Improvements in and relating to Machinery for Forming Toe-calks.
Year: 1899

page_text: Improvements in and relating to Machinery for Forming Toe-calks.
A communication from abroad by EDWARD ODEL ELY, Manufacturer, of Townsend
Street, Boston, in the County of Suffolk and State of Massachusetts, United
States of America.
I, ALFRED GEORGE BROOKES, of 55 & 56, Chancery Lane, in the County of
London, Chartered Patent Agent, do hereby declare the nature of this invention
to be as follows:--
This invention relates to the production of a novel machine for forming toe
calks, the general plan of the machine to be herein patented comprises a furnace
of any suitable construction in which may be heated bars which are to be trans-
formed into completed toe calks by the mechanism of the machine, the bars being
transferred from the furnace to bar carrying devices whence they are auto-
matically fed by a pushing mechanism to a shearing mechanism, the blanks
formed by the shearing mechanism being thence transferred to an anvil or blank
carrier to be operated upon by forming mechanism, or mechanism which acts upon
the ends of and draws the heated blanks to prepare their ends with the usual
projections found in toe-calks.
A plurality of bar carriers will preferably be employed, and they will be in tube
form, and correspond in cross section substantially with the shape of the bars
to be handled therein.
These bar carriers are rocked to thereby lay the bars carried by them first with
one side and then with the opposite side uppermost, in order that the blanks cut
from the bars may have the desired reversely bevelled ends.
'The bar carriers have suitable pinions which are engaged by devices inter-
mediate said pinions and a pinion on the main shaft, and preferably in the
driving train of mechanism there is employed a sprocket pinion and chain and
sprocket wheel, and cam wheels having face paths and segmental racks.
The carriers are rocked back and forth to permit a cut to be made in a bar
in one direction and then in the reverse direction as the bars are fed forward, the
bars being fed first one and then the other to the shearing mechanism.
The cutting dies herein to be used are of peculiar form. That is they have
at one end an ell offset carrying the movable cutting die proper, it cooperating
with a fixed die, and at one end of said ell offset is an arm which serves to support
the extreme end of the blank as the latter is being cut from the bar, an adjustable
stop mounted on a threaded stud serving to accurately limit the forward feeding
movement of the bar and thereby determine the precise length of each blank,

page_text: The bars are fed red hot through their carriers and are delivered to the dies
through openings which guide and retain the ends of the bars, said openings being
large enough to permit the bars to be rotated back and forth, the bottoms of the
openings constituting rests for the free ends of the bars adjacent the moving dies.
The hot bars are fed to the shearing mechanism alternately by feeding mechan-
ism having capacity for self regulation, so that as the ends of the said bars meet
the stops which position them, inequalities of expansion of the bars, due to
differences in temperature, will be compensated for.
The carriers are entered by push rods which act against the rods to push them
through the carriers.
As the blank is being cut from the hot bar it is momentarily held in a rotary
carrier, and said blank is pushed therefrom into position between an anvil and a
suitable clamp or retaining device. The blank having been put in proper position
between the anvil and retaining device a powerful lever, pivotted on the blank
carrier, is moved to clamp the blank firmly in place. The blank is rigidly held
with a vice like grip between the anvil and clamp while it is being treated to
have a prong drawn out at one end.
The time of movement of the blank carrier is such that it brings one of its
anvils beneath each blank just as the latter is cut off from the bar, and thereafter
the blank is immediately grasped and put in position and immovably gripped to
he acted upon by forming mechanism, or means which hammers and draws it and
shapes the pronged end of the toe-calk. A train of forming mechanism is
employed.
The forming mechanism comprises preferably a plurality of die holders which
are preferably rotary in their action, that is they have a circular movement which
may be more or less limited in amplitude, or they have a complete continuous
rotation.
The end of the calk to be shaped is acted upon successively by a series of
forming dies, said dies being arranged to operate as bars and as single dies alter-
nately. Before commencing the forming operation the hot blank will preferably
be acted on by a roller die which will serve to press the blank against the peri-
phery of the carrier and mark the same with a device of some sort indicating the
manufacturers name or quality.
After this, dies having their axes of rotation parallel with the axes of the
carrier meet the blank to pinch between them one corner of the hot blank, thus
partially disposing material to be subsequently formed by other operations into a
calk point.
Next after this first pair of dies a roller die having its axis of rotation at right
angles to the axis of the carrier acts to roll the partially formed point against
the face of the anvil, further partially indicating the point material first acted
upon and started by the two dies.
These operations are continued by other like dies in pairs and single dies alter-
nately, each succeeding die being so set as to still further reduce and draw the
part of the blank to form the point of the calk, and when these points have been
sufficiently drawn out and off set from the end of the blank the calks so formed
are discharged from the machine.
The forming of the points is done on the blanks after they have been removed
from the bar and while the said blanks are held clamped and are moved successively
within the range of movement of the forming devices.
Tatad the 2011.
'
1 1000
WM. BROOKES & SON,
55 & 56, Chancery Lane, London, Agents for the Applicant.

page_text: Improvements in and relating to Machinery for Forming Toe-calks.
A communication from abroad by EDWARD ODEL ELY, Manufacturer, of Townsend
Street, Boston, in the County of Suffolk and State of Massachusetts, United
States of America.
°
I, ALFRED GEORGE BROOKES, of 55 & 56, Chancery Lane, in the County of
London, Chartered Patent Agent, 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:-
This invention relates to improvements in machines for automatically forging
toe-calks for horseshoes, and has for its primary object the production of toe-calks
with extreme rapidity, further objects being the reduction of expense, economiz-
ing of power, avoidance of waste of stock, and the production of an improved calk.
This invention relates to the production of a novel machine for forming toe-
calks, the general plan of the machine to be herein patented comprises a furnace
of any suitable construction in which may be heated bars which are to be trans-
formed into completed toe calks by the mechanism of the machine, the bars being
transferred from the furnace to bar carrying devices whence they are automati-
cally fed by a pushing mechanism to a shearing mechanism, the blanks formed
by the shearing mechanism being thence transferred to an anvil or blank carrier
to be, operated upon by forming mechanism, or imechanism which acts upon the
ends of and draws the heated blanks to prepare their ends with the usual pro-
jections found in toe-calks.
A plurality of bar carriers will preferably be employed, and they will be in
tube form, and correspond in cross section substantially with the shape of the
bars to be handled therein.
These bar carriers are rocked to thereby lay the bars carried by them *first
with one side and then with the opposite side uppermost, in order that the blanks
cut from the bars may have the desired reversely bevelled ends.
The bar carriers have suitable pinions which are engaged by devices inter-
mediate said pinions, and a pinion on the main shaft, and preferably in the
driving train of mechanism there is employed a sprocket pinion and chain and
sprocket wheel, and cam wheels, having face paths and segmental racks.
The carriers are rocked back and forth to permit a cut to be made in a bar in
one direction and then in the reverse direction as the bars are fed forward, the
bars being fed first one and then the other to the shearing mechanism.
The cutting dies herein to be used are of peculiar form. That is they have at
one end an ell offset carrying the movable cutting die proper, it co-operating with
a fixed die, and at one end of said ell offset is an arm which serves to support
the extreme end of the blank as the latter is being cut from the bar, an adjustable
stop mounted on a threaded stud serving to accurately limit the forward feeding
movement of the bar and thereby determine the precise length of each blank.
The bars are fed red hot through their carriers and are delivered to the dies
through openings which guide and retain the ends of the bars, said openings
being large enough to permit the bars to be rotated back and forth, the bottoms
of the openings constituting rests for the free ends of the bars adjacent the
moving dies.
The hot bars are fed to the shearing mechanism alternately by feeding mechan-
ism having capacity for self-regulation, so that as the ends of the said bars meet
the stops which position them, inequalities of expansion of the bars, due to
differences in temperature, will be compensated for.

page_text: The carriers are entered by push rods which act against the rods to push them
through the carriers.
As the blank is being cut from the hot bar it is momentarily held in a rotary
carrier, and said blank is pushed therefrom into position between an anvil and a
suitable clamp or retaining device. The blank having been put in proper position
between the anvil and retaining device a powerful lever, pivoted on the blank
carrier, is moved to clamp the blank firmly in place. The blank is rigidly held
with a vice like grip between the anvil and clamp while it is being treated to
have a prong drawn out at one end.
The time of movement of the blank carrier is such that it brings one of its
anvils beneath each blank just as the latter is cut off from the bar, and thereafter
the blank is immediately grasped and put in position and immovably gripped to
be acted upon by forming mechanism, or means which hammers and draws it and
shapes the pronged end of the toe-calk. A train of forming mechanism is
employed.
The forming mechanism comprises preferably a plurality of die holders which
are preferably rotary in their action that is they have a circular movement which
may be more or less limited in amplitude, or they have a complete continuous
rotation.
The end of the calk to be shaped is acted upon successively by a series of
forming dies, said dies being arranged to operate as pairs and as single dies alter-
nately. Before commencing the forming operation the hot blank will preferably
be acted on by a roller die which will serve to press the blank against the peri-
phery of the carrier and mark the same with a device of some sort indicating the
manufacturers name or quality.
After this, dies having their, axes of rotation parallel with the axes of the
carrier meet the blank to pinch between them one corner of the hot blank, thus
partially disposing material to be subsequently formed by other operations into
a calk point.
Next after this first pair of dies a roller die having its axis of rotation at right
angles to the axis of the carrier acts to roll the partially formed point against the
face of the anvil, further partially indicating the point material first acted upon
and started by the two dies.
These operations are continued by other like dies in pairs and single dies
alternately, each succeeding die being so set as to still further reduce and draw
the part of the blank to form the point of the calk, and when these points have
been sufficiently drawn out and off set from the end of the blank the calks so
formed are discharged from the machine.
The forming of the points is done on the blanks after they have been removed
from the bar and while the said blanks are held clamped and are moved succes-
sively within the range of movement of the forming devices.
The details of construction of this invention and further advantages thereof will
be fully described hereinafter, reference being had to the accompanying drawings,
illustrative of a preferred embodiment of the invention, and the latter will be
more particularly defined in the appended claims, also forming a part of this
Specification.
In the drawings, Fig. 1 is a view in rear elevation of the main part of the
machine. Fig. 2 is a top plan view thereof. Fig. 3 is a vertical cross section
thereof, taken on the line 3, 3 Fig. 1. Fig. 4 is a similar sectional view taken on
the line 4 Fig. 1. Fig. 5 is a vertical longitudinal section thereof. Fig. 5ª is a
broken detail in front elevation illustrating the relation of the blank stop and
guide to the blank-carrier. Fig. 6 is a detail in elevation of a roller bearing to
take up end thrust, Figs. 7, 8 and 9 are sectional details, parts being broken
away in Fig. 8, showing the adjacent parts of the end-thrust roller-bearing.
Fig. 10 is an enlarged front elevation of a pair of die heads. Fig. 11 is a frag-
mentary detail thereof in side elevation. Fig. 12 is a view in end elevation of a
part of the feeding mechanism. Fig. 13 is a fragmentary view, parts being

page_text: broken away showing in side elevation the remote end of the feeding mechanism.
Fig. 14 is an enlarged broken detail of the anvil or blank carrier, viewing the
same from the left. Fig. 1, the same as is shown in Fig. 4.
Fig. 15 is a front elevation of the parts shown in Fig. 14, looking toward the
left. Fig. 16 is an enlarged detail in elevation of the shearing mechanism shown
in Fig. 4. Fig. 17 is an end elevation of the parts shown in Fig. 16 looking
toward the left. Fig. 1S is a perspective view of the movable cutting-die. Fig. 19
is a section on the dotted line 19, Fig. 17. Fig. 20 is a view in elevation illus-
trating the general arrangement of the plant. Fig. 21 is a view in end elevation
of the mechanism for rocking the bars and bar-carriers of the feeding mechanism,
looking at Fig. 2 from the left. Figs. 22 and 23 are views in elevation of the
cam-wheels for operating the rocker-arms thereof. Fig. 24 is an enlarged detail
in vertical cross-section taken on lines 24, 24, Fig. 25. Fig. 25 is a front elevation
viewing Figs. 21 and 24 from the left. Fig. 26 is a broken detail in front
elevation, showing the feeding mechanism. Fig. 27 is an end elevation thereof
looking at Fig. 26 from the right. Figs. 28 to 35 are perspective views, illus-
trating the successive shapes assumed by the blank in the manufacture of the
improved toe-calk. Fig. 36 shows in elevation parts being broken out, the leading
features of the feeding mechanism of the apparatus.
Referring to Fig. 20, the general plan of the invention will be seen to comprise
a furnace A of any suitable construction, in which the bars are heated which are
to be transformed into completed toe-calks by the machine, the bars being trans-
ferred from the furnace A to bar-carrying devices B, whence they are automati-
cally fed by a pushing mechanism to a shearing mechanism D, the blanks
formed thereby being thence transferred to an anvil or blank carrier E to be
operated upon by forming mechanism G, all of the mechanism mentioned being
preferably entirely automatic.
Referring to Figs. 26 and 27 they show two carrier-bars beach in the form of
a tube provided with a longitudinal passage rectangular in cross-section corre-
sponding in shape and approximately in size to the bars K which are to be
transported therethrough and to be manufactured into calks, said bars being
shown therein in Fig. 25. These carriers b₁ are mounted adjacent and parallel
to each other in stands 2, the latter stand containing mechanism (see Figs. 21
to 25) for reciprocatingly rocking the carriers and thereby laying the respec-
tive bars carried thereby first with one side uppermost and then with the opposite
side uppermost in order that the blanks cut may have the desired reversely-
bevelled ends, as shown in Fig. 28.
The rocking mechanism, as herein shown, will be understood viewing Figs. 21
to 25, where it will be seen that the main driving shaft F of the machine is
provided with a sprocket-pinion f and chain f¹, passing over a sprocket-wheel f
on the end of a shaft b, journaled in the stand and adjacent stand b, secured
to the bed of the machine. The shaft carries opposite cam-wheels 66, 67
having opposite face path-cams 68, 69 (shown in detail in Figs. 22 and 23), in
which travel rolls 10, carried in the free ends of segmental arms 612, 61,
pivoted, at 6, to the stand, and carrying segmental racks 16, 617 at their rear
ends in engagement, respectively, with cog-pinions 18, 19, fast on the bar
carriers b, . By this means the carriers b, are alternately rocked back and
forth, so as to permit a cut to be made in one direction and then in the reverse
direction as the bars are fed forward, the feeding mechanism hereinafter described
serving to feed forward one bar and then the other to the shearing mechanism.
The latter in a preferred embodiment is shown in Figs. 4 and 16 to 19, as in the
form of reciprocating slides d, d, carrying the cutting-dies reciprocable in ways d²
in a plate or frame d. These dies are preferably of peculiar form, one of them
being shown in perspective in Fig. 18, where it will be seen that at its upper
end it has an L-offset ', (see also Fig. 17) to which is bolted the movable cutting
die proper, d³, which co-operates with a fixed die do, and at the rear of the offset d

page_text: is an arm d, which serves to support the extreme end of the blank as the latter is
being cut from the bar, as will be clearly understood viewing Fig. 17. An
adjustable stop ds, mounted on a threaded stud d', serves to accurately limit the
forward feeding movement of the bar and thereby determine the precise length
of the blanks k.
The bars are fed red-hot through their carriers b, and delivered thereby
to the dies through the openings d, d, these openings serving to guide and
retain the ends of the bars, and yet being large enough to permit the latter to be
half-rotated back and forth, as already described, the bottoms of the openings
constituting rests for the free ends of the bars K immediately adjacent the moving
dies.
The slides d, dare reciprocated by means of toggle-links 2, 3, secured at
their opposite ends at to a bracket d, bolted to the frame, and at 6 to
brackets or lugs d, cast on the slides d, d.
In order to maintain the greatest speed, I have not only provided two bar
carriers alternately reciprocable and two sets of cutting-dies as described, but I
also construct the shearing mechanism to cut the blanks by the breaking the
toggle, as shown at the left, Fig. 16, inasmuch as the links forming the toggle-
joint serve to move their respective slides with greater rapidity when moving
away from the dead centre rather than when moving toward it.
The two sets of toggles are connected to operate in reverse direction by means
of a link 18, pivoted thereto at 9, 20 and connected at 2 by a link to a
rocker arm 2, rigid on a shaft d2, (Figs. 1, 4 and 21), having at its opposite
end a lever, carrying a roll in engagement with a heart-cam 27, fast on the
driving shaft F.
The bars Kare fed to the shearing mechanism alternately, as stated, and in
order that the forward ends thereof may always be projected fully against the
stop into the positions indicated by dotted lines, (Fig. 17) I have not only
provided an automatic feeding mechanism, but one in which there is a great
capacity for self-regulation, so that inequalities in expansion due to differences in
temperature or any other irregularities which are liable to occur in the feeding of
the bars will be compensated for.
Referring to Figs. 12, 13, 26, and 27, taken in connection with Fig. 20, it will
be seen that the bar carriers receive the bars from the furnace at their outer ends
in the stand 62, the feeding mechanism C, comprising push rods c, c, adapted to
enter the carriers b, behind the bars, and push the latter forward against the
stops as already explained. These push-rods are supported at their rear ends
by plungers 2, yieldingly reciprocable in barrels by means of coiled springs ct.
The barrels are fast on travellers herein shown as square pieces of wood,
although they may be of any other form or material desired, and extending
forward toward the machine proper between opposite pairs of rolls c, c, mounted
in the stand and positively driven with opposite rotation by means of spur-
gears, and bevelled gears clo in mesh with pinions c¹¹ on a shaft c¹², carrying
a pulley 3, driven from the line-shafting (not shown). The barrels are con-
nected to the travellers by arms c, Fig. 12, each provided with slight recesses c¹³
adapted to reciprocate on guide bars 16, held by a support €17
Fig. 20, at one end, and by a stand 2 at the other end. The
rolls are herein shewn as mounted adjacent their ends in movable journal
boxes 18, normally held forward in yielding engagement with the travellers co by
means of springs 9, held adjustable in sockets 20.
From the above description it will be understood that the constantly rotating
rolls, tend to move the travellers forward uniformly but inasmuch as the
push-rods which move the heated bars forward against the stop s to be acted
upon by the shearing devices have necessarily an intermittent forward movement
by reason of the halting of the bars while they are being sheared the travellers c

page_text: are thereby caused intermittingly to compress the springs et behind the push-
rods, and whenever these springs are compressed to a predetermined degree the
travellers slip between the rolls and, the slipping point thereof being
capable of definite regulation by means of the adjustable springs c, which hold
one set of rolls toward the other set of rolls in frictional engagement with the
travellers. Thus it is impossible that any false or short blanks should be cut.
Each push-rod is provided with a returning weight, slung on the axis of a
pulley, running on a cord, said cord passing over guide pulleys, 33, ² for
aiding in returning it into its original position.
Just as the blank is being finally cut off from the bar K it is received by a
blank-carrier herein shown as moveable and as containing two anvils or recesses,
Figs. 2 and 4, to hold the blanks while they are being formed, although it will
be understood that in this respect this invention is not limited, but includes any
means for retaining the blanks and includes any number of these devices which
are herein called "anvils."
The details of construction of the blank carrier and its anvil are shown in
enlarged view in Figs. 14 and 15, these views showing the position of the parts
after a blank has been partially formed. In the peripheral face of the carrier,
which is herein shown as a hollow wheel or disk mounted on the drive shaft F, I
secure a block e, herein shown as held in a transverse dovetailed way by means
of a draw bolt e¹ set up by a nut e³, bearing against a shoulder et, and on the top
of this block I secure a shouldered block e, the forward face of the block e
and the adjacent outer face of the block e constituting the pocket or recess of the
anvil, in which a blank k is held during the forming operation. A leaf-spring e
at one end of the blank-recess last mentioned projects forward, as shown in
Fig. 14 in the path of the blank being cut from the bar K, this spring con-
stituting a moveable retaining device to receive and retain the blank on the anvil,
said spring having its path of movement in line with the space between the
urm and the die , Fig. 17, so that as the said arm and die carry the blank
forward adjacent the blank carrier E the spring e6 slides over and retains the
blank just as it is being finally sheared from its bar, the blank being firmly
supported, until caught by the spring e, by the arm, and the end of the
offset which are beneath it (see Figs. 4, 17 and 18). The blank is momentarily
held in the position last mentioned on the periphery of the blank-carrier E, and
is then pushed over to the right, Fig. 15, by a positioning device in the form of a
finger on the end of an armes of a slide e, supported on a slideway el⁰ secured
by bolts el rigidly to the blank carrier E. The slide is provided with a roll e¹2
on its under side which travels in a stationary cam-groove e, formed in a
drum e, rigidly secured to an end bearing f of the frame of the machine. The
cam groove e has an offset el, which at the proper moment moves the slide e
forward on its way 10 and thereby causes the finger e to shove forward the blank k
just deposited in the recess on the anvil beneath the spring e, as described, and
upon the proper positioning of the blank, thus a clamping plate el, adjustably
carried at the end of a powerful lever e¹, pivoted at 18 on the blank-carrier, is
moved forward to clamp the blank in place, this clamping movement being herein
shown as accomplished by a roll 19 on the inner end of the lever c which travels
in a proper cam groove 20, in the face of the drum e, the shape of this cam-
groove being indicated in dotted lines in Fig. 4 and its relative position being
clearly shown in Fig. 5, where it will be seen that the lever e7 is moved into
clamping position by an offset e and so remains until released by an offset e²².
It will thus be seen that the blank is rigidly held in vice-like grip between the
block and the plate e as described. The timing of the movements of the parts is
such that the blank-carrier brings one of its anvils beneath each blank just as the
latter is cut off from the bar K, the mechanism described immediately grasping
the blank, positioning it, and immovably gripping it to be acted upon by the
forming mechanism. The blanks are held firmly gripped as they pass under the
train of forming mechanism, as presently described, and having been completely

page_text: formed the roll e19 of the clamping lever e engages the offset e23 last mentioned,
thereby releasing the blank from its gripped position and thereupon the position-
ing finger e, acting as a delivering device, is quickly actuated by an offset 23 of
the cam-groove e¹³, (see Fig. 1) so as to give the blank a sufficient blow or move-
ment to dislodge it from the carrier and permit it to drop by gravity onto a chute
or into a receptacle on the base F¹, preferably on an incline f° thereof.
The forming mechanism is herein shown as comprising a plurality of die-
holders, which are preferably rotary in their action, by which I mean that they
have a circular movement which may be more or less limited in amplitude,
although herein shown as a complete continuous rotation.
Referring to Figs. 1 to 5, 10 and 11, g designates a gear fast on the drive-
shaft next to a suitable driving-pulley and in mesh with a plurality of cog-
pinions (indicated by dotted lines, Fig. 3) these pinions being mounted on
shafts g, firmly journalled in hub-like bearings f4 on a heavy web or bridge
piece of the frame. The pinions are wider than the gear g being shown as
substantially double the width thereof, in order that they may mesli with and
drive a second set of pinions g and shafts g³, herein shown as concentrically
mounted in bearings f6 in the web f5, similar to the bearings f4 already described.
The web falso contains radially-extended bearings f7, which support shafts go,
rotated by beyel-pinions g', in mesh with a bevelled gear g³, fast on the drive
shaft F.
At their outer ends the shafts g, g, g, above mentioned are provided with
suitable die carriers, herein shown as all substantially similar, and therefore a
description of one will serve for all. These die carriers or heads are shown in
enlarged detail in Figs. 10 and 11, and each comprises a face-plate g', provided
with elongated slots go for proper adjustment on and to be secured against a head
plate by bolts 912, said face plate being provided with ribs 3, forming a
way 4 for a forming-die 15, adjustable therein by means of bolts g1 g17. Said
forming-die g is firmly held in its adjustment, so as to cooperate with an
opposite forming-die where they are arranged in pairs. The successive dies and
pairs of dies are shaped to draw out and form the calk, as shown in Figs. 28
to 35, as will be more particularly explained later on.
While the parts have been constructed and arranged as already described, to
position the blanks with substantial accuracy, yet as a further precaution it is
possible to employ a guide and stop S (shown in detail in Fig. 5) secured to the
web f and projecting in front of the path of the inner or overhanging ends of
the blanks, so that as the fingers e shove the blanks forward into position they
are stopped with absolute precision by the stop S, which also serves to guide
them until they come beneath the die I.
It will be observed that this die projects over the body of the blank on the
anvil. One main purpose of die I is to press the blank firmly into its recess,
the clamping plate 16 being at that moment moved into clamping position.
In order to take up the considerable end thrust which exists in the machine I
provide thrust roller-bearings (shown in detail in Figs. 6 to 9). In a spider or
annular plate M herein shown as made up of two parts m, m', there is mounted a
plurality of radial rollers m², having an outer shouldered bearing m³ resting
against a hardened steel block mt, said rollers bearing against a stationary wear-
plate m³ on the rib f and a movable wear plate m against the gear wheel y.
It has been explained above in detail the construction of the machine and its
preferred embodiment as herein shown; but it will be understood that the
various arrangements and relations of parts, as well as the specific details of
construction, may be slightly varied within the spirit and scope of the invention.
In order that the operation of the improved machine may be fully understood.
the successive steps in the manufacture of a toe-calk from the start to the finish
will be now described.
The heated bars which are to be formed into toe-calks are taken alternately
from the furnace A and pushed into the bar-carriers b, b¹, these carriers serving

page_text: to maintain the rods straight and hold in their heat, preventing buckling and
wedging. The pushers c, c¹ gradually force forward the rods, tending to main-
tain them successively in position against the stops do, and the shearing mechanism
cuts off blanks & alternately from one rod and then from the other. The feeding
mechanism herein shown is of particular importance in this invention as it is
strong and certain in its operation. The feed rolls 6, care positive in their
operation up to a predetermined point, which may be varied at will, and beyond
that point they allow the travellers to slip without feeding them, thus holding
the springs under a uniform tension ready to project either of the bars K.
instantly upon the delivery of a blank to the blank-carrier and the restoring of
the cutting-die to the position shown in Fig. 17 out of the path of said bar K
ready to cut another blank. In other words, the bar K is held forward all the
time, and when in the position shown in Fig. 17, it bears against the stop d³,
but immediately upon the upward movement of the cutting-die, which carries
the blank end of the bar ahead of it, the bar proper as the blank is being severed
bears against the inner face of the moveable cutting-die d and is thereafter held
against forward movement by said die while the blank cut is being delivered to
the blank-carrier and also until the cutting-die d and supporting arm move down
again out of the way of the bar, whereupon it is instantly projected against the
stop dready to be immediately sheared off again for the formation of another
blank k. This operation proceeds with extreme rapidity the successive blanks
being alternately formed by quick movements on the breaking of the toggle
from the position shown at the right, Fig. 16, to the position shown at the left.
It is of great importance to gain speed at every point and withal to insure
accuracy and certainty, so that no false cuts or movements shall be made. The
shape and positions of the cutting-dies are such that, presupposing the bar to lie
with its side ¹, Fig. 28, lowermost, one cut, 2, will be at an angle, as shown in
Fig. 28, and in order that the next cut ³ may be at a reverse angle, as shown
in Fig. 28, the corresponding racks 616 617, Figs. 21 to 25 serve to rock the bar
and its carrier one half rotation immediately upon the cut being made, so that
the bar is turned over in the recess 10 or 1, as the case may be, so as to bring
its side lowermost into the position previously occupied by the side. This
rocking movement may take place simultaneously with the forward movement of
the bar, previously or subsequently thereto, as desired under the particular
circumstances.
า
Fig. 21 shows the rocking and shearing mechanisms connected by a sprocket-
chain, this provision insuring that there shall be absolute precision of movement
one relatively to another; but it will be understood that any other suitable con-
nection or relative arrangement of these mechanisms may be substituted without
departing from this part of the invention, broadly considered.
Viewing Fig. 4, it will be seen that the position and arrangement of the
shearing mechanism are such as to afford a firm support to the blanks after they
are cut from the bars K. It has been chosen in this preferred form of the inven-
tion to make the shearing mechanism stationary relatively to the blank-forming
mechanism and make the latter moveable this being a compact and convenient
arrangement and it has been chosen to give the blank carrier a rotary movement,
preferably continuously in one direction. Accordingly the blank being held up
at both ends by the cutting-die and the supporting-arm carried thereby, as herein
shown, and the blank-carrier E being rotated in the direction of the arrow,
Fig. 4, it will be clear that the spring e, Fig. 14, will come against the blank
from the under side of the latter, and this takes place preferably just as the
blank is being finally severed, so that the instant that the block strikes against
the side of the blank the latter is freed to move ahead with the carrier under the
retaining-pressure of the spring e, and preferably also simultaneously with this
movement the finger e' is moved to the right, Figs. 2 and 15, by the engagement
of the roll el of its slide e with the offset e¹ of the stationary frame e¹, thereby

page_text: pushing the blank forward along the adjacent surfaces of the anvil blocks e, e³ the
precise distance required, so as to leave just the amount of metal overhanging
the far edge thereof which is required for the subsequent forming of the calk,
accuracy being further insured by the guide and stop S, against which the blank
may strike.
It will be understood from the description thus far that all the blanks must
necessarily be absolutely uniform in every respect, inasmuch as the mechanism
is so constructed, as already fully explained, that every blank is treated precisely
the same, and the movements in every respect are absolutely alike for the succes-
sive blanks.
The blank having been properly positioned as stated, is thereupon pressed down
into its seat by the overhanging die 1 and immovably gripped by the clamping-
plate el actuated by the cam-groove e20, operating on the roll e¹ of the lever e¹,
being thereafter held rigidly thereby as it is carried around to be operated upon
by the successive forming-dies.
One object of the invention is to form the calk by working and drawing the
metal forward, so as to lay its grain properly for the greatest strength and without
offsetting the grain of the metal at the base of the calk, and thereby render it
brittle at that point, so as to be liable to break off easily, as has heretofore
frequently resulted in machine made calks, the machine herein described drawing
the metal forward a little at a time, as distinguished from spreading it in all
directions, as by a blow with a flat surface. This feature of the invention also
insures less noise, requires less power, and produces a neater and more perfect
calk, besides giving absolute uniformity of product.
The forming dies are shown as continuously rotated, this being a preferable
motion in connection with the continuous rotation of the dic-carrier; but it will
understood that the invention is not limited in this respect, inasmuch as an
oscillating or any other movement may be employed.
The blank carried on the anvil by the blank carrier is first acted upon simul-
taneously by the dies 2, 3 and brought thereby into the form shown in Fig. 29,
these dies serving to produce a projecting nib or prong by crowding forward the
metal thereof by a simultaneous pressure on the opposite sides of the
calk. As the blank moves forward it is next worked by die 4, which
crowds down the end of the calk against the end of the anvil,
and thereby tends to sharpen, as well as to elongate, the prong
or point to the form shown in Fig. 30, whereupon it is again operated upon by
the dies 5, 6, which act in the same manner as the previous pair of dies and
simultaneously elongate and slightly thin down the point into the form shown
in Fig. 31. The next die 7 crowds down the end of the point slightly sharpening
it to the form Fig. 32; and the following pair of dies 8, 9 again thin down and
elongate the point with sidewise pressure to the form shown in Fig. 33. Then
die 10 again sharpens the point with an endwise pressure and brings it into the
shape shown in Fig. 34, whereupon the dies 11 and 12 finally shape it into the
form shown in Fig. 35. It will thus be seen that the grain of the metal is not
violently disturbed at any step of the process: but the metal is gradually drawn
out by a series of alternate side pressures and end pressure, one succeeding the
other with extreme rapidity.
The rotary movement is preferred inasmuch as thereby greater rapidity of
operation may be gained in the form of machine in which we have herein chosen
to embody the invention, and it is preferred to have the blanks carried around
beneath the forming-dies, the latter remaining stationary relatively to each other
and to the general movement of the blank carrier, but it is considered within
the invention to reverse these movements or to substitute others therefor.
It is considered broadly new to provide automatic means for working the metal
of the calk forward continuously and evenly; also to provide an automatic feed
whereby the machine feeds itself.

page_text: All these general features of the invention not only conduce to extreme rapidity
of output, but are of material advantage in economy of operation.
It is considered of decided advantage, especially by reason of the superior calk
produced thereby, to have no spreading-out blows delivered on the metal, but
instead thereof to have solely a working and drawing action.
Having now particularly described and ascertained the nature of my said
invention and in what manner the same is to be performed I declare that what
I claim is: :-
1. A machine for making toe-calks, comprising means to hold a blank, and
mechanism for forming a calk from said blank, said mechanism including auto-
matic means for working the metal by a series of side rolling pressures and end
pressures in alternate succession.
a
2. In a machine for making toe-calks, a blank carrier provided with
plurality of anvils, means to deliver separate blanks to said anvils, and their
ends slightly projecting thereover, mechanism for forming calks from said blanks,
said mechanism including automatic means for working the metal by a series of
side pressures and end pressures in alternate succession, and means for relatively
moving said blank-carrier and forming mechanism, whereby the end of each blank
receives said pressures successively.
3. In a machine for making toe-calks, a blank carrier, means for feeding
separate blanks thereto, means to clamp said blanks in place on the carrier,
means maintaining said clamp in rigid clamping engagement with the blanks
until the toe-calks are finished, a succession of forming dies, means for moving
said dies with an outward drawing movement over the calk end of the blanks.
4. In a machine of the class described, a plurality of bar carriers, shearing
devices, and forming mechanism, means for automatically feeding the bars alter-
nately in succession to said shearing devices to be cut into blanks for said
forming mechanism.
5. In a machine of the class described, a plurality of bar carriers, shearing
devices, and forming mechanism, means for automatically feeding the bars alter-
nately in succession to said shearing devices to be cut into blanks for said
forming mechanism, said shearing devices being arranged to cut obliquely across
said bars, and means to rock said bars.intermittingly.
6. In a machine of the class described a plurality of bar carriers, shearing
devices, and forming mechanism, and means for automatically feeding the bars
alternately in succession to said shearing devices to be cut into blanks for said
forming mechanism, said means including mechanism for maintaining said bars
under a constant tendency to feed forward.
7. In a machine of the class described, a plurality of bar carriers shearing
devices, and forming mechanism, and means for automatically feeding the bars
alternately in succession to said shearing devices to be cut into blanks for said
forming mechanism, said means including mechanism for maintaining said bars
under a constant tendency to feed forward, and means to regulate said tendency.
8. The use with bar-shearing mechanism and forming mechanism, of means to
feed said bars intermittingly to the shearing mechanism, a uniformly-moving
driving mechanism, means for continuously moving said driving mechanism, said
driving mechanism being connected with and to operate said means for the inter-
mittent feed, the latter feeding intermittingly and the driving mechanism acting
continuously.
9. A feeding mechanism, comprising a bar-carrier to receive bars to be fed, a
push rod to feed said bars, positive driving means for actuating said rod, and
an intermediate yielding connection between said rod and driving means whereby
an intermittent movement of the rod is permitted without requiring a correspon-
dent movement of the driving means.
10. A feeding mechanism, comprising a bar-carrier to receive bars to be fed, a
push rod to feed said bars, positive driving means including opposite rolls, a

page_text: traveller held between said rolls and moved longitudinally thereby, and a spring
connection between said traveller and said rod.
11. A feeding mechanism, comprising a bar-carrier to receive bars to be fed,
a push rod to feed said bars, positive driving means including opposite rolls, a
traveller held between said rolls and moved longitudinally thereby, a spring con-
nection between said traveller and said rod, and means to regulate the pressure of
said rolls on said traveller.
12. The use with a long tubular bar carrier, having substantially the same
angular shape and size of cavity throughout its length, said angular shape corre-
sponding in cross section to the bar to be fed therein, of a push-rod operating in
said carrier and means to intermittingly move said push-road progressively in
the carrier, and means to intermittingly give said carrier a partial rotation.
13. The use with two long tubular bar-carriers to receive and retain the heat of
bars to be fed therein, said carriers having substantially the same angular shape
and size of cavity throughout their entire length, and a push-rod for and operating
in each carrier, and means to intermittingly move said bars progressively in said
carrier, of means to partially rotate said bars alternately.
14. A shearing apparatus, comprising a plate having a way therein, a fixed
cutting die, an opening to receive a bar to be cut, and a rest for said bar, and
a slide reciprocable in said way, said slide having an L offset provided with a
movable die co-operating with said fixed die.
15. A shearing apparatus, comprising a plate, a slide movable therein, said
plate having a fixed cutting-die and said slide having a movable cutting-die to
co-operate therewith, and a supporting-arm carried by and moving with said
slide, said supporting arm engaging and supporting the free end of the blank as
it is being cut from a bar and said slide and its cutting die supporting the inner
end of the blank, and means to actuate said slide.
16. A shearing apparatus, comprising a plate, a slide movable therein, means to
actuate said slide, a fixed cutting die carried by said plate, a movable cutting
die carried by said slide to cooperate with the fixed die for cutting a blank
from a bar, and an adjustable stop to limit the forward movement of the bar and
determine the length of the blank to be cut by said dies.
17. A shearing apparatus, comprising a plate, a slide movable therein, means to
actuate said slide, a fixed cutting die carried by said plate, a movable cutting die
carried by said slide to co-operate with the fixed die for cutting a blank from a
bar, an adjustable stop to limit the forward movement of the bar and determine
the length of the blank to be cut by said dies, and a supporting-arm carried by
and in line with said movable cutting die, said arm and die supporting the
respective ends of the blank as the latter is cut from a bar.
18. The use with an anvil, a movable retaining device to receive and retain a
blank on said anvil, a positioning device, of means to operate the latter for accu-
rately positioning the blank on and relatively to the anvil.
19. The use with an anvil, a movable retaining device, to receive and retain a
blank on said anvil, a positioning device of means to operate the latter for
accurately positioning the blank relatively to the anvil, a clamp, and means to
actuate it to grip said blank and hold it immovable after it has been positioned.
20. In a machine of the class described, a drum and a blank-carrier relatively
rotatable, said carrier being adapted to receive blanks and retain the same, said
drum having a cam-groove, a positioning device for accurately adjusting the blanks
in position on said carrier, said positioning device being actuated by said cam-
groove.
1
21. In a machine of the class described, a stationary drum, and a rotatable
blank carrier, the latter provided with means for supporting blanks, and carrying
a positioning device movable laterally thereto to position the blanks, said drum
having a cam-groove for actuating said positioning device, and a clamp pivotally
supported on said carrier and means to actuate it to grip the blanks.
22. The use with an anvil adapted to support a blank to be formed, of a poși-

page_text: tioning device to place the blank in position on the anvil, a stop to limit the
movement of the blank by said positioning device, a clamp and means to actuate
said clamp to grip the blank and hold it for forming.
23. A blank carrier, means for positioning blanks thereon, a stop to limit the
movement of the blanks under the action of said positioning device, means to
press said blanks against said carrier and a clamp to keep the blanks so pressed.
24. A machine of the class described, composed of a blank-carrier adapted to
receive and support a plurality of blanks, clamps to grip and hold said blanks
immovably on said blank-carrier, means to actuate said clamps, and a plurality
of forming devices, said forming devices and blank carrier being relatively movable
whereby each blank is progressively operated upon by all of said forming devices.
25. A machine of the class described, composed of a blank carrier, adapted to
receive and support a plurality of blanks, clamps to grip and hold said blanks
immovably on said blank-carrier, means to actuate said clamps, and a plurality of
forming devices, said forming devices and blank carrier being relatively movable
whereby each blank is progressively operated upon by all of said forming devices,
and means to give said forming devices an individual rotary movement.
26. A machine of the class described, composed of a blank-carrier adapted to
receive and support a plurality of blanks, clamps to grip and hold said blanks
immovably on said blank-carrier, means to actuate said clamps, and a plurality
ot forming devices, said forming devices and blank carrier being relatively mov-
able whereby each blank is progressively operated upon by all of said forming
devices, said forming devices being arranged successively singly and in pairs
whereby the blank is operated upon alternately by a single forming device and by
a pair of co-operating forming devices.
27. A machine of the class described, composed of a blank-carrier adapted to
receive and support a plurality of blanks, clamps to grip and hold said blanks
immovably on said blank-carrier, means to actuate said clamps, and a plurality of
forming devices, said forming devices and blank-carrier being relatively movable
whereby each blank is progressively operated upon by all of said forming devices,
said forming devices being arranged successively singly and in pairs whereby the
blank is operated upon alternately by a single forming device and by a pair of
co-operating forming devices, means to give the forming devices composing said
pairs rotative movement in opposite directions.
28. A machine of the class described, composed of a blank carrier adapted to
receive and support a plurality of blanks, clamps to grip and hold said blanks
immovably on said blank-carrier, means to actuate said clamps, and a plurality
of forming devices, said forming devices and blank-carrier being relatively moveable
whereby each blank is progressively operated upon by all of said forming devices,
said forming devices being arranged successively singly and in pairs whereby the
blank is operated upon alternately by a single forming device and by a pair of
co-operating forming devices, and means to give said forming devices an individual
rotary motion in the direction of relative movement of said blanks.
29. A machine for making toe-calks, comprising means to support the blanks
to be formed into toe-calks, and forming mechanism to operate on the side of
the toe calk, means to move said toe-calk relatively to said side forming mechan-
ism, forming mechanism to operate on the end of the toe-calk, and other forming
mechanisms to operate subsequently on the side of the toe-calk and again on the
end thereof, and means to successively present the toe-calk to said different
forming mechanisms.
30. A machine for making toe-calks, comprising a blank-carrier, means to
rotate it, a plurality of shafts mounted in fixed bearings approximately at right
angles to the plane of movement of said carrier, each shaft being provided with a
transverse head carrying a forming die projecting into the path of movement of
said blanks, and means to communicate rotary movement to said shafts.
31. A machine for making toe-calks, comprising a blank-carrier, means to rotate
it, a plurality of shafts mounted in fixed bearings approximately at right angles

page_text: to the plane of movement of said carrier, each shaft being provided with a trans-
verse head carrying a die, said die projecting into the path of movement of the
said blanks, the first of said dies projecting over said carrier and the blanks
thereon farther than the others of said dies to press the blanks against the carrier,
a clamp to grip said blanks as the latter pass under said last mentioned die, and
means to communicate rotary movement to said shafts.
32. A machine for making toe-calks, comprising a blank carrier, means to
rotate it, a plurality of shafts mounted in pairs approximately at right angles to
the plane of movement of said carrier, each shaft being provided with a transverse
head carrying a forming-die, said forming dies projecting into the path of move-
ment of the said blanks, one of each pair on opposite sides of the blank, the dies
of each pair being respectively rotated in opposite directions.
33. A machine for making toe-calks comprising a blank-carrier, means to rotate
it, a plurality of shafts mounted in fixed bearings approximately at right angles
to the plane of movement of said carrier, each shaft being provided with a trans-
verse head carrying a forming-die, said forming dies projecting into the path of
movement of the said blanks, and means to communicate rotary movement to
said shafts, and shafts mounted in fixed bearings approximately parallel to the
plane of movement of said carrier, said shafts being intermediate the said pairs
of shafts and each provided with a transverse head and die rotatable in the
path of movement of the blanks.
34. In a machine of the class described, a moving blank-carrier, means to
deliver blanks thereto, a clamp to clamp said blanks in place on said carrier, formi-
ing mechanism to operate on said blanks, means to release said clamp from the
blanks after the latter have been operated upon, and a delivery device to auto-
matically remove said blanks from the carrier.
35. In a machine of the class described, a shearing apparatus comprising a fixed
and a movable cutting-die, the movable die supporting the blank after it is severed,
combined with a rotating blank carrier, said movable cutting-die supporting the
blank in the path of movement of said blank-carrier, and the latter being pro-
vided with means for receiving the blank from the cutting-die and retaining it
on the carrier.
36. The use with an anvil adapted to support a blank to be formed, of means to
retain a blank on the anvil, a positioning device to position the blank so retained
on the anvil, a stop to limit the movement of the blank by said positioning
device, a clamp and means to actuate said clamp to grip the blank and hold it
for forming.
37. A machine of the class described, composed of a blank-carrier adapted to
receive and support a plurality of blanks, anvils on said carrier, one for each blank,
clamps to grip and hold said blanks immovably on said blank carrier against said
anvils, means to actuate said clamps, and a plurality of forming devices for
shaping the blanks over the anvils, said forming devices and blank carrier being
relatively moveable, whereby each blank is progressively operated upon by all
of said forming devices.
Dated the 12th
1
1000
WM. BROOKES & SON,
55 & 56, Chancery Lane, London, Agents for the Applicant.