Improvements in or relating to the Manufacture of Files, Rasps, and other similar Tools.
Year: 1892

page_text: Date of Application, 9th June, 1892
Complete Specification Left, 9th Mar., 1893--Accepted, 9th June, 1893
PROVISIONAL SPECIFICATION.
Improvements in or relating to the Manufacture of Files, Rasps, and
other similar Tools.
I, FRITZ EVERTS BUSCH of Lennep, Rhine Province, Prussia, in the Empire of
Germany, do hereby declare the nature of this invention to be as follows:-
This invention relates to a process of manufacture of files, rasps and other similar
tools and consists in submitting the blank in a hot condition to the action of rollers,
presses or hammers, or if necessary, auxiliary pieces or devices fitted to such
rollers, presses or hammers, and in which the hollow mould or pattern for the
formation of the "cut is formed or secured.
"
Grooved rollers should in preference be employed to provide the blank with the
"cut" during the revolution of the raised portion in which the matrix-groove with
the hollow form is fitted directly or through the medium of special attachments.
The grooved portion should be so proportioned that, during that revolution, the
blank may be inserted between the rollers, though it may be reduced to a minimum
when the rollers, instead of rotating constantly, may be thrown out of gear
whenever they have completed one revolution.
The grooves or matrices differ according to the shape of the files or rasps to be
rolled; they may be in the form of a pair of flat matrices in gear with each other,
or a pair of open shaping grooves, placed one over the other or facing each other,
or a pair of simple flat shaping surfaces without sides or cheeks, whereby the vertical
surfaces of flat or square files or rasps may not be filed together with the horizontal
surfaces.
From the following description it will be seen how the shaping grooves or ribs of
the rollers may be formed for the different types of files.
In one form the matrix may be detachable from the roller and cousist of a piece
of steel curved so as to correspond to the diameter of the roller, into which is sunk
the hollow die or matrix proper. Or it may, as hereinafter described be formed of
a number of plates arranged side by side so as to form in conjunction what may be
called an < open
"die or matrix, suitable for files of flat-and-blunt form. In
employing this matrix the tool will only be shaped on the upper and lower surfaces,
while the sides must be shaped separately. If the die be formed angularly in the
matrix block the sides or edges of the tool may be rolled at the same time as the
upper and lower surfaces. Triangular files may be formed in what is termed a
"closed" matrix. One of the dies or matrices engages with the other by means of
a rib or projection either inclined or rectangular in shape. Between this die and
matrix the blank to be rolled or shaped is placed in such a manner that its central
or axial line coincides with the rolling line. The shaping arrangement presenting
two sides for a triangular tool, is formed of two parts to facilitate the fitting of
the hollow matrix. As before stated the removable matrices may consist of one
or more solid steel blocks in which a recess of the desired shape may be formed
by a subsequent operation; or they may be formed of a series of plates placed
one against the other in a suitable frame or the like. To a piece forming or
closing the back end of this "composite" matrix, is secured a curved projection
The thickness
or bracket in which are placed the plates arranged side by side.
of the plates corresponds to the required coarseness or fineness of the "cut,'
or in other words to the width of space or "pitch" between every two succeeding
ribs or cuts
" of the file, the number of which ribs is determined by the
length of the tool. When the said bracket is provided with a sufficient number
of plates a front closing piece-which may if required have the trade mark or
name of the builder or manufacturer stamped upon it is placed against the row
of plates and secured in position by means of a suitable nut or other clamping
"

page_text: device. In order to provide with "cuts "files or rasps of flat-and-pointed, flat-and-
blunt and square section, simultaneously on the horizontal and vertical sides, it is
proposed to employ what are known as universal rolling-mills, in which are fitted
detachable dies or matrices of the desired shapes. The matrices in this case will
be flat i.e. unprovided with cheeks. Such rolling mills may also be used for cutting
flat-and-pointed files, the blank being first passed through vertical rollers provided
with flat ribs, having no recessed matrices fitted on to them. The diminution of
size in section which will result from such operation will enable the blank to pass
readily on to and between the horizontal grooved rollers, in which it will be
provided with the desired "cut
on the upper and lower surfaces. The "cut on
the sides must then be produced by a special operation. The advantage of this
method, however, is that it enables the ordinary roughing rollers, employed to give
the tool its general tapering shape to be dispensed with.
"
""
'It will be understood that if required hollow matrices may be worked in direct
into the grooved rollers, or into steel plates screwed thereon.
'If the " cut is to be given to the files or rasps by means of pressure stamping
or hammering the matrix may consist of a back closing block, a number of cutting
plates and a front closing block. These parts are all passed on to a supporting
pin or bracket and the whole arrangement is then located in a bed or block in such
a manner that the end of the supporting pin or bracket enters a perforation or slot
provided for the purpose in the adjacent wall or surface whereupon the whole is
tightly secured by means of a nut while at the back the block may be further
strengthened or supported by means of pieces inserted into slots lateral displacement
being moreover prevented by means of wedges. The bed is open at the back, while
its front wall is of such a height as just to allow the surface formed by the juxta-
position of the cutting plates to emerge. The central piece composed of a number
of parts, passed side by side on to the supporting pin, may be replaced by a solid
steel block in which a recess of the desired shape is formed by means of a suitable
tool or chisel. Steel strips suitably recessed and screwed to the block may also be
employed. By means of a flat die without side pieces or cheeks, two sides of flat or
square files may be provided with the cut at the same time. By fitting in suitable
side pieces, however, this die may be converted into an open or closed matrix of
the desired shape. If the side-pieces should cover or close-in part of the surface
formed by the juxtaposition of the plates, the lower matrix may be utilized for
tools of various shapes in section such as flat or square. The removable side-pieces
intended to form the cut on the vertical surfaces will in most cases consist of one or
more solid steel blocks instead of being formed of thin plates.
The invention is carried out in practice as follows:-
Blanks are first cut from a suitable steel bar, and if required at once provided
with their tangs or spikes in the usual way by forging or rolling. Each blank is
then passed through one or more grooved rollers unprovided with hollow matrices,
where it receives the general shape or outline which the file should assume; where-
upon it is passed through the rollers described, or placed under a suitable press or
hammer, provided in each case with dies and hollow matrices of the desired shape,
whereby the file receives its final shape or "cut."
For this purpose the blank is heated and for practical purposes it is preferable
that this finishing operation should be performed at one
"heat."
It is most desirable that the heated pieces of steel, when between the dies and
matrices, whether of rollers, presses, or stamps, should present as pure and clean a
surface as possible to the operation of the dies; and therefore the manner in which
they are heated and subsequently treated requires special attention.
The best course is to heat the steel blanks to incandescence by electricity, after
having freed them from rust and other impurities which may adhere to them
externally by means of a slightly acidulated bath; and the arrangement should be
such that the blanks continue subjected to the electrical current until just a moment
before they are to pass through the rollers.
Where electricity is not available for heating purposes, the heating of the blanks

page_text: should take place under such conditions that as little air as possible is admitted, as
air is liable to cause so-called "scale," which would interfere with the neatness of
the "cut." The employment of a regenerating or recuperating furnace is therefore
suggested, so that the blanks are not directly exposed to the products of
combustion. These furnaces enable the temperature to be exactly controlled; and
they will be closed ou all sides with only sufficiently large passages or interstices to
enable the blanks to be conveyed through them into the heating chamber. To
avoid the formation of magnetic oxide of iron during the whole time of the heating
process and until the blanks are further worked in the rolling-mill or press, a
protective coating capable of resisting the influence of the atmospheric air and
consisting of a very fluid solution of shellac in alcohol, with a small addition of
oxide of zinc may be employed.
As a rule it will be sufficient for the steel blanks to get in a clean condition under
the roughing roller, as there is practically no chance of any magnetic oxide of iron
forming on the blanks while they pass from the roughing to the finishing rollers,
and even should a small amount of such oxide form, provision for its removal may
easily be made by arranging a stripping or scraping device just in front of the
finishing rollers, so as to sweep off any oxide from each blank previously to its
entrance into the finishing mill. Where however between the roughing and
finishing operations, it is deemed necessary once more to heat the blanks to
incandescence, or where other occasions of loss of time may be foreseen, it is
best to provide the blanks with the before mentioned protective coating immediately
after it leaves the last roughing roller.
It is imperative that the grooves or matrices of the finishing rollers should be
kept scrupulously clean, and they may therefore be submitted to the action of
revolving brushes a steam-jet or a blast of air, acting upon the roller, press or
stamp after each operation, to remove any impurities that may have been deposited
by the finished blauk. No oil should be allowed to come in contact with the
matrices. The pieces of steel should not be heated to an exaggerated extent
(never to white-heat), and after leaving the finishing rollers, presses or stamps they
should not be too long exposed to the air, but either dipped at once into the
tempering bath, or coated with a layer of wheat-flour, pulverized horn and a
solution of common salt, then heated again to the temperature required for
tempering and tempered in the usual way.
.
The removable 'dies or matrices, to be attached to grooved rollers, presses,
hammers or stamps as the case may be, may be made in the following manner: A
suitably shaped blank is formed of a solid block of steel, which itself is of suitable
form or outline. The hollow matrix is obtained by making transverse recesses in
the blank extending from right to left at equal intervals apart and all at the same
angle in accordance with the "cut" which it is desired to produce on the file. This
arrangement will be sufficient for files with a "single cut." To produce, however,
the "double " Ol' cross-cut with which most files are provided, a somewhat more
pointed toothed tool may be driven into the said recesses, having just so many teeth
as there should be rows of teeth extending from left to right upon the file.
66
"
A hollow matrix for rasps may, for example, receive the proper shape from a
toothed cutter placed at right angles to the longitudinal axis of the rasp and
arranged, at every alternate row of teeth, to shift sideways a sufficient distance for
one of its teeth each time to enter the space between two teeth of the front row.
The same principle will apply to ❝ cross-cut files, it being only necessary
correspondingly to diminish the pitch.
">
:
The cutting plates by the juxtaposition of which removable matrices or dies may
be formed, as before described may consist either of one piece or of several parts
each, their shape varying according to the desired section of the files.
Dated this 9th day of June 1892.
W. P. THOMPSON & BOULT,
Agents for the Applicant.

page_text: COMPLETE SPECIFICATION.
Improvements in or relating to the Manufacture of Files, Rasps, and
other similar Tools.
I, FRITZ EVERTSBUSCH, of Lennep, Rhine Province, Prussia, in the Empire of
Germany, Tool Maker, 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, reference being had to the accompanying
drawings and to the figures and letters marked thereon:-
This invention relates to a process of manufacture of files, rasps and other similar
tools, and consists in submitting the blank in a hot condition to the action of rollers,
presses or hammers, or, if necessary, auxiliary pieces or devices fitted to such
rollers, presses or hammers, and in which the hollow mould or pattern for the
formation of the "cut" is formed or secured.
Grooved rollers, an example of which is shown in Figures 1, should in preference
be employed to provide the blank with the "cut".during the revolution of the
raised portion, in which the matrix-groove with the hollow form is fitted, directly
or through the medium of special attachments. The grooved portion should be so.
proportioned that, during the revolution, the blank may be inserted between the
rollers, though it may be reduced to a minimum when the rollers, instead of
rotating constantly, are capable of being thrown out of gear whenever they have
completed one revolution.
27
Continuously rotating rollers without grooves are to be used in cases where,
instead of single files, rasps and the like, whole bars are to be provided with "cuts"
for either files or rasps, which bars are afterwards divided into files or rasps unless
they are intended to be otherwise used.
27
The matrices differ according to the shape of the file or rasp to be rolled.
Figures 2 and 3 in the accompanying drawings show cross sections taken at
different points of a very simple form of a pair of flat matrices having no sides or
cheeks. These matrices serve to provide square ended or pointed flat files with
" cuts
on the two flat sides, whatever may be the width of the files, as the teeth
cover the whole width of the matrices. The thickness of files is dependent upon
the distance between the two matrices. The sides of the files are finished in special
edge matrices, which latter are at a distance apart according to the required width
of the file.
Figures 4 and 5 show cross sections of another pattern for the shape of the
matrices, which are intended for three cornered files.
Figure 6 is a side view of an auxiliary matrix for flat files, as shown in
Figures 2 and 3. It consists of a bent steel piece corresponding to the diameter of
the roller and which is attached to a web or flange intended to enter and to be
fixed in a suitable groove in the roller.
It is advisable to prepare the flat surface of the steel piece when still straight
and only afterwards to bend it to the required diameter of the web or flange, to
which it is fixed by means of a screw at the front end.
As is clearly shown in Figures 1, the auxiliary piece with its web or flange is so
inserted in the roller that a lateral shifting of it is impossible. This method of
constructing the auxiliary matrix is preferred on account of ready interchange or
replacing, wherever a simple form of matrix is used.
Auxiliary matrices, as shown at c in Figures 4 and 5, are readily made of two
strong steel pieces suitably bent and having the teeth directly worked into the
prepared surfaces of the matrix.
The auxiliary matrices may also be constructed of a number of suitably formed
plates sharpened and fixed together, for example, as shown at Figure 7. The end
locking piece a Figure 8 is provided with a square mandrel bent to the required
diameter, on which mandrel the plates c, Figures 9, are placed one after another.

page_text: The teeth are obtained by the placing of the sharpened plates together one after
the other, and it is obvious that the thickness of the plates gives the distance
between the rows of teeth, while the number required is dependent on the length of
the file. After having placed a sufficient number of these plates against each other
on the mandrel, the front closing piece, which may bear the name of the maker, is
then placed in position and the whole pressed tightly together by means of the
nut e.
In order to provide with "cuts," files or rasps of flat and pointed, flat and blunt
and square section, simultaneously on the horizontal and vertical sides, it is pro-
posed to employ what are known as universal rolling-mills, in which are fitted
detachable dies or matrices of the desired shapes.
"
The most suitable method of producing the "cuts on the file by pressing or
hammering is illustrated in the following example.
Figure 10 shows the side elevation of a pair of matrices coupled together by a
strong spring for flat pointed or flat blunt ended files. It is made simply of two
steel blocks corresponding to the width of the file and provided with suitable
"cuts." It can be used in the form shown between two parallel pressing surfaces
of a press or hammer.
The rear end of the lower matrix may have a cross strip formed or fixed thereon
to serve as an abutting piece for the file as well as a stop for limiting the pressure.
If it be required to produce a deep "cut" for a rough, or bastard," file, a matrix
such as represented at Figure 11 can be used. The two parts of the matrix are in
this case hinged together by two strong flat links. The action of the matrix is
obvious from the drawing and the full lines therein represent the position of the
matrix with the blank inserted therein before the application of the pressure,
while the dotted lines represent its position at the finish. The lever action in this
case requires much less power than when the pressure is exerted simultaneously
over the whole surface of the file.
In order to ensure an automatic opening of the matrix, it may, similar to that
represented at Figure 10, be provided with a spring. These forms of matrices are
only suitable for pressing the upper and lower sides of pointed and blunt ended flat
files.
The following example shows how all the sides can be finished simultaneously.
The bed G, Figures 12, is made narrower towards the front end and is provided
with dovetail-formed longitudinal grooves for the reception of the side pieces S.
A pair of matrices, as represented at Figure 10 or Figures 11, which must in this
case correspond exactly to the width of the file, is placed in the middle of the
bed G, after which the side pieces S, connected together by a cross-head, are
drawn forward to the front until they press tightly against the matrix. The
side pieces S are provided with "cuts" for the edges of the file. After having
applied pressure the said side pieces are pushed back to the rear and consequently
loosened from the matrices, the upper of which is at the same time lifted by the
action of the spring so that the file is laid bare.
The rollers, presses or haminers or the parts adapted thereto, meaning the
surfaces which are to produce the teeth on the files or rasps, may be variously
constructed, and it is proposed hereafter to describe several forms of construction
for the same.
"
The simplest construction is that of the "cuts for the manufacture of files
having only single "cuts" as represented at Figure 13. The prepared surface is
for this purpose provided with grooves or "cuts" running angularly from right to
left, and which correspond in form, distance or pitch and depth to the desired
"cut for the file. The "cross cut" used on the larger number of files can be
produced by using a chisel having as many teeth as the number of indentations
required across the angular "cuts on the file similar to a hand made file. When
"
"
the matrix is built up of a number of plates, each plate has to be chamfered at its
upper edge corresponding to the depth of "cut required. The latter edge may
also, as shown in Figures 9, be intersected by as many projections as are required

page_text: for producing the teeth in each transverse angular "cut." The "cut" for
producing rasps can be obtained on the same principle, but can also be made with
very little trouble by making the recesses which cause the formation of the tooth
on the rasp severally one by one in a similar manner to what is done when cutting
rasps by hand.
"
Figures 14 and 15 show respectively the "cross-cut "for files and the " cut
for rasps, which may either be worked into the surface of the matrix or may
be produced by building up a number of separate plates. The "cross-cut
"of the
files can also be produced by cross rolling, pressing or hammering with single cuts.
In this case the prepared surface having cuts running from left to right, which may
be blunt at their base as represented at Figure 16, is used first and the tool thus
prepared is then submitted to the action of another surface the " cuts of which
run from right to left but sharp at the base, as represented at Figure 13, which.
causes the tool to receive its "cuts from the latter surface, whilst the indentations
therein, or teeth, result from the action of the former which thus forms the
::
cross-cut on the file. By using the "cuts" in the first surface shown at
Figure 16 at various angles or even parallel to the longitudinal axis of the file
as well by varying the shape of the "cuts," the form of teeth may be varied
.greatly.
.66
"
are based on the
In passing the blank
66 cut is similarly
The hereinbefore mentioned methods of forming the "cuts
idea that the rolling is effected in the length of the file.
at an angle to its length through the rollers, the angle of the
altered.
"
"
When holding the tool as shown at Figure 17, the 66 cuts in the matrix must
be parallel to the direction of the roller, and not at an angle as shown at
Figure 13.
Whether it is preferable to work the "cut" directly into the surface of the
roller or in auxiliary pieces, as used for rollers, presses or hammers, or whether
it should be built up of a number of plates, depends much on the description
of file to be produced and on the construction of the roller, press or hammer
used.
The invention is carried out in practice as follows:
Blanks are first cut from a suitable steel bar and, if required, at once provided
with their tangs or spikes in the usual way by forging or rolling. Each blank
is then passed through one or more gauge rollers unprovided with "cuts," where
it receives the general shape or outline which the file should assume; whereupon it
is passed once or several times through the rollers before described, or placed under
a suitable press or hammer, provided in each case with dies or matrices having the
cuts and being of the desired shape according to the file to be produced as
hereinbefore described, whereby the file is completed.
"
In manufacturing files of a simple form, for example flat files with blunt ends,
after first finishing the tang or spike, the passing through gauge rollers or matrices
without "cuts" may be dispensed with.
When whole bars are provided with the "cuts
" of either a file or rasp, the
cutting up into lengths and the shaping of the tangs or spikes has to be done
afterwards.
The blanks are heated by suitable means as hereinafter described and, for
practical purposes, it is preferable that this finishing operation, not considering the
forming of the tang or spike, should be performed at one "heat."
It is of great importance that the heated pieces of steel, when between the dies
and matrices, whether of rollers, presses or stamps, should present as pure and clean
a surface as possible to the operation of the dies; and therefore the manner in
which they are heated and subsequently treated requires special attention.
The best course is to heat the steel blanks to incandescence by electricity, after
having freed them from oxide and other impurities which may adhere to them
externally, by means of a slightly acidulated bath.
Where electricity is not available for heating purposes, the heating of the

page_text: blanks should take place under such conditions that as little air as possible is
admitted, as air is liable to cause so-called "scale," which would interfere with the
neatness of the "cut." The employment of a regenerating or recuperative furnace
is therefore suggested, so that the blanks are not directly exposed to the products.
of combustion. These furnaces enable the temperature to be exactly controlled,.
and they will be closed on all sides with only sufficiently large passages or apertures.
at the front to enable the blanks to be conveyed through them into the heating-
chamber. These passages are provided with movable covers made of iron rings.
with fire-proof glass. Moreover a chemical may be introduced into the furnace as
a medium for absorbing the oxygen of the atmosphere. To avoid the formation
of magnetic oxide of iron during the whole time of the heating process and until
the blanks are further worked in the rolling mill or press, a protective coating
capable of resisting the influence of the atmospheric air, and consisting of a very
fluid solution of shellac in alcohol with a small addition of oxide of zinc may be
employed. The shellac burns away while the infinitely thin coating of oxide of
zinc leaves no trace on the films in the "cuts."
"
As a rule it will be sufficient for the steel blanks to get in a clean condition
under the roughing roller, as there is practically no chance of any magnetic oxide
of iron forming on the blanks while they pass from the roughing to the finishing
rollere, and even should a small amount of such oxide be formed, provision for its
removal may easily be made by arranging a stripping or scraping device, such as a
wire brush, or the like, just in front of the finishing rollers, presses or hammers, so
as to sweep off any oxide from each blank previously to its entrance into the.
finishing mill.
It is imperative that the grooves or matrices of the finishing rollers should be
kept scrupulously clean, and they may therefore be submitted to the action of
revolving brushes, a steam jet or a blast of air acting upon the roller, press or
stamp after each operation to remove any impurities that may have been deposited
by the finished blank and cooling it at the same time. Straight matrices, especially
such as those shown at Figures 10 and 11 which can be easily removed, can be
kept clean or brushed by hand. No oil should be allowed to come in contact with
the matrices.
If, on leaving the finishing rollers, presses or stamps, the files, rasps or the like
should no longer have the required temperature for hardening, they should be.
coated with a layer of the usual hardening medium, such, for instance, as a mixture
of wheat flour, pulverized horn and common salt, then heated again to the
temperature required for tempering and tempered in the usual way.
Having now particularly described and ascertained the nature of my said inven--
tion and in what manner the same is to be performed, I declare that what I
claim is :-
1. The process and apparatus for the manufacture of files, rasps and similar tools.
or objects, in which the blanks, after having first passed through a shaping process,
should this be required, are submitted in a heated state, in either a single or
repeated operation, to the action of rollers, presses or hammers, or to the action of
special auxiliary pieces attached to said rollers, presses or hammers, and which are
provided with "cuts or teeth and are of such a form and size as to suit the
width and section of the file or rasp to be manufactured and to produce the teeth
of the file or rasp, substantially as herein shown and described.
"
2. In mechanism for carrying out the process above claimed, the adaptation of
auxiliary matrices above claimed to roller mills having two horizontal and two
vertical rolls (so-called universal roller mills), and which auxiliary pieces are made.
to correspond to the form and size of the files to be manufactured for the purpose
of simultaneously finishing the horizontal and the vertical sides of the file, rasp or
similar article, substantially as herein shown and described.
3. In carrying out the process above claimed, the preparation of the surfaces of
the roller or presser parts, or auxiliary pieces, matrix or mould therefor, which

page_text: 66
"
66
"
produce the teeth or cuts on the file, rasp or similar article, in one or more
pieces having corresponding teeth or cuts worked in the working surface of
such parts, or formed of a number of plates connected together, the edges of
which are made to form the teeth, substantially as herein shown and described.
4. The preparation of the roller or presser parts herein described, by the use of
a toothed chisel which has a number of teeth corresponding to those on a band
made file running across from left to right over the angular cuts thereon,
substantially as herein described.
"
5. The various improvements in or relating to the manufacture of files, rasps
and other similar tools substantially as herein described.
Dated this Oth dor of Monah 1902
FRITZ EVERTSBUSCH,
By Harris & Mills,
23, Southampton Buildings, London, W.C., Agents.