proper size to permit raising of a flange of desired height around it to form a boss having an external diameter cor-responding to the internal diameter of the branch which :it is to receive. The flange israis'ed by placing the tube in a female die which has a semi-cylindrical channel for receiving it. At right angles to the channel is a circular boss-forming chamber which is adapted to receive a male die member. This boss-forming chamber is disposed in surrounding relationship to the opening in the tube and has a diameter greater than-the transverse axis of the opening in the tube, to permit raising of the flange of desired height around the'o'pening. The male die member is disposed initially within the tube and is then moved at right angles to the axis of the tube through such opening into the chamber of the female die member. The male die member is of such size that it will 'raise the metal around the opening until it"contacts with the wall of the chamber, thereby forming the upstanding flange. Thus, the desired boss is formed on the tube.

The saddle complemental to the boss is -formed on the end of the branch tube by first trimming the end 'to-a-suitable shape. This shape is such that the -'end fits the contour of the main tube when the branch is disposed on the main tube at the same angle at which it is to be connected "to the main tube. To form the desired flange on the trimmed end of the branch and, thereby, fdrmthe saddle, the end is placed in a female die member. This die member has a cylindrical tubereceiving chamber and a semi-cylindrical channel or chamber disposed at right angles thereto for receiving a male die member. The tube is so disposed in the tube-receiving chamber that its trimmed end extends a selected distance into the semi c'ylindrical channel. The male die has a cylindrical forming portion which is complemental to and is adapted to be inserted into the tube-receiving chamber, and a semi-cylindrical forming portion at right angles thereto which is complemental to and is adapted to be forced into the semi-cylindrical channel. When the male die member is inserted into the female die member, the extending end of the tube is engaged by the semiwylindrical portion of the male die and is bent to the shape of the channel in the female die member. This channel will be of the same shapeand size as the outside contour of the main tube to which the branch is to be joined. Thus, the desired s'a'ddle is formed on the end of the branch.

After the boss 'or'ithe main tube and the compleme'ntal saddle on the branch tube are formed as'ind'icated, the saddle is positioned over the boss and the two sections are suitably joined together, as "by soldering. It will be found that thetwo portions accurately interfit and will serve to connect the branch to the main tube at the desired angle.

The preferred embodiment of my invention is iliustrated in the accompanying drawings wherein similar characters of reference designate corresponding parts and wherein:

Fig. 1 is a front elevational view, partly broken away, of a machine which I preferably employ in forming the branch receiving boss on the main tube.

'Fig. 2 is an end elevational view o'f the machine shown in Fig. 1.

Fig. 3 is a transverse sectional view illustrating the main tube positioned between the cooperating male and female die members used on the machine of Figures 1 and 2 in forming a boss adapted to receive a branch at right angles to the main tube, the male die member shown being the one used in the first step of the forming operation.

Fig. 4 is a similar view to Fig. 3, illustrating the male member used in the second and final step in the formation of the boss in position in the female die member.

Fig. 5 is a perspective view of the bottom side of the female die used in the boss forming operations.

Fig. 6 is a plan view of a short length of a tube having an opening of preselected size and shape to facilitate the formation of the 90 boss.

Fig. 7 is a side elevational view of the length of tubing showing the boss formed thereon.

Fig. 8 is a longitudinal sectional view illustrating cooperating male and female die members for forming a boss adapted to receive a branch at approximately 45 from the main tube, the male die member shown being the one used in the first step of the forming operation.

Fig. 9 is a view similar to Fig. 8 but taken at right angles thereto.

Fig. 10 is a longitudinal sectional view taken through the female die of Fig. 8 and illustrating the male die member used in the second step of the forming operation in position in the female die.

Fig. 11 is a perspective View of the male die member of Fig. 8.

40f Fig. 10.

.on theuend of the branch tube.

Ri -.12 is a similar .viewof the'ma esliemem e Fig. 13 is a perspective view of the :buttom. side of. the female die used. in the. formation of he 45 angle boss. Fig. 14 is a top plan yiew of a. len th. f. tubing showing an openingformed therein of preselected .size and shape to facilitate forming the 45. angle 13055.. ..J Fig. 15 is a side elevationalNifiW showing ,the. completed 45 angle boss formed-,onthe tube. Fig. 16 is a side elevationaleviewiofamachine .which I preferably employinzforming the. saddle Fig. 17 is a longitudinal .sectionalwiew illustrating the cooperating. male. and female, die

members used on the machine .of Fig.;{.16 in. forming the 90 saddle, the end of. the,;branch being -in.position therebetween. 1... 1. 1

Fig. 18 isaview. similar to Fig. 17. but'taken at .right angle thereto... I

Fig. 19 is an enlarged perspective view of, the male die member used for forming the 90. saddle.

Fig. 20 is an enlarged perspectiveviewillustrating the female die member usedforforming' the 90 saddle.

Fig. 21 is a side elevational view illustrating 'the manner in which the end .of the branch is trimmed to facilitate formation of the 90..saddle.

Fig. 22. is a view similar to. Fig. 21 but taken at right. angles thereto.- I

. Fig. .23 is aview similar to Fig. 21 butshowing the 90 saddle formed on the .end of. the branch. Fig. 2i is a view. similar .to Fig. .23..but.taken at right angles thereto. 1

Fig. 25 is a detailed viewymainly in. section, illustrating the female die member used informingthe 45 angle saddle, the male die.member which isused in the first forming. operation being shown in position therein with the: end of. the branch being positioned between the; two die members.

I 1 Fig. 26 is a similar view. illustratingthemale die member used in the final. 45? saddle forming operation positioned in the female die member. Fig. 27 is a perspective view; of the male die member of Fig. 25. Fig. 28 is a perspective view member of Fig. 26. Fig. 29 is a perspective-viewer .thei'emale die member shown in Figs. 25 and 26..

Fig. .30 is a side elevational view.,; illustrating howthe end of the branchis trimmed tofacilitate formation of the 45 saddle.

1dr the mat die Fig. 31 is a view. similar to Fig. but taken at right angles thereto. v 3 Fig. 32 is a similar view to, Fig.- 3Q illustrating the-45 saddle formed on the end of the branch.

Fig. 33 is a view similar to Fig. 3 2 but taken at right angles thereto.

4 b Fig. 34 is a transverse sectioinaliview through the main tube and-associated 905. branch illustrating how the two members interiit and are secured together.

Fig. 35 is a side elevational view, partly broken 6 away, of the structure illustrated in Fig. 34.

Fig. 36 is a view, partly inside elevation and partly in section, illustrating the 45 angle branch positioned on the main tube. .trated inFigs. 1, and 2 a machine uponwhich the boss forming dies are adapted to be mountedfor actuation. This machine comprises a table I p n t upper r ace ,of wh c -ris su p te to support the dies and the actuating means, for :the dies.

The standard 2 consists of a. pair of vertically disposed supporting Plates 3. These plates are laterally spaced on the table I and each of them has a horizontal flange 4 which rests on the upper surface of the table and. which is bolted thereto by bolts 4a. Each of the plates 3' has a lower vertically disposed section 5, which carries flange 4, an intermediate forwardly and upwardly curved section 6, and an upper vertically disposed section I. The lower edge of the section 1, indicated by the numeral Ia, is horizontally disposed at a point spaced a, suitable distance above the upper surface of the table. It will be noted in Fig. 2 that the section I of the plate and, consequently, the edge Ia is disposed forwardly beyond the front edge of the table. The plates 3 are rigidly joined together by a vertically disposed rear plate 8, which has its ends bolted thereto by the bolts 9 adjacent the upper ends of plates 3, and by a horizontally disposed plate ID which is bolted by bolts I I to the extreme upper ends of the plates 3.

Mounted for vertical movement between the plates 3 is a slide I2. This slide has the lower end of a piston. rod l3 threaded thereinto, as at I4. The rod I3 extends upwardly through a packing gland lfi into a vertically disposed hydraulic cylinder IS. The cylinder I6 is carried by the horizontal plate ID. The cylinder l6 has a piston I'I disposed therein which is connected to the upper end of the rod I3. Mounted above the hydraulic cylinder I6 is an air cylinder I8. The cylinder I8 has a piston I9 therein which is connected to the piston IT by a vertical rod 20.

A. hydraulic pump 2l is secured to the upper surface of table I and may be of any suitable type. The pump is connected by a line 22 to the lower end of the cylinder IS. The flow of fluid to and from the cylinder I6 is controlled by a valve 23 of a suitable type. The valve 23 may be opened to connect the pump 2| to the lower end of cylinder I6 and by actuating the handle 24 of the pump, fluid will be forced into thelower end of cylinder I6 and will force the piston II upwardly. This will also force the piston I9 of the air cylinder I8 upwardly. The upper end of cylinder I8 is connected by a line 25 to a valve 26 of a suitable type. The valve 26 will serve to connect the line 25 either to an air pressure line 21 orv to a vent 28. At the time the hydraulic piston I1 is moved upward, the valve 28 will be in such a position as to vent the line 25. To move the slide I2 downwardly, the valve 23 is actuated to permit hydraulic fluid to fiow from cylinder IS, through line 22, back into the pump 2! At the same time, the valve 26 will be in such position as to connect the pressure .force, while air pressure will move the slide I 2 downwardly and more quickly than the upward movement. Thus, means is provided for moving the slide l2 vertically relative tov plates 3. 'An indicating pointer I2a may be attached to the H v b front side of the slide I2 for cooperation with Withreferenceto the drawings I have illus- .70

suitable calibrations on the forward edge of one of the plates 3 to indicate the vertical position of the male die member, as will appear later. The slide I2 is in. the form of an. inverted box and a link 29 ,extends upwardlydnto the ayertical standards-aimsstanda d zris-.adapted.;-, ql pp tiq thei's t. .T ppe tfiudfi sth f9fi11$886 Z L liiil pivotedat a point nn'dway 'be'tween the anii mldway btweeri lts 'efidsfithere chromed an sides of slide l2 by means of a pin 30. The link opening extending through the top of the die n -is providedwith'a bifurcated lower en'd3l, wvhich- 'produces a siibstan-tiallycylindrical formeas indicated in'Figs. 3-an'd4. :AsWill later appear, ing chamber 5El disposed 'at rightangles to the -this bifurcated lower end 3 is adapted to receive ch l 49.

a -cooperating lug" formed on a male die member. Each -ofithe-male die members is provided'with Iheend3 I-' carries-a'pin-32 which-extends through aan upwardly xteriding lugfi lfadapted'to'b i'djg aligned transverse openings 33 formed therein. -'"p0sed"'-in 'theibifurcated. rnd 3i1oftther1ifik T which is s d v1J0 Carry 2B. The lug 5| is Provided with a transverse female' die, is adapted to 'be mounted in horizon-i 10 opeping f receiving th pin 32, The lug 5|"wi11 *tal position on the lower edgesla ofthe vertical fib 'tig-htly-iwithjn-the.end:3|I0f'lthe 11111;, *sections' 1 ofthe plates-t. Iheplate 34 carries 'As illustrated bestin FigS.-3 and"4,the t0p 0f mmea'chend-an-angle membeftt suitably secured the 'female die "member 48 .is "provided "with T-thereto. Each angle member cooperateswith the threaded sockets 5z:fortreeeivin ;t x -r t top surface of the plate s i to form a channelfor 15 '39-carrie'd by 'ithei 'plate u. 1- It will'be apparent ireceivinga tongue 36'fastened to the outersurthat withf the female die' 'member 48rzsecure'd'to faceof 'eachplate 3 in alignment with the edge 'the' plate i withithef plate positioned ontth'e la thereof. Thus, the die-carrying plate 34 may sstandai d' l' and with 'one bf them-ale die'membe qui'cltly mounted on the standard' z by slipping bers suspended by the link: 29;?themale'die'memthe angle: members 35 over'the' tongues tt. The iizo ber nay be move'd upwardly-through the chamupper surface of platedd will abutedgesia while ber 50 of th female die member-by raising the "the inner-edges "of angle members '35 "will e-but sli'de l2.

'the outer surfaces of the plates'tfOne of the plates ln fo'rming a 90 angle Lboss according to' my '-"'3*carries'a sleeve3'l on its outer surface at a point -methodiand' withitheapparatus described, I 'first "slightly above the edge la. This sleeve 3'! carries 325 l-talke a' length of main tubing 53' (Fig. 6)'and'form a pin 38 which maybe moved vertically therein an elliptical opening 54 therein. This opening- 54 *and relative to aligning openings formed in the may bei punched 'or'iotherwise formed in the'side adjacent angle member'35 and tongue 36. When 0f"the"t1'1be." Thdcenter of' this openin the' plate 34 is positioned on the standard 2, the located at the centertofthbranch to extend from *pin 38 will extend into the aligned openings in 93 i theltl l'be-l il *TheopenmgI M' willxexten'dilengthmembers35 andtt and will serve to lock the wise of the tube with its transverse axis inthe *plate 34 in position. Thus, horizontal and vertical rsam 'r ane as t axisefithe u p "movement of the plate 34 relative to thestandar'd ing'fifisrdf apredetermined'siz toz-permit raising "*2 will be precluded. ofi a fiangei 6f desired heightraround it to form the i The plate' 3 i, as previously indicated, isadapted i355 cylindrical boss 55 (Fig. l7) ihavlng an external *to carry the female die member of the boss formniameterlcorrespondirrg to thezinternal diameter Ing die. The die member will be bolted thereto of the' branchiwhich it is to. receive. The trans- "by-means of screwbolts 39,-as indicated in Figs. '=verse axis rof the opening willbe of alength 1, 3, and' i. The platefifiis provided with alarge, :e'qualrto" the deslrd 'internal diameter of the boss 'centrally disposed opening 46 extending com- '40 55 less the total height'irof the two portionsof' the :pletely' therethrough. This opening lllwill receive flange raised at the' ends of the' open'ing and which *the'lowerend of 1ink29 and is adapted to permit will extend upwardly from the highestpointon the male die member to pass upwardl through the tube. The' conjugate axis 'o'f the .opening 54 the plate, as Will later appear. The die carried :W'illbe of a' len'gthtequal'tmthe 'diameterof the "by plate 34 may be easily removed, by removing boss 55les's the-height of 'the" two portions of the "bolts SS, and bereplaced with a die of di'fierent flange'raise'd at the-sides of the'opening. Thus, a size. On the other hand, 'if preferred, several flange can be raised around theopenin'g'and thls "of-the plates fit may beprovided for carrying flange will' have alevel upper edge, as shown in diilerent size dies and maybe quickly'm'ounted Fig. 7. 'on thesta-ndard 2 orbe removed therefrom. "Toraise'the flange in'theman'ner indicated to 'Attached to the table l, ubstantially midway produc the boss 55,' the't11be53with theopen- "betweenthe plates 3, and extending outwardly ing 54"formed therein is placed upwardly within from the tableis-a horizontal Supp ng arm-4|. thechannel lll'o'fthe femal die '48, the'die being This arm carries a splitsleeve or collar 42 on carried by the plate '34jwhich ismounted'onthe itsouter end'w-hich is in axial alignment with a =gtand rd 2'. The channel 49 has the same oonhe p g 49 in the plate 'The Sleeve M tour as the outer surface ofthe tube 53. 'Thetube receives a post 43 which may be adjusted veriis=suppoi-bediby the which i djuste'd t tically therein. The post "43 may be held in any the proper vertical position. The tube 53 'is so .desired positio y means f n eccentric locking 'posltioned-that'th'e opening "54 is centeredrela- 'device 44 which will actuate the split sleeve' t2 to 0 tive to the forming chamb'er50 in the die '48, it grip the post. T pper end of the post -43 being understood thata selected area'o'f th metal carries a horizontally disposed tube supporting "surr midigg'the openingill will'extendinwardly ithedlsk t5. from'allfiire'ctions towards the center of the In Figs. v3 to'-5, I have illustrated'the die memchamber 50 beyond the wall thereof. Since'the bers which are used in forming the 90 angle'boss "diameter or the-chamber 50 corresponds to the on th tube. In this operation I preferably emexternal diameterof theboss 55to be formed,an'd 'ploythe two

male die members

46 and 41 and a since-thesizeidfand shape of the'opening 5 4 is single female die member '48. The die members preselected 'as indicated above, the area of

th'e

46 and 41 are substantially bell shape. The memmetal extending inwardly beyond'the wall of -the "ber 41 is of somewhatgreater diameter than the 'm "chamber50' -wi1l bejust sufficient to form the up- 'member 48. The female die member is shown'in *s'tandingfiange which' wil1 produce' the'cylindri- .inverted position in Fig. 5. It comprises a tube- "cal bos's"55. receiving channel 49 which is formed on the lower The flange is preferably raised in two successide of the die'and extends lengthwis thereof. sive operation's' by employing"flrst"the male-die The-"channelw-is substantially semi-cylindrical menilzier 48 i-Eig. 3')-= antl thenthe' male rliein'em ber 41 (Fig. 4-) To accomplish this, the die member 45 is first positioned in the tube with the lug 5i extending upwardly through the opening 54, as indicated in Fig. 1. The pin 32 is used to attach lug "5| to the link 29. The slide I2 is then raised. This pulls die member 46 upwardl through the opening 54. The tapering side of member 46 engages the edge of opening 54 and gradually raises the surrounding metal and presses it outwardly, in the manner indicated in-Fig. 3. Th metal is bent without contacting the wall of the forming chamber 50 even a the die is pulled completely through the opening 54 and out of the tube, due to th fact that the largest diameter. of die 45 isconsiderably less than the diameter of chamber 50. a

The next operation employs the male die memher 4'! (Fig. 4) which is of larger diameter, and which is positioned in the tube 53 with its upper end extending through the partly formed boss. The male die member 4'! is attached, as before, to the slide I2. which is raised to pull the die upwardly. As the member 41 is pulled upwardly through the partly formed boss, it completes the formation of the boss. The greatest diameter of member 41 is equal to the internal diameter of chamber 50 less twicethe thickness of the metal of the tube 53. Consequently, as the member 41 is raised, it willpress the metal of the partly formed boss intocontact with the wall of cham-.

ber 50, as indicated in Fig. 4, and will form cylindrical boss 55, illustrated in Fig. 7. It is PIB-r ferred to draw the metal, surrounding opening 54 to form the boss in two successive operations rather than in a single operation to prevent cracking of the metal. However, it will be noted that metal extending completely around the opening is raised simultaneously, as distinguished from the hand method where only small sections are raised by successive contact of the pin with the edge of the opening. Better and more uniform results will be obtained with my method.

The boss 55 will serve to connect the branch at right angles to the tube 53. However, it is often desirable to connect branches at other angles. In Figs. 8 to 15, I have illustrated die members for producing a boss for connecting a branch to the main tube at an angle of approximately 45.

In forming a 45 angle boss, I first take a. length of main tubing 56 (Fig. 14) and form an opening 51 therein. Theopening 51 will be similar to opening 54 (Fig. 6) except that it will be more elongated since the boss 58 (Fig. 15) to be produced in this instance must be of elliptical form. The boss 58 will have a beveled shoulder 59 at one end and a curved shoulder 6|] at the other end formed on the upstanding flange. The elliptical boss 58 will have transverse and conjugate axes corresponding in lengths to those of the elliptical end of the branch which the boss is to. receive. Therefore, the corresponding axes of the opening 51 will be the same lengths, less the height of the portion of the flange raised at the ends thereof, as those of the boss. The die members which I employ in forming to the 45 boss include the two male die members BI and 62, illustrated in Figs. 8 to 12, and a single female die member 63, illustrated in Figs. 8, 9, and 13.

The male die member 6| has the shape illustrated best in Fig. 11. It is of elliptical cross-section and has a vertical lower surface Bio and an inwardly tapering upper forming surface 64. It is provided with an upstanding lug 65 for connecting it to the link 29 depending from the slide The male die member 62 is considerably longer than the die member Bl although it has a midportion of the same width as the mid-portion of die 6|. It i of elliptical cross-section and has an inwardly tapering forming surface 66 which extends completely therearound with the exception of one end thereof. At'this'end there is formed a blunt vertical lower endportion 61 and an upper concave forming surface 68. Attached to the upper top surface of the die 62 is a lug 69 which is used for connecting'the die to the link 29.

The female die member 63 is-shownin inverted position in Fig. 13. It comprises a tube-receiving channel 10 which isformed'onthe lower side of the die and extends lengthwise thereof. "The channel 10 is substantially semi-cylindrical and is of the same contour as the outer surface of the tube 56. Midway between-the ends of channel Ill, there is formed anopening extending through the t0p-0f the die which produces a forming chamber-1|. The forming chamber II is mainly of elliptical form with its transverse axis in the same plane'as the axis of channel HI. As best shown in Figs. 10 and 13 at one end of the cham ber '11 there is aconvexsurface I2 complemental to the surface 68 formed'on the end of the male die member 62. The remaining surface of the chamber II is complemental to the surface 65 of the-male die 62. I I

To raise the flange inthemanner indicated to produce the boss 58,.thetube-5G with the opening 51' formed therein. is placedupwardly within the channel). of thefemale die 63, the die being carried-by the plate-34 on the standard 2. The tube is supported by'the disk-'45. The tube 56 is so positioned-that the opening 51 is centered relative to theforming chamber It in the die 63. A: selected area of the metal surrounding the openingET-will extendiinwardly from all directions towards-the center of the chamber H be-. yondthe wall thereof, Since the size and-shape of the chamber H correspond to that of the boss 58 to be-formed, and-since the size and shape of the opening51 is preselected as indicated above, the area of themetal extending inwardly beyond the -,wall of the chamber 1 twill-bejust sufiicient to form the upstanding flange and will produce the ellipticalboss 58. i I Y The flange is preferably raised in two successive operations by employing first the male die member 6| (Fig. 11') and then the male die mem-- ber '62 (Fig.-12). To accomplishthis, the die member 6! is first positioned in the tube with the lug 65 extending upwardlythrough the opening 51. The lug 65 is attached to link-29 and the slide "is then raised. This pulls die;member 6| upwardlyithrough the opening 51. The tapering forming surface 64 of'the' die engages the edge "of opening 59. and gradually raises the surrounding metal and presses it outwardly, in themanner indicated in Figs. Band 9.- As shown in Fig. 8, thewidth of themid-portion of the die is the same as that ofchamber 1| less the thick ness of the metal of the tube at each side thereof. Consequently, themetalwill be-pressed against the sidesof -the chamber 1|." However, the metal at the end of the opening 51 will not be'pressed against the ends ofthe chamber H, as shown in Fig. 9, due to the fact that the'die member lit-is shorter than the chamber-H.411 order to permit upward passage of the, maledie 6| through the female die 63. 9 1

The next operation employs the male die member 62(Fig. 12). This die memberis alsoposltioned in thet'ube 56 and has its upper end extending through the partlyformed boss. The male die member 62 is attached to link 29. As the die member 62 is pulled upwardly into the partly formed boss and the complemental forming chamber "II, the formation of the boss is completed. However, it will be noted that the inale die member 62 merely moves completely into the female die member 63 and not through it. The tapering surface 66 will further bend the metal with which it contacts into forming relationship with the complemental surface of the chamber II. Also, the concave forming surface 68 will bend the adj'a'c'entmetal "into contact with the complemental convex surface I2. Thus. the elliptical boss 58 will be formed with the inclined portion '59 of the flange formed by cooperating stiffaees 66 and TI and'with the 'c'onvexly curved portion 60 of the flangeformed by the cooperating

complemental surfaces

68 and 12.

It is to be understbod that bosses of other shapes and sizes may be formed by varying the shapes of the 'die members.

In Fig. 16, I have illustrated a machine u on which the saddle-forming *die's are adapted to be inounted for actuation. This machine comprises a supporting table I3. 011 the top surface of this table I3 at one 'e'iid thereof is a die-supporting bed plate M which may be 'wel'ded to the table. Also at this end is a U-shaped standard I which has its open end directed toward the front of the table. At the opposite end of the table is everti'c'al standard I6. The

standards

75 and 16 are connected together by a top plate I1 which has it's-one ehd bolted to member 76 by bolts I8. The opposite end of plate I! carries an "abutment I9, which may b welded thereto, and which abuts the outer surface or standard adjacent its upper "end. A similar abutment 80 is welded to the top surface of the table I3 and abuts the outer surface of standard I5 'at its lower 'end. The'meihbers 19 "and 8t serve as thrust members to prevent outward movement of the standard 15. curing the metal-arming farming operatioi as will 1ater wheat. The lower portion of standaid I6 has its inner surface abutihg theend of 51' e "M whicnwin serve topr'event inward moveneat cf standard T5. I H

The female die unit, illustrated generally bythe athe sm, merely'rests-"oh the'top surface of'the plate 14. Its outereffd w'iIl 'e g'age the standard I5. Adjacent the inner end o'f'the die unit 81 an upstairs bin '82 is provided on the bed plate 14 for preventing inward movement of the unit =8I.

'Oh'the upper "siiiface of 'the table 13 at the end opposite to where the late M is disposed, a bed plate 88 "is secured "in a suitable manner by welding. This -plate 83 has a guid'ew'ay 84 formed therein and extending longitudinally thereof. This guidew'ay receives suitable guide members 85 that' are attached to the lower 'side of a h orizoht'ally disposed hydraulic cylinder 86. Thus,

the cylinder "86 is merited "'for axial movement. I

- The cylinder at has a biston 90 =slidably mounted therein. This piston is "secured to a. piston rod 9| which projects from the cylinder through a packing gland 92. As shown best in Figs. 17 and 183 the end of piston iod'9'l is previded With an enlarged disk-like portion 93 which has a reduced 'c'ylihdrical shank 94 extending therefrom. This shank 94 is adapted to extend into a cylil'rdiical secket termed 'in'the male' die member; indicated generally by numeral 96. l

A hydraulic ump 91 is provided for mating the iston in t'he cylinder 86. Thispump maybe 01 any suitable type and is operated by aha'ndle 98. A line 99 leads from one end of the cylinder 96 to the 'puhip'while a second line 160 leads from the other "end of the cylinder to the pump. ey actuating a suitable valve IDI, thelines 99 and 'I 99 maybe selectively connected to the high pressure or low pressure side of the pump. Thus by actuating valve I01 and handle 98, the piston 90 and, ccnsequent1y, the rod 9| may be moved in the desired axial direction.

The female die unit "BI includes a tube-holding section I92 and a forming section I93, which are adapted. to be disposed side by side in the manner illustrated in Figs. ldancl 17. The section 102 is composed of an upp r block 104 (Fig; 16) and a lower block I05 which have semi= cylindrical channels of proper contour and size to receive and clamp the tube upon which the saddle is to be formed. The cooperating blocks I04 and I05which embrace the tube are secured in clamping relationship to the tube by bars I96 which have their lower ends pivoted to blocks 5 and which swing into and out of vertical aligning channels formed on the outer surfaces of the blocks. Each bar has threaded on its upper end a nut I91. By tightening nuts IIl'I after the bars are swung into operative positions, the two blocks I94 and I95 will beclam ed together. The forming section I03 of the female die unit is adapted to be used in forming the 90 saddle. It is similarly formed of two blocks I98 and I09, as shown best in Fig. 20. These blocks have semicylindrical channels therein adapted to cooperate to form -'a cylindrical chamber I I9 in which the tube will be clamped. These blocks are secured together by pivoted bars I II similar to the bars I06 of the unit I02. The faces of the blocks I08 and I99 are provided with aligning semicylindrical channels which cooperate to produce a forming channel 1I-2 having its axis disposed at right angles to the axis of the formin chaznber III]. Securedto the outer side of the block 199 and projecting into the channel II-Z is'a tongue I I3. I

The male die member 96 for cooperating with the section 163 of the female die member to form the 96 saddle is illustrated in Fig. 9. It comprises a semi-cyiindrica-l forming portion H4 which is complemental to thechannel 'II-2 of the female die -section I63. 0n the curved side of the portion H4 midway between th ends thereof and at right angles thereto is a cylindrical shaped forming portion which is comple'rhen'tal to the chamber III] of the female die section I03; One end of the portion H4 is provided with a channel I I6 for receiving the tongue I=I3 as the male and fem-ale dies are moved into cooperative relationship as will later appear.

When the male die member 96 is disposed on the piston rod 9I, the cylindrical shank 94 ex tends into "a cylindrical socket I-II (Figs. 17 and 18) which is formed at a central position in $5 the fiat surface II 8 of the forming portion I'll 13 of the die. To fasten the die to the piston rod, a screw bolt H9 is provided which is inserted through a chamber I20, formed in the portion H of the die, and which is threaded into the shank 94.

In forming the 90 saddle, the end of the branch tube I2! is trimmed in the manner illustrated in Figs. 21 and 22. The edge I22 will have such a curvature that it will straddle the main tube 56, to which it is to be joined, when it is disposed at right angles thereto. To form the desired flange on the trimmed end of thebranch, and thereby, form the saddle I23 (Figs. 23 and 24), theend of the tube I2I is disposed in the female die unit 8|. It is so disposed in the forming portion I03 of the die unit that its trimmed end I23 extends a selected distance into the semicylindrical channel H2, as illustrated in Fig. 16. To properly position the end of tube I2I in the die I03 it is merely necessary to align the outermost extremity I22a of edge I22 with the flat face H8 of the die. The portion of the metal extending into the channel H2 will be suflicient to form the flange or saddle I23.

The die unit 8|, in which the tube I2I is clamped, will be positioned on the bed plate 14 in the manner illustrated in Fig. 16, the outer end of the tube extending through the member 15. The male die member 96 is mounted on the piston rod M. The cylinder 86 is adjusted by operating the handwheel 89 until the forming portion H5 of the male die extends into the end of the tube I2I in the female die section I03. The unit 8I is shifted laterally to the necessary extent to permit this. It maybe necessaryalso to initially adjust the die 96 about the axis of rod 9| until the tongue H3 is guided into slot H6. This properly aligns the forming portion H4 of the male die with the channel H2 of the female die. To complete the metal drawing or forming operation, it is' merely necessary to properly actuate pump 91 to move piston rod 9| in the proper direction. This will force the male die member completely into the female die member.

As the male die member is forced into the female die member, the cylindrical portion H5 will extend into the end of the tube disposed within chamber I I0 and will maintain the tubular shape of the end of the tube. The semicylindrical forming portion H4 will engage the projecting trinnned edge I22 of the tube and will bend it into contact with the surface of the channel H2 around the end of chamber H0. Thus, all of the material of the projecting edge I22 is simultaneously bent to form the saddle I23 which will be at right angles to the axis of the tube. Consequently, the saddle will be more accurately and uniformly formed than with the prior art method wherein small sections of the metal are bent successively with a hammer.

As shown in Figs. 34 and 35, the end of the branch tube I2I which has the saddle I23 formed thereon, is placed over the boss 55 of the main tube 53. The external diameter of the boss 55 will be the same as the internal diameter of the tube I2I. The saddle I23 will exactl fit the contour of the tube 53 around the boss. The branch tube I2I may be secured to the main tube by soldering, as indicated at I24. The saddle and the boss will accurately interfit and will serve to join the tube sections at right angles to each other.

' In forming the 45 saddle for cooperation'with the 45 boss'58 of Fig. 15, I employ the die mem-' bers illustrated in Figs. 25 to 29 inclusive.

The forming section of the female die unit is illustrated in Figs. 25, 26 and 29. This section I25 is made from two parts I26 and I21. These parts are secured together by pivoted rods I28, which cooperate with aligning channels in the two parts in the manner described with reference to the die unit BI. The parts I26 and I21 have semi-cylindrical channels formed therein which cooperate to produce a tube receiving chamber I29 of cylindrical form. One face I30 of the section I25 is flat and vertically disposed. The other face includes an inclined surface I3I and a vertical surface I32 at the lower end thereof. The surface I3l is disposed at an angle of 45. Joining the surface of the chamber I29 to the surface I3I and the vertical surface I32 is a' saddle forming seat I33. This seat I33 inclines inwardly from the surface I32 to its junction with the wall of chamber I29. The seat I33 also inclines inwardly from the surface I3I to its junction with the wall of chamber I29 with the exception of a convex portion I34 at its upper end.

The male die members for forming the 45 saddle are illustrated best in Figs. 25 to 28. I preferably employ a male die member I35 and a male die member I36 which are used successively with the female die member I25. The member I35 is adapted to be attached to the piston rod 9I in the same manner as described with reference to the die member 96 (Fig. 17). This die member I35 comprises a forwardly projecting portion I31, which is of smaller cross-section than that, of the tube to be formed, and an upstanding forming portion I36. The top surface I39 of portion I31 is curved to the same contour as the inner surface of the tube to be formed. A forming surface I40 is formed on the forward edge of the portion I38and merges with the surface I39. The surface I40 curves concavely in a vertical plane and convexly in a horizontal-plane. Also, it is angularly disposed relative to the horizontal so that it will be complemental to the convex surface I34 of the female die I25, as shown in Fig. 25.

The male die member I36 is similar to the die member I35 but is of larger cross-section. It is provided with a forming surface I4I which is of the same outline as the surface I40 of die I35 and which, consequently, will be complementary to the convex surface I34 of the female die I25, as shown in Fig. 26. However, the forwardly extending portion I42 is of larger cross-section than the similar portion I39 of the die I35. This extension I42 is mainly of cylindrical form and will fit into the tube to be formed, corresponding in contour to the inner surface thereof. The rear endof the die I36 at its lower edge is provided further with an inclined forming surface I43, which merges with the lower curved surface of extension I42. This surface I43 will be complemental to the inclined surface I33 of the female die I25, as illustrated best in Fig. 26.

In forming the 45 saddle, the branch tube I44 is trimmed in the manner illustrated in Figs. 30 and 31. The trimmed edge will fit the contour of the main tube 56, when the branch is positioned at the angle it is to extend therefrom, which in this instance will be at an angle of 45. Thus the trimmed edge will have the concave curve I46, as shown in Fig. 31, and the convex curve I41, as shown in- Fig. 30, at right angles thereto, the curve I41 extending at an angle of 15 substantially 45. The open end of the tube will, consequently, be of elliptical outline.

.Theend of the tube I44 is clamped in the female die I25 so that its trimmed end will extend from the forming chamber I29 of the die a sufiicient amount to produce the saddle I48 illustrated'in Figs. 32 and 33. To properly locate the tube in the female die, it is merely necessary to position the outermost extremity I49 thereof in substantially the same vertical plane as the surface I32 of the die, asshown in Fig. 25.

As shown in Figs. 32 and 33, the final saddle tobe produced will be of elliptical form and will be disposed at a 45 angle relative to the axis of the branch. Its flange will include an inclined forward section I50 and a concave rear section II. It is preferred that this saddle be formed by two successive metal forming or drawing operations to prevent cracking of the metal In the first forming operation, the male die I35 is employed. This die is forced into the trimmed end of the tube I 44 disposed in the female die I25. The only surfaces of the die I35 which will. contact with the trimmed end of the tube will be the surfaces I39 and I40. The surface I39 cooperates with the top of chamber I29 in the female die I25 to maintain the contour of the tube. The surface I40 engages the metal adjacent the end of the tube and bends is-upwardly and rearwardly into contact with the complemental forming surface I34 of thefemale die member. Thus, the complemental surfaces A40 and E34 will produce the curved section I5I of the saddle.

The next forming operation employs the male die I 35. In this operation, the die I36 is forced into the partly formed saddle and the female die in which the tube is supported. The extension I42 will serve to maintain the tubular shape of the tube adjacent its end. The surface I M will cooperate with the surface I34 to maintain the shape of the section I5I of the flange previously formed. The inclined surface I33 of die I35 will engage the extremity I49 of the tube and bend it downwardly into contact with the complemental surface I33 on the female die I25, as shown in Fig. 26. These surfaces I43 and I33 cooperate to produce the inclined section I50 of the saddle.

It is to be understood that saddles disposed at angles other than 45 on the branch maybe produced by variations in the shape of the male and female dies.

The branch I44 may now be mounted on the main tube 45 at a 45 angle. This is accomplished by placing the saddle I48 over the boss 58. The curved section I5I of the saddle will interfit with the curved section 60 of the boss; The section I53 of the saddle will cooperate with the inclined section 59 of the boss. The two sections may be secured together, as by solder indicated at I52. The saddle I48 and the boss 50 are ccurately formed so that they will properly interfit and so that the branch I44: will beconnected to the line 56 at an angle of approximately 45.

It will be apparent from the above description that I have provided a, method and apparatus for forming the necessary complemental portions on sections of tubing to permit joining of the sections in various desired angular relationships. The method is simple, eflicient, economical, and readily adaptable to modern production methods. The use of dies in forming the boss and the saddle will result in extreme accuracy and uni- 16 formity. Consequently, it is not necessaryto fit each saddle to a boss with which it is to co operate. Any saddle will fit any boss for which: it is designed to cooperate. The saddles and bosses will not only be accurately formed so that they properly interfit but also will be accurately located so that the branch will extend from. the main tube at the proper position. They will also be so formed that the branch and main tube will be disposed in the proper angular relationship.

The invention described herein may be manu factured and used by or for the Government of. the United States of America for government purposes without the payment of any royalty thereon or therefor.

Having thus described my invention, I claim;

1. The. method of joining a branch tube and a main tube in angular relationship, which comprises forming in the main tube an opening of elliptical outline, the opening being so disposedthat its transverse axis extends longitudinally of the tube and is in the same plane as the axis of the tube, the transverse axis of said opening being of a length substantially equal to thatof the corresponding axis of the branch less the height of the flange portions to be raised at the ends of said opening, the conjugate axis of the opening being of a length substantially equal to that of the corresponding axis of the branch less the height of the flange portions to be raised at the sides of said opening, simultaneously forcing the entire edge of said opening outwardly to raise a continuous boss around the opening which has a level upper edge, shaping the end of the branch tube to fit the contour of the main tube when disposed at the angle it is to be' connected to the main tube, simultaneously forcing the entire edge of the shaped end of the tube outwardly to form a saddle of uniform width which fits the contour of the main tube when disposed at the angle it is to be connected to the main tube, disposing the saddle of the branch tube over the boss of the main tube, and secur-- ing the tubes together.

2. The method of joining a branch tube and a main' tube in angular relationship, which comprises forming in the main tube an opening of elliptical outline, the opening being so disposed that its transverse axis extends longitudinally of the tube and is in the same plane as the axis of the tube, the transverse axis of said opening being of a length substantially equal to that of the corresponding axis ofthe branch less the height of the flange portion to be raised at the ends of said opening, the conjugate axis of the opening being of a length substantially equal to that of the correspondingaxis of the branch less the height of the flange portions to be raised at the sides of said opening, placing over said opening a female die having an opening therein corr'e sponding to the shape of the boss to be raised on said main tube, inserting a shaped male die into said tube, forcing said male die outwardly through said opening thereby simultaneously forcing the entire edge of said opening outwardly to raise a continuous boss around the opening which has a level upper edge, shaping the end of the branch tube to fit the contour of the main tube when disposed at the angle it is to be connected to the main tube, clamping the end of said tube in a shaped female die with said shapedend projecting therefrom a preselected distance, forcing a shaped male die against said projectiing end thereby simultaneously forcing the yen- 17 tire edge of the shaped end of the tube outwardly to form a saddle of uniform width which fits the contour of the main tube when disposed at the angle it is to be connected to the main tube, disposing the saddle of the branch tube over the boss of the main tube, and securing said tubes together.

JOHN J. CULLEN.

REFERENCES CITED UNITED STATES PATENTS Name Date Youngs Dec. 21, 1886 Number Number 18 Name Date Higgins Apr. 14, 1896 Chillingworth Jan. 4, 1898 Halifax Nov. 21, 1899 Sneddon Feb. 11, 1902 McCoy May 14, 1918 Kellogg Mar. 2, 1926 Kellogg Jan. 17, 1928 Lewis Mar. 29, 1938 Vogel Aug. 9, 1938 Ferris Mar. 12, 1940 Cornell Apr. 5, 1941 Nichols Sept. 29, 1942 Holmes et a1. Feb. 2, 1943 Kalwitz Oct. 16, 1945