Improved methods or and Apparatus for welding, shaping ада otherwise Working Metals by the Aid of Electricity.
Year: 1889

page_text: Improved methods or and Apparatus for welding, shaping ада
otherwise Working Metals by the Aid of Electricity.
I, HENRY HARRIS. LAKE, of the firm of Haseltine Lake & Co., Patent Agents,
Southampton Buildings, in the County of Middlesex do hereby declare the nature of
this invention and in what manner the same is to be performed, to be particularly
described and ascertained in and by the following statement :-
My invention relates to methods and apparatus for shaping, forming, welding and
other metal working operations, and utilizes electricity as the heating agency for
bringing the metal under treatment to the desired temperature and plasticity.
or
My invention relates first to a novel art in the nature of upsetting or swaging
whereby enlargements may be formed upon the ends or sides of metal bars, rods,
other metal pieces.
My invention relates further to novel apparatus for forming or shaping metals by
the application of dies, rollers or other tools, and affords likewise a device that may
be readily used for welding by eléctricity:
The invention consists first in passing a heavy electric current through the part of
the bar or other piece to be operated upon so as to bring such part to a working heat
irrespective of the other portions not to be forged or otherwise treated, and then
shaping by pressure or by hammering or other convenient application of force to effect
an upsetting operation, and in such a manner as to move the heated particles in the
direction required to give the work the intended or desired form.
The invention may be utilized in forming expanded heads on large bars, or by
forming beads or projections from the sides of such bars, or by forming shoulders,
necks or projections of any kind which result from an end wise compression of an
object under the welding heat of an electric current and a lateral displacement of its
heated particles.
The invention consists further of an apparatus for shaping, forming or welding,
comprising in combination, two-rotary chucks or holders insulated from one another
----

page_text: by any proper means and provided with suitable connecting cables, or other electric
connecting devices, whereby an electric current may be passed through the metal
pieces in the chucks or holders. By properly insulating one of the chucks of an
ordinary lathe, an apparatus is produced which may be used for the purposes of my
invention.
My invention consists also in the combination with any suitable means for holding
and rotating the metal to be operated upon, of suitable connecting devices for passing
heavy electric currents through the same, and means for imparting the lateral pressure
of die or forming surfaces to the rotating metal.
My invention consists also in a die or roller for use in electric metal working
operations having surfaces faced with carbon, soapstone or other non conductor of heat,
of a refractory nature.
My invention relates further to methods or processes of metal working having for
their object the separation of metal rods, bars or pieces, or the local diminution of the
section of the metal under treatment, and the invention consists in the novel art,
method or process hereinafter described of heating the metal rod, bar or piece by an
electric current of large volume or heating effect, and then, either during or after the
heating and while the piece is hot, cutting or drawing, or pulling the hot metal to
separate the piece or to locally diminish or modify its cross section.
In the following description it is to be understood that in each case electricity is
caused to pass through the metal operated upon, and from a source of very heavy
electric currents such as a secondary coil of an induction coil of few turns whose primary
is fed by alternating currents, or a secondary battery of large surface, or a dynamo
machine with very heavy conductors, or an alternating current dynamo in which the
armature has only a few convolutions of heavy conductor, or a continuous current
machine of. a unipolar type in which the currents are generated by the revolution of
copper tubes or discs through a uniform magnetic field. The force of the current
should be under proper control in order that it may be adapted to the size and character
of the part to be heated and formed.
In the accompanying drawings
Figure 1 is a partial section of a form of induction coil which may be used for
déveloping the heavy electric currents.
Figure 2 is an edge view of the same.
Figures 3 and 4, illustrate apparatus for forming enlarged heads on the ends of bars
in accordance with my invention.
Figures 5, 6, 7 and 8, illustrate the formation of beads and collars in accordance
with my invention..
Figures 9, and 10 illustrate apparatus for forming enlargements on the side of metal
bars.
Figures 11, 12, 13 and 14, illustrate further useful applications of this phase of my
invention.
Figure 15 is a plan, and Figure 16 a side elevation, of a lathe adapted for use in
forming or shaping metal bars or pieces, and to the welding of bars or pieces by butt
welding.
:
Figures 17, 18 and 19, show various modifications involving the use of forming dies
or rollers.
Figure 20 illustrates a modification in the manner of applying the forming dies,"
rollers or surfaces.
Figure 21 is a front elevation, and Figure 22 a side elevation of an apparatus
suitable for use in dividing metal pieces after the manner of my invention.
Figure 23, is an example of work performed by such apparatus..
Figure 24 is a side view of an apparatus suitable for use in dividing or separating
metal pieces by the electric heating and drawing or pulling operation.
Figures 25, 26 and 27, are examples of work done by said apparatus.
Figure 28 illustrates a modification in the process of dividing a piece of metal
according to my invention, and Figure 29, shows the piece divided by such modified
process.

page_text: Referring to Figures 1 and 2, N,.is a bar or bundle of rods of copper connected to
cables or conductors C, C, which convey the current developed in said bar to the
clamps or holders for the metal piece or pieces which are to be formed, shaped or
treated, as hereinafter set forth. This bar is the secondary of an induction coil the
primary of which is supplied with alternating currents from any source, and is
indicated by the letter V. The form of the secondary is one which permits a current
of low potential and great volume to be developed. The coil V, passes along the side
of the conductor N, and is made of insulated wire, oblong in shape, connected with an
alternating current dynamo or other source. The amount of current flowing in the coil V,
is controllable by means of a rheostat or artificial resistance R, which shunts current
from the same to greater or less extent and thereby determines the amount of current
developed in the bar N, and delivered to the work. Around the two conductors N
and V, which are insulated from one another, is wound a mass of sheet iron, or iron
wire, as indicated, to increase the inductive action at the part where the conductors
are in proximity. The section of the bar N, should be many times that of the bar
or piece of metal which is to be heated by the passage in it of the current developed
in the conductor N. unless the specific conductivity of the metal is very low
compared with that of the bar N, and conductors U, C, leading to the metal to be
heated.
Referring now. to Figures 3 to 14, illustrating the formation of enlargements or
lateral projections on bars or rods B Figure 3, indicates a metal bar. firmly held in a
fixed clamp E.
D) is a contact block guided so as to be moved in a line with the clamp E, by a
force, as of a spring S. The bar B, abuts against D, which is massive and a good
conductor of electricity and whose end in. contact with B, may be hollow or otherwise
formed as illustrated in, Figure 4.
C, C are the terminals of the heating current which traverses the fixed block E,
the metal bar B, and the block D. For convenience the clamp E, and the contact D,
are located at a short distance from each other, the bar B, extending entirely, through
the clamp E with but a short length projecting from it upon which the contact D bears.
On the passage of the current the end of the bar B, heats and is upset under the
pressure of the spring exerted on the contact block D, the result being an expanded
head K, as shown in Figure 4.
The same principle of operation is applicable to raise and form collars or heads or
expanded portions on bars at other points than the ends. In accomplishing this result
it is only necessary to clamp the bar at other metal piece on each side of the part
where the bar or piece is to be swelled and then to pass the current through this small
section so as to heat the bar at that point and arrange one or both clamps to be
movable towards each other by a pressure of any convenient kind.
Thus in Figure, B is the bar as before held in the fixed clamp E. D, is a movable
clamp as in Figure 3, forced toward clamp E, by a spring S. The clamp D, takes
hold of the bar at any desired point in its length thereby determining by its relation
to the clamp E, the section of the bar or piece which is to be heated and upset.
The current being on as before and the clamp D, being moved toward the clamp E,
in the line of the bar B, the metal of the bar between the two clamps is heated and the
particles are moved outwardly in the nature of an upsetting operation to form an
expanded head as illustrated in Figure 6.
It is apparent that this bead or enlargement K, may be turned down in a lathe to
the form of a finished square collar as indicated at K, K', Figures 7 and 8. In this
form the beads will be useful for preventing end motion of a shaft and bearings.
Where it is decided to have the expanded or upset portion only on one side of the
bar it is well to enclose the part of the bar operated upon in a non conducting cover or
mould taking care that it does not fill the space between the .clamps D, and E, and,
interfere with the end motion of compression. In Figure 9, such a device is shown.
and also in section in Figure 10. The mould may consist as shown of a split tube of.
fire clay or hard carbon which loosely encloses the bar where it is to be heated and is
held in place thereou by bands encircling it as shown. There is a lateral opening a,

page_text: in the mould into which the bar B, can expand or be upset when compressed end wise
under the heat produced in it by the heating current. This is indicated in Figure 10,
where a lateral projection on the bar B, is shown. This knob or protuberence may be
utilized in a variety of ways, as for example a lateral bar Figure 11, may be welded
to the knob of my electric welding process, or the lateral projection b, Figure 12,
having been formed at a distance from the end of a bar the end may be bent to shape
as shown in Figure 13, and finally welded electrically as a ring as shown in Figure 14,
thus forming a loop on the end of the bar.
It will be apparent that there are many other useful applications of my invention
and I do not therefore confine myself to the formation of the precise forms described
as these are only shown as illustrative of my invention.
In Figures 15 and 16 an ordinary lathe is shown modified by insulating the pulley
head N, from the bed or shears so as to insulate the two chucks from one another.
Means, as a very heavy cable are used to convey current thereto.
The bed and back head R, are connected to the other cable from the source of
current. Chucks are provided as C2, C3, to centre and hold in line various sized bars
for welding by current passed frou one to the other head, through the abutted ends
of the bars. In this operation the requisite pressure can obviously be imparted to the
work by moving the back head by the usual or similar means.
After such welding is accomplished the lathe chuck (%, may be revolved and C³,
(mounted so as to be free to turn) is carried around also. A roller or die G, may
now be forced against the work at the end to form its other surface, or a tool as a
cutting tool may be applied in obvious manner to turn off the expansion left by the
welding.
The die or roller G, can be carried by the tool post of the lathe. I use such a lathe
or machine in a similar way to form or shape bars of metal held in the chucks and
through which bars currents are passed to heat them so as to give shape to the bars as
may be needed.
Thus in Figure 17, a roller G, pressed against the heated bar B, will give its form
to the exterior surface of the bar B, but reversed as in Figure 19. To get good
effects it is best to apply three rolls pressed against the bar as in Figure 18, instead of
one only. It is well also to permit the end movement of the bar as it lengthens
during the process. The heat is kept up while the bar revolves by the current sent
through it, and the rolls Figure 18, are arranged to be drawn away from the bar to
permit such heating.
Figure 20, shows an instance of the production of a form on the end of a bar..
This is done by holding the bar in C, Figures 15 and 16 with a sufficient length'
projecting and abutting against a block of metal carried by the back head R. The
current is passed and heats the projecting end of the bar and the subsequent application
of three rolls of proper form, as in Figure 18, completes the work.
It is best to face the die surfaces of the dies or rolls with carbon soapstone, or other
non-conductor of heat of a refractory nature.
To separate or reduce metal rods apparatus such as shown in Figures 21, 22, 24
and 28, inay be employed.
Referring to Figures 21 and 22, C, C¹, indicate suitable conducting clamps of any
desired form or shape mounted upon a proper table or support P, and adapted to hold
the bar, rod, or piece B, B, to be operated upon. The clamps C, C, are suitably
insulated from one another and are connected to cables or conductors K, K!, of large
size with the source of heavy currents. The clamps may if desired, be made
adjustable to and from one another to vary the length of the piece subjected to the
heating operation by means of the cables K, K', connected with the source, heavy
currents are passed through the pieces between the clamps until the same is heated
say to redness in the case of iron and steel, or to a less temperature for some other
metals. When so heated the revolving cutter S, is brought against the bar or piece
at or near. its middle portion to separate the same. The cutter S, may be mounted
and operated in any desired manner. It is here shown as supported in a frame E,
centered on the main driving shaft X and provided with a suitable handle H. The

page_text: current should be shut off before the completion of the cut which with iron and steel
at a bright red heat is very quickly accomplished.
Figure 23, shows the piece B, B, severed into two pieces B, B' the line of the
cut or separation being smooth and the form of the bar at the point of severance being
preserved.
In Figure 24 the clamps C, 0, mounted on a suitable support are properly
insulated from one another, and one of them as for instance C, may be pulled or
drawn away from the other by the operation of a screw S', having an operating
handle H. In using this device the bar B, B, is clamped firmly and heated by the
current passed from clamp to clamp until it assumes a more or less plastic condition
when the clamps are drawn apart thus thinning the bar or piece at the heated portion
up to even the point of rupture. In the case of iron and steel which become plastic
the metal may be drawn to a point as indicated in Figure 25, and if the heat be still
more localized, as may be done by starting the operation with the clamps nearer
together, the drawing or pulling action when quickly performed will result in the
production of pieces like those shown in Figure 26. If a piece be heated to a very
high temperature, nearer fusing and then the tension or pulling force be applied the
piece will separate or divide into the form shown in Figure 27, drawing out very
little. This action is also the result in the case of metals or alloys which do not
assume a pasty or tenacious condition before melting.
If it be desired to sever or cut a bar or piece squarely by pulling or drawing it
apart, it is well to nick the bar or piece by means of dies D, DI, Figure 28,
forced against it while cold or when hot, after which the sudden application of heating
current and tension will divide the bar at the nicked point producing two pieces as
shown in Figure 29.
With my invention the cutting off or reducing of stock such as iron or steel bars
may be rapidly performed and various forms of ends or sections where reduced or cut
off may be readily obtained.
Having now particularly described and ascertained the nature of the said
invention and in what manner the same is to be performed, as communicated to
ine by my foreign correspondent I declare that what I claim is.
First. The herein described method of upsetting metal bars or blauks which
consists in heating the bars or blanks by electric currents traversing it and upsetting
the metal bar into the desired shape.
Second. The herein described process of forming a lateral expansion or projection
on a bar or piece of metal consisting in passing a heavy electric current through the
metal blank, and then subjecting the blank to pressure while enclosed in a non
conducting mould having a lateral opening.
Third. In a machine for shaping forming and welding metals, means for holding
and rotating the metal to be operated upon connections to pass heavy electric currents
through the same, and means for imparting the lateral pressure of die surfaces to the
rotating metal, as and for the purpose described:
Fourth. In an electric metal working apparatus, die or forming surfaces faced with
a non conductor of heat of a refractory nature.
Fifth. The herein described novel art of cutting off or reducing the section of bars
or rods consisting in heating the bar or rod electrically at the point of division or
reduction and then applying the proper separating or reducing power or force, as and
for the purpose described.
D
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1009
HASELTINE, LAKE & Co.,
45, Southampton Buildings, London, W.C.