US2889622A - Cold weld butt tool - Google Patents

Description

June 9, 1959 w. A. BARNES 2,389,622

coLD WELD BUTT TOOL Filed D80. 16, 1957 3 Sheets-Sheet 1 a) INVENTOR.

I WILLIAM A. BARNES "27/ rdinl June 9, 1959 w. A. BARNES 2,889,622

COLD WELD'BUTT TOOL Filed Dec. 16, 1957 3 Sheets-Sheet 2 inn k mw hf" W n FIG.8 t F39; I ,3 I6 ri WILLIAM A. BARNES 2/ KW m June 9, 1959 w. A. BARNES cow WELD BUTT TOOL Filed Dec. 16, 1957 5 Sheets-Sheet 5 FIG.6

INVENTOR. WILLIAM A. BARNES United States Patent COLD WELD BUTT TOOL William A. Barnes, Utica, N.Y., assignor to Kelsey-Hayes Company, a company of Delaware Application December 16, 1957, Serial No. 703,220

1 Claim. (Cl. 30-233) This invention relates in general to preparation of metal members for uniting by controlled conditions of pressure and confinement of fiow to produce a solid phase bond at a temperature less than the normal welding temperature thereof, and relates more specifically to a cutting tool for the performance of such preparation.

This application is a continuation-in-part of William A. Barnes, Serial No. 348,069, filed April 10, 1953, which application has been abandoned in favor of this application. This application relates quite closely to the subject matter found in the application of William A. Barnes et al., Serial No. 695,986, filed November 12, 1957. The specific center-stop feature of this invention is shown in applicants issued Patent No. 2,779,954. That patent is limited to specific blade formation features for preparing the end of workpieces, but shows the center-stop feature of this teaching, which was filed earlier.

The union of two metallic members by the use of controlled cold flow of the metal structures, is a relatively recent accomplishment insofar as reducing the basic principles to a practical and useable procedure is concerned. It has long been known that metal can flow at room temperature under proper conditions of loading. It is possible that the uniting, or welding, of two metal objects by controlled application of high pressure at room temperature has been known. However, the reduction of this knowledge to a practical level has only recently been accomplished.

Some metals will actually diffuse in such manner that a polished section of the union will not reveal a distinct junction between the two original members. Other metals have a distinct line dividing the original members. It has not definitely been determined what the nature of the union is in this line. It is definitely established, however, that an exceptionally strong union is produced between the two original members whether or not there is an actual diffusion. It is not the concern of the present invention whether the union is achieved by actual diffusion or some other phenomena of metal union, but rather with the results obtained. Accordingly, in this specification and in the claim, reference will be made to a union between members caused by controlled cold flow of the metal structures, or to a cold weld. It is not intended that this invention should be limited by the choice of words to describe the junction between the members.

Therefore, the object of this invention is to provide an improved spacing and surface preparation tool to provide clean ends on two workpieces to be joined, and to properly space the workpieces with respect to one another and to the die faces, in a cold-weld butt welding tool.

Other objects and a fuller understandingof the invention may be had by referring to the following description and claim, taken in conjunction with the accompanying drawings, in which:

Figure 1 is a perspective view of a hand type tool for cold welding butt joints in wire, the principles of this invention being incorporated in the construction and use thereof; 1

Figure 2 is a sectional view taken substantially as indicated by line 2-2 of Figure 1;

Figure 3 is an exploded view of one split conical die and its actuating spring, as employed in the die holders in the tool of Figure 1;

Figure 4 is a view as shown in Figure 2, and in addition illustrates a removable type of a spacing and surface preparation tool in the position assumed by the tool when attached to the cold-weld tool in preparation of the workpieces prior to operation of the cold-weld tool;

Figure 5 is a side elevational view of the spacing and surface preparation tool;

Figure 6 is a sectional view of both tools taken along line 66 of Figure 4;

Figure 7 is a sectional view of the cold-Weld tool only, but taken along line 6--6 of Figure 5, showing the dies closed upon the two wires and the wires at the moment of upset and cold welding, and;

Figure 8 is a view of the cold-weld tool opened and the conical dies parted ready to remove the workpieces as a single cold-welded unit piece.

In the drawings there is represented a hand type tool for cold welding butt joints in a wire. The tool is represented generally by the reference character 10. The prmciples of the present invention can apply equally well to power driven, hand, and bench types of tool.

The tool 10 has a carriage 11 and a carriage 12. The carriage 11 has a front face wall 13 and the carriage 12 has a front face wall 14. The carriages 11 and 12 are mounted for relative movement toward and away from one another along a fixed path of reciprocation with the front face walls thereof facing one another.

In the embodiment of the invention as the tool 10, the carnage 11 is secured in a fixed position upon a handle 15 for convenience. The handle 15 is provided with a slot 16 similar in many respects to the longitudinal slot of a conventional sliding side jaw wrench. In fact, the carriages 11 and 12 are analogous to the fixed and movable jaw of a conventional sliding side jaw wrench. The carriage 12 is provided with a jaw guide rail or key 17 to fit into the slot 16 and reciprocate longitudinally therein. The carriages 11 and 12 are further aligned with respect to one another by means of a guide dowel pin 40 which may be carried by one of the carriages and fit slidably into a socket of the other.

In order to drive the front wall faces 13 and 14 toward one another, a linkage drive mechanism is provided to force the key 17 to move longitudinally in the slot 16. The drive mechanism comprises generally a handle lever 13 pivotally carried at the end by means of a pivot 20 as illustrated best in Figure 1 of the drawing. A link 19 is pivotally secured to the handle lever 18 by means of a pivot 21, and is pivotally secured to the handle 15 by means of a pivot 22. It can be seen from the illustration in Figure 1 of the drawings that the linkage thus provided affords a fast movement of the carriage 12 toward the carriage 11 during the first portion of the movement, with relatively low driving force. The speed of advance of the carriage 12 rapidly decreases as it approaches carriage 11, but the power multiplies rapidly. This type of linkage drive is well known and understood, and need not be further described except to point out that the amount of pressure which will be exerted be.- tween carriage members 11 and 12 is exceedingly high. I

Each of the carriages 11 and 12 are substantially identical except for the fact that one is preferably stationarily mounted and the other is reciprocally driven. Accord ingly, the construction of carriage 12 and its associated die parts will be explained, and it will be understood that the construction of the carriage and associated die parts of the carriage 11 is substantially identical.

The carriage 12 has a slot 25 running longitudinally thereof with respect to the direction of reciprocation, as best shown in Figure 2. The slot has a mouth portion 26 and a tapered die bed portion 27. Any particular cross section of the slot 25 will be substantially key-hole shape with a small mouth and a large die bed portion. The tapered die bed portion 27 opens in the front face wall 14 and tapers rearwardly through the carriage 12.

A split die 20 resides within the slot 25 of the carriage 12. A similar split die 31 is provided in the carriage 11. The die 39 is conical in shape and comprises two sections 32 and 33. The section 32 has a longitudinally extending clamping passageway cavity 34 extending axially along the mating face of the section 32. 1 The section 33 has a similar clamping passageway cavity extending axially along the mating surface thereof, this cavity being indicated by the reference character 35. Together the cavities 34 and 35 define a longitudinal opening through the axis of the conical die 30. The passageway is formed to clamp a round wire of one particular size. However, the cavities can be formed to clamp any shape of workpiece including Wires having odd shaped surfaces and also including ribbons and similar type workpieces. Any longitudinal member which is to be butt-welded on an end of the workpiece can be held in suitable clamping cavities within the die 30.

The tapered die bed 27 and the split die 30 are of the same taper but are larger than the taper which would cause a locking of the die within the die bed. However, the tapered fit between the die and the die bed permits a tight clamping of the split die upon a workpiece to hold the workpiece in an excellent gripping action. The more force placed upon the large end of the split die 30 the greater will be its holding action so long as the mating surfaces are not in actual contact.

The faces of the split dies 30 and 31 are recessed by upset cavities 36 and 37 respectively. The form of these cavities can best be seen in Figure 6. These cavities are termed upset cavities although their function is not merely to provide an upset on the end of a workpiece, but are designed to produce a cold weld butt joint according to the principles of such cold welding.

Tapered dies and die bed holders are not necessarily new because of the very recent development of practical knowledge concerning cold welding. However, whenever a tapered die is employed for the purpose of holding a workpiece as the workpiece is formed against the surface of the die, there must be a provision for removing the workpiece. In the case of joining two longitudinal workpieces in end-to-end butt welded relationship, it is simple enough to insert the workpiece through the die from the back end thereof, but it is not possible to withdraw the workpiece after the end has been upset and accordingly, other means for removing the workpiece must be provided. In the embodiment of the tool as illustrated, provision for removing the workpiece is made by having the slot 25 with the mouth 26 opening to the surface of the carriage. Therefore, by advancing the split die 30 forward out of the tapered die bed 27, lateral movement of the sections 32 and 33 can take place to such a degree that the workpiece can be lifted out of the die through the mouth 26.

In modern industry, it is undesirable to require a considerable amount of time and patience on the part of the workmen in operating and positioning tool parts entirely by hand. In fact, if the proper positioning of the dies were done manually, very often the dies would fall out of the tool or would be improperly returned to operating position within the tool, or both. Therefore, in the present embodiment of the invention, there is provided a spring device 23 anchored and guided by means of a retainer 24 as illustrated best in Figure 2 of the drawing. This spring device 23 is illustrated as one integral piece of spring steel wire bent as illustrated in Figure 2 to provide a looped arm portion 28 and a looped arm portion 29 encompassing a portion the face of the split die 30. The arms 28 and 29 preferably lay against the face wall of the carriage. The dies 30 and 31 project beyond the face walls 13 and 14, and, therefore, the spring arm will not interfere with full pressure contact of the dies. Near the opposite side of the split die from the anchor side, the arm portions are each provided with a hook end; The hook end is indicated by the reference character 38 on arm portion 28 and by the reference character 39 on the arm portion 29. This construction of the spring device is best illustrated in Figure 3 of the drawing.

Also in Figure 3 of the drawing, it can be seen that the die sections 32 and 33 are recessed along the top edge thereof as indicated by reference characters 48 and 49. These recesses provide space for the hook ends 38 and 39 and thereby hold the spring device 23 and the die sections 32 and 33 against longitudinal shifting of the die sections with respect to the hook ends.

The spring device 23 is stressed to provide an outwardly acting force upon the die sections 32 and 33 tending to spread the sections apart, particularly at the top thereof adjacent the mouth portion 26 of slot 25. Furthermore, the spring device has a tendency to urge the die 30 back into the tapered die bed 27, although not with appreciable force. Thus, although the die 30 can be readily shifted within the die bed 27, it cannot be unintentionally removed therefrom. Furthermore, as the die 30 is moved in a direction out of the die bed 27, the sections 32 and 33 thereof are parted properly to withdraw a workpiece. Therefore, with respect to the tool illustrated in Figure 1, the operator can reach around both carriages 11 and 12 with one hand and press gently on the small end of the dies 30 and 31 and cause the dies to advance and open. With the other hand the operator can lift the completed butt weld wire from the tool. I

As previously indicated, the tool illustrated in Figure 1 is intended primarily for driving the ends of two workpieces, such for example as aluminum or copper wires, together under controlled conditions of high pressure and confined flow in such a manner as to cause the wires to cold weld by flowing together at a temperature less than the usual thermal Welding temperature. However, i in order to cause a proper welding, the surfaces being welded must be thoroughly cleaned. In the embodiment of the invention illustrated, the workpieces are in the form of wires 56 and 57.

The wires must be clamped by the split dies 30 and 31 with the wire projecting from the face thereof an exact distance sufficient to cause a proper flow of the metal in the upset cavities 36 and 37. There must not be too much wire or too little wire, and the amounts must be equally divided between the two wires being joined, for like materials. When joining unlike materials, the ratios are suitably divided. Furthermore, the ends of the wire which abut must be absolutely clean and free of any oxide or contaminating film.

In order to assure an exact proper spacing and relationship of the wires 56 and 57 with one another and in respect to their particular split dies, and also to provide the necessary clean surface, a spacing and surface preparation plier tool 41 is provided. The construction of the tool plier 41 is illustrated best in Figures 4, 5, and 6 of the drawing.

The plier tool 41, in its preferred'form, has a hook 42 to catch around the guide dowel pin 40. The dowel pin 40 then serves as a pivot point and anchor to properly guide the plier tool 41 and hold it firmly in proper position between the dies 30 and 31. In the construction of the plier 41 as illustrated, the hook 42 is an integral part of the handle 44. A section of reduced width between the hook 42 and the handle 44 serves as a bumper plate 43. In other words, the hook serves as a convenient guide for positioning the bumper plate 43 betweenthe dies 30 and 31, and the handle 44 serves as a holding means.

The bumper plate 43, whether constructed in one piece with the hook and handle as illustrated, or separately fabricated, nevertheless is provided to block the passage between dies 30 and 31. The wires 56 and 57 are inserted from the rear of the dies 30 and 31 and it has been found that operators of this type of mechanism may thrust one of the wires almost against the face of the opposite die. Consequently, the wire coming through the other die projects a very short distance. The burnper plate 43 assures an even distribution and proportioning of the workpieces.

The plier tool 41 is provided with oppositely disposed work receiving shear plates 45 and 46 secured to the handle 44 by means of rivets 47. The plates 45 and 46 bridge between the wide hook 42 and the wide handle 44 and therefore define slotted chambers in conjunction with the opposite side of bumper plate 43.

Each of the work receiving shear plates is provided with a cutting notch 50 having a wide guiding entrance mouth 51 and having an apex formed as a cutting die portion indicated by the reference character 52.

The shearing action is provided by a shear 60 having spaced shear blades 61 and 64 operating within the space between the work receiving shear plates and the surface of the bumper plate. A handle 62 provides for actuation of the blades. A common pivot pin 53 extends through both work receiving shear plates 45 and 46, through both shear blades 61 and 64, and through the bumper plate 43 to give a strongly constructed pivot about which the shear 60 may operate. In operation, the plier tool 41 is hooked under the dowel pin 40 and pivoted into a rest position, as illustrated in Figure 4, against the bed of the tool 10. In this position, the plier tool 41 is held in a tightly fixed relationship with respect to the tool 10. The operator can hold both the handle 15 of the tool and the handle 44 of the plier tool 41 with one hand and thereby provide a firmrelationship. Although the separable hook construction is illustrated, a permanently attached tool may be provided and swung about a fixed pivot, if desired.

When held firmly as illustrated in Figure 4, the bumper plate 43 will prevent the extension of the wires beyond their desired limit. After the wires 56 and 57 have been advanced against the bumper plate 43, the handle and the handle lever 18 are closed with a moderate force to push the tapered dies 30 and 31 against the outer face of the work receiving shear plates 45 and 46, and thereby cause a preliminary gripping action upon the wirm. Thereafter, the handle 62 is depressed against the urge of a convenient spring 63 to shear the ends of the wires 56 and 57. If the ends of the Wires are not properly located in the apex 52, the wide mouth portion 51 and the closing action of the blades 61 and 64 will move the wire ends into the apex and shear the ends as the blades pass the apex.

In the use of the tool 10 in actual production, there is a need for a moderate amount of speed in producing the welded joints. Consequently, it has been found that it is possible for the shear ends of the work pieces to lodge between the front face walls 13 and 14 and prevent proper closing of the carriages 11 and 12 to produce the cold weld. In such an event, there is an annoying delay until the wires can be hand trimmed and the entire process repeated. By the construction of the plier tool 41 as illustrated and described, the trimmed ends are caught between the surfaces of the work receiving shear plates and the bumper plate by the shear blades 61 and 64. Cutting is accomplished by the shear blades moving backward-1y into the space between the work receiving shear plate and the bumper plate. Furthermore, when used in the position as illustrated in Figure 4, the cutting is in an upper direction. Consequently, the trimmed ends we held within the plier tool 41 until the plier tool is turned over and the trimmed ends shaken out. These features alone remove a source of annoying and costly delay in the production of welded butt joints in commercial practice.

Although the invention has been described in its preferred form with a certain degree of particularity, it is understood that the present disclosure of the preferred form has been made only by way of example and that numerous changes in the details of construction and the combination and arrangement of parts may be resorted to without departing from the spirit and the scope of the invention as hereinafter claimed.

What is claimed is:

In a workpiece holding device adapted to grip a workpiece with the workpiece projecting therefrom, and which requires the workpiece to project an exact distance from the holding device, the improvement which comprises, a cutting tool for preparing and conditioning the workpiece held by the holding device, said tool having a central division plate bumper block, a first and a second work receiving shear plate positioned laterally of said bumper block, a first shear blade movable in a shear action between said first work receiving shear plate and the bumper block, a second shear blade movable in a shear action between said second work receiving shear plate and the bumper block, means to drive said first and second blades "in said shear action path, said first and second work receiving shear blocks being laterally spaced and presenting one side of the first block as an abutment surface and the one side of the second block as another abutment surface, said abutment surfaces being laterally spaced and in substantially parallel relationship, said first and second work receiving shear blocks having aligned through passageway spaces to accept workpieces for shearing action, and said central plate positioned to block oif the aligned through passageway to prevent extension of workpieces fully through the tool.

References Cited in the file of this patent UNITED STATES PATENTS 2,779,954 Barnes Feb. 5, 1957

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