Improvements in the Manufacture of Weldless Chains.
Year: 1889

page_text: Date of Application, 8th Jan., 1889
Complete Specification Left, 1st Aug., 1889-Accepted, 28th Sept., 1889
PROVISIONAL SPECIFICATION.
Improvements in the Manufacture of Weldless Chains.
[HIPPOLYTE RONGIER of 18 Bath Row, Birmingham, Engineer do hereby declare,
the nature of this invention to be as follows:-
My Invention has for its object the manufacture of weldless stayed chains, of which
each link and its cross-strut, or stay is made in one piece of metal, without any weld
or joint and it consists in punching out the stayed links, from the solid bar, of such
form, and the operation being performed in such a manner, that the links are already
enchained together at the time of their formation.
The Invention also comprises the subsequent operations of stamping up, and otherwise
bringing, the links to their finished form.
In carrying out my invention, I take a rod of section, and punch, by a series
of operations, sets of mortises in the webs of the rod, the mortises in the pairs of
diametrically opposite webs being so arranged with regard to each other that the
links will be forined alternately out of the one and the other pair of diametrically?
opposite webs of the rod, the links when severed and completed, as hereafter describe.l,
being already enchained together at the time of their formation.
The successive operations of forming the weldless stayed chain are as follows:-1
first punch out of the edge of one web of each pair a series of notches at equal
intervals apart, the notches of one series being opposite the middle of the space
between the notches of the other series. These notches serve as guides to ensure
uniformity of spacing in the subsequent operations of punching out the links. I
now punch out, of a pair of opposite webs, pairs of oblong mortises, situated one in
each web and close up to the faces of the other pair of webs. The mortises so
punched are so spaced as to correspond in position with the eyes of the links to be
formed and with the intervals by which the links formed' out of the same pair of
webs will be separated when completed. Similar sets of mortises are then punched
out of the other pair of webs close up to the faces of the first pair of webs, the
'mortises in the one pair alternating in order with those in the other pair. The
punching of these sets of mortises inay be performed in two stages or operations in
order to facilitate the punching out of sufficient inetal, and the formation of apertures
approximating to the intended internal form of the links.
The next operation consists in the punching out of portions of the webs joining
the ends of the links lying in the same plane or formed out of the same pair of
webs.
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Up to this point a continuous core of metal has been left at the end-section of
the webs and the next operation consists in punching out the portions of this core
which connect the stay of one link with the adjacent outer ends of the links enchainell
therewith This operation is performed by means of a pair of punches which impart
the desired form to the stay.
The rod-like form is now only maintained by the portion of the core which unites
the insides of the ends of the consecutive links. The severing of these intervening
portions of the core and the breaking up of the rod into the constituent. links of the
chain is effected by torsion. For this purpose one end of the rod is fixed whilst the
other is twisted a few times backwards and forwards until the whole of the links are
severed. By this means a chain of roughly formed stayed links is produced, and I
now proceed to remove the superfluous metal and bring the links to their finished
form: For this purpose the two ends of each link are operated on at the same time
by two pairs of punches whereby the surplus portions of metal both at the inside and
the outside.of both ends of the link are removed:

page_text: The finished form is now given to the link by stamping in a series of dies or swages
whereby the two ends of the link are operated on and receive their final cross-
sectional form at the same time; then the middle portion, i.e. the side members of
the cross-stay, receive their final sectional form; and lastly the two eyes of the link
are slightly contracted by lateral pressure applied to the side members of the link
so as to correct imperfections and bring the link to the desired oval form.
A further advantage obtained by this mode of manufacture is that the ends of the
links may be conveniently made of greater cross section than the remainder so as to
compensate for the wear to which they are exposed.
Dated this 7th day of January 1889
COMPLETE SPECIFICATION.
Improvements in the Manufacture of Weldless Chains.
I HIPPOLYTE RONGIER, of 18 Bath Row Birmingham, in the County of Warwick,
Engineer 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 has for its object the manufacture of weldless stayed chains whereof
each link, together with its cross-strut or stay, is made of one piece of metal without
any weld or joint; and the invention consists in producing a chain of stayed links
from a bar or cruciform section by the consecutive series of punching, twisting, and
stamping, operations hereafter described, the punching operations being entirely
performed on the metal when in the cold state.
My present Invention is in certain respects similar to that described in a previous
application for Letters Patent made by me on the 29th day of May 1888 No. 7835,
my said former Invention also having for object the manufacture of weldless chains
but of ordinary unstayed links, whereas the present improvements are particularly
designed for, and are limited to, the manufacture of weldless chains of stayed links.
I am aware that it has also been proposed by others, to make weldless chains
from the bar of cruciform section by punching and squeezing operations, but no
practical and efficient method of accomplishing this result by punching out the metal
in the cold has been devised except by myself. In this connection I would par-
ticularly point out that the comparatively simple operations of punching or notching
the edges of the webs in the flat for the purpose of giving the external contour to
the links, as heretofore proposed to be accomplished, has been such as to weaken the
bar transversely to such an extent that when the operation of punching out the
insides of the links is performed the bar could not resist the pressure of the tools but
would necessarily become bent and crippled to such an extent that the work would
be so defective as to be practically useless.
Reference is to be had to the accompanying drawings forming part of this
Specification, wherein I have represented the consecutive stages of manufacture of
the stayed chain throughout and also the tools successively employed in such manu-
facture. Figures 1 to 10 shew the progressive stages in the manufacture of the
chain, and the remaining figures shew the series of tools that are employed.
The general method of operation of making stayed chains according to my invention
is so far similar to the methods heretofore proposed for making unstayed chains
from the bar of cruciform section that the links are formed alternately out of the one
and the other pair of diametrically opposite webs of the rod, the links when severed
and completed being already enchained together at the time of their formation. The
successive operations differ however in many important practical respects from those
heretofore proposed, as will appear from the following detailed description of the
successive steps in the process as illustrated by figures 1 to 10.

page_text: I will distinguish the one pair of diametrically opposite webs of the bar, and the
notches and mortices-punched therein and the links formed therefrom, from the other
pair, by an index. figure "1"affixed to the reference letters appertaining thereto...
a a are one pair of diametrically opposite webs and a' a' the other pair of webs. of
the bar.
<
"
The first operation illustrated in figure l is to punch out of the edge of one of the
webs a. a series of shallow notches at equal intervals apart corresponding to the
pitch of the links to be formed out of that pair of webs and situated where
the spaces will ultimately be formed between the ends of that series of links. The
notches are made with bevelled ends and are no, deeper than is absolutely necessary
(for the purpose of a guide stop in the subsequent operations, as hereafter described)
so as to avoid as far as possible weakening the bar transversely. This operation is
repeated upon one of the pairs of webs a¹, but whereas, in the. first operation of
notching the web, the "pitch" of the notches detormined by the feed mechanism
in this second operation of notching, the notches cut in the web a serve. as. guides
to influence, and compensate for any inaccuracy of, the feed mechanism, so that the
second set of notches shall be intermediate of, and rigorously equi-distant from, the
first set of notches b. This compensation is effected by the notches 6 fitting on to a
bevelled stop on the bed of the punching tool by which the notches ₁ are cut, the.
bevelled ends of the notches & causing the bar under the pressure of the punch to
adjust itself in the longitudinal direction (if necessary) sufficiently to. rectify any
inaccuracy of feed. These notches & similarly serve as guides to ensure uniformity
of spacing in the subsequent operations of punching out the links.
The second operation illustrated in figure 2, is to punch out of the pair of opposite
webs a a, pairs of oblong mortices two pairs c c and. one pair d d. These three pairs
of mortises (which might be punched at separate. operations .but are preferably
punched at one stroke of the press) are situated as close as possible up to the faces of
the other pairs of webs a! a', the pairs of mortices cc being so spaced as to correspond
in position to the eyes of the links to be formed to which they correspond approxi-
mately in form, whilst the pair d correspond in position to the notches & and therefore
to the intervals by which the links formed out of the same pair of webs a a will be
separated when completed. This operation is continued along the whole length of the
pair of webs a. It will be observed that a considerable thickness of metal is left
at a between the notches and the mortices d. This is of primary importance and
is one of the essential features of my method of manufacture, inasmuch as by first
punching out the mortices.d the subsequent removal of the metal from between, the
outer ends of the links is greatly facilitated whilst by leaving the solid metal a the
transverse strength of the webs a a is not materially diminished so that when
the operation of punching the mortices c and d in the other pair of webs a¹ is
performed the bar will not be bent and crippled as would. inevitably be. the case
were the whole of the metal opposite the notches which is ultimately to be
removed to be punched out at so carly a stage of the manufacture. The operation
of punching the pairs of mortices c and d having been repeated along the other pair
of webs a', it will be observed that, like the notches b, the mortices c d in the one
pair of webs alternate with those ed in the other pair of webs.
The third operation illustrated in figure 3, is to elongate the mortices c d. and
bring the mortises c c¹ more nearly to the final form. This is performed by punches
similar to, but larger (in the direction of the length of the rod) than, those used in
the second operation. The third operation which is repeated upon both pairs of
webs a a a¹ a¹, may be considered as a second stage of the second operation, it being
preferable to punch out the mortices in two stages in order to remove sufficient
metal without unduly straining the bar.
The fourth operation illustrated in figure 4 consists in roughly shaping the ends of
the links externally by punching out the portions a* of the webs a between the links.
lying in the same plane, or formed out of the same pair of webs. This operation is
repeated upon the other pair of webs a'. Up to this point a continuous core of metal
has been left at the intersection of the two pairs of webs..

page_text: I'
The fifth operation illustrated in figure 5; consists in punching out the portions
of the core at each side of the cross-stay of the link so as to separate the cross-stay
from' the 'outer ends of the adjacent links. This operation is performed by removing
a portion only of the metal of the core which intervenes between the cross-stay and
the outer ends of the adjacent links enchained with the link under operation that is to
say portions of the core are temporarily left attached to the outer ends of the links
in order to avoid crippling or bending the bar which might occur were the whole of
this metal which is ultimately to be removed-to be punched out at once these
portions €* being supported by the bed die, in the operation of punching out the
spaces e as hereafter described. This operation having been repeated upon both pairs
of webs, it will be observed that the rod like form of the chain is now only maintained
by the portion of the core at the points where the inner side of the eye or bow of
one link is united with that of the next one. The severing of these intervening
portions of the core and the breaking up of the rod into the constituent links of the
chain constitutes the sixth operation.
The sixth operation illustrated in figure 6, is performed by torsion and for this
purpose one end of the rod is held fixed whilst the other is twisted once or twice in
opposite.directions until by fatigue of the metal at the points, the whole of the links
are severed almost at the same instant and a chain of roughly-formed stayed links is
produced.
The seventh operation illustrated in figure 7, is to remove the superfluous pro-
jecting pieces of metal both from the inside and outside of the ends of the links.
For this purpose the two ends of each link are operated on at the same time by
two pairs of punches corresponding to the outline of the ends of the link.
The eighth operation illustrated in figure 8, is to bring the ends of the links to their
finished rounded form. This is performed by stamping both ends of each link at the
same time between pairs of shaping dies or swages.
The ninth operation illustrated in figure 9, is to bring the middle portion of each
link (that is to say the side members and the cross-stay) to the finished rounded
form, which is also performed by means of a pair of dies or swages.
The tenth, and last, operation illustrated in figure 10, is to contract the link slightly in
the lateral direction in order to correct any imperfections at the sides left by the two
previous operations and bring the link to a more perfect and stronger form, as
shewn. This operation has the important result of strengthening the link con-
siderably by contracting or rendering more pointed the arched form of the bow or
end of the link, and also by thickening the metal at that part where the wear is
greatest, this thickening of the metal at the ends of the link occurring in the
direction of the line of strain (as indicated by the line in figure 10) and being brought
about by the compression or "upsetting" of the metal at the end of the link.
It may be preferable to perform this operation immediately after the seventh
operation and I reserve the right to do so. In this event the form of the dies
shewn in figures 14, 15, 16, and 17 would of course be modified accordingly.
In the case of large cables only, the metal is preferably heated for the eighth,
ninth, and tenth, operations.
I will now refer to the figures which illustrate the series of tools whereby the
above mentioned operations are performed.
Figure 1 shews a plan (the punch being in section) and figure 1b an elevation of
the bed die of the tool by which the notches of the first operation are performed.
The feed mechanism is not shewn, but might be of any ordinary intermittent kind.
y is a groove in the bed in which lies the lower vertical web of the rod of cruciform
section, the two horizontal webs lying upon the bed with the edge of the web to be
notched lying just over the die in which works the punch B of which B' is the
cutting edge. The punch is operated in the usual way, its lower end, which does not
rise out of the dic, acting as a guide. B* is the bevelled stop in the groove g
which, by fitting in the notches or corrects inaccuracies of the feed.
Figure 2 is a sectional plan, and figure 26 an elevation, of the tool by which the
second operation is performed, the same tool being also used for performing the third

page_text: operation, illustrated in figure 3ª. hh are a pair of bed dies having a space between
them to receive the lower web of the bar and having notches CC and D D in their
inner ends forming counterparts of the punches by which the pairs of mortices (cd
figure 2) are punched in the pair of webs lying upon the bed dies h. These bed dies
are fitted to slide a little in opposite directions upon a suitable bed plate and are
caused by the inclined cams on the guides i of the press head (which pass through
corresponding apertures in the bed dies ) to approach each other at the moment the
punches come down on the work so as to grip the lower web of the rod and support
the pair of webs being operated on, close up to the sides of the lower web lying in the
space whilst, when the punches rise, the bed dies more apart so that the web is
quite free in said space and the rod may be easily fed forward for a fresh stroke
of the press. B* is the bevelled stop in space ¹, as in the tool first described. The
bed dies have a second set of notches CD at their outer ends similar to, but
longer than, those CD, so that by reversing the bed dies, they will form counter-
parts for a second set of punches corresponding thereto for performing the third
operation, i.e. enlarging the mortices ed as represented in figures 3, and 3. Or
instead of adapting the dies to perform the two operations, separate tools may be
used for the second and third operations.
1
Figure 4 is an elevation, and figure 4 a sectional plan, of the tool for performing
the fourth operation, namely removing the portion a*, figures 3, 3, 4, and 4". This
is done by a pair of punches A* corresponding in shape to the ends of the links in
the rough, and to the aperture shewn in the bed-die k, figure 4b, which has a
groove to admit the lower web of, and to guide, the rod. The bevelled stop B*
used in operating on the pair of webs a corresponds to the notches 6 but in operating
on the webs a' the stop must be replaced by one corresponding to the aperture left
by the removal of the portion a*.
Figure 5 is an elevation, figure 5 a plan, and figure 5 a longitudinal vertical
section, of the tool for performing the fifth operation, the work being shewn in
Eection in the latter figure. It consists of a bed die with groove m to receive the
lower web, but terminating at a distance from the die apertures so as to leave
supports for the parts e of the rod to resist the downward pressure of the
punches E which remove the portions e from each side of the cross-stay, as shewn
in figure 5 and 5. The correct position of the work in regard to the punches is
ensured by these supporting parts n which terminate the grooves m.
Figure 6 is an elevation of the winch for performing the sixth operation.
Figure 7 is an elevation, and figure 7 a plan, of the tool for performing the
seventh operation. PP are the punches for trimming the outside, and Q Q those
for trimming the inside, of the ends of the links. The links adjacent to the one to
be operated on are brought together into the position shewn in figure 7, the bed
die having an aperture in it to admit of this, so that both ends of the link to be
trimmed may be operated on together.
The tool for performing the eighth operation consists of a pair of swages, the
bottom one only being shewn in figure 8. The swages correspond to the intended
rounded sectional form of the ends of the link which is placed in position between the
swages in a similar manner to that described for figure 7 so that both ends are
rounded or finished.off at once.
Figure 9 is a plan of the bottom swage of the tool for performing the ninth
operation, the upper swage corresponding thereto at least in so far as the middle part
of the link to be operated on is concerned.
The tool for performing the tenth operation is represented in elevation, and plan, in
figures 10 and 10°. It consists of a pair of bed dies R. fitted to slide together and
operated by the cams s on the guide rods S, the operation being similar to that of the
tool shewn in figures 2" and 2 except that there are no punches and that the link
which lies in the cavity of the dies is merely compressed in the lateral direction by
the inward motion of the bed-dies.

page_text: Having now particularly described and ascertained the nature of the said
Invention and in what manner the same is to be performed, I declare that what I
claim is ;
1. The manufacture of weldless chains of stayed links, by the consecutive series of
punching twisting, and stamping, operations substantially as herein described:
2. In the process of manufacturing weldless stayed chains, from a bar of cruciform
section, the step in the process which consists in punching out (whether in one or
two operations) pairs of mortices corresponding in position to the intervals to be
formed between the outer, ends of the same series of links, said step being so
performed as to prepare the webs for the ultimate operation of removing the metal at
these points and yet leave the metal so disposed as to maintain the transverse
stiffness of the bar during the repetition of the same operation on the other pair
of webs, as described.
3. In the process of manufacturing weldless stayed chains, from a bar of cruciform
section, the combination or series of steps herein designated as the second, third, and
fourth, operations, as described.
4. In the process of manufacturing weldless stayed chains, from a bar of cruciform
section, the combination or series of steps herein designated as the second, third,
fourth, and fifth, operations, as described..
5. In the process of manufacturing wellless stayed chains, from a bar of cruciform
section, the combination or series of punching and twisting operations herein designated
as the second, third, fourth, fifth, and sixth, operations, as specified..
6. In the process of manufacturing weldless stayed chains, from a bar of cruciform
section, the combination or series of steps herein designated as the fifth, sixth, and
seventh, operations, as specified.
7. In the process of manufacturing weldloss stayed chains, from a bar of cruciform
section, the step which consists in compressing the bows of each link laterally in such.
a way as to cause the ends of the links to become thickened in the direction of the
line of strain and of wear by the "upsetting" or compression of the metal at these
points, as described.
Dated this 1st day of August 1889.