Claims
- 1. A method of forming a plurality of parts from a continuous stock material, the method comprising:
intermittently advancing the continuous stock material along a predetermined path such that the stock material advances longitudinally in a downstream direction; and forming a portion of the continuous stock material into a first predetermined shape at a forming station following at least one intermittent advancement of the continuous stock material, wherein intermittently advancing the continuous stock material comprises:
intermittently pushing the continuous stock material in the downstream direction from a location spaced in an upstream direction from the forming station; and intermittently pulling the continuous stock material in the downstream direction from a location spaced in the downstream direction from the forming station, wherein the intermittent pushing and pulling are synchronized such that the continuous stock material is advanced longitudinally in the downstream direction along the predetermined path.
- 2. A forming method according to claim 1 wherein intermittently pushing the continuous stock material comprises intermittently pushing the continuous stock material a predetermined distance in the downstream direction, and wherein intermittently pulling the continuous stock material comprises intermittently pulling the continuous stock material the same predetermined amount in the downstream direction such that the continuous stock material is intermittently advanced by the predetermined amount in the downstream direction.
- 3. A forming method according to claim 1 wherein intermittently pulling the continuous stock material and intermittently pushing the continuous stock material are synchronized such that the continuous stock is concurrently pulled and pushed in the downstream direction.
- 4. A forming method according to claim 1 wherein forming the portion of the continuous stock material comprises causing longitudinal growth of the continuous stock material, and wherein the method further comprises at least partially compensating for the longitudinal growth of the continuous stock material caused by forming the portion of the continuous stock material by allowing movement of the continuous stock material in a longitudinal direction away from the formed portion of the continuous stock material.
- 5. A forming method according to claim 4 further comprising clamping a fixed portion of the continuous stock material following at least one intermittent advancement of the continuous stock material so as to securely hold the fixed portion of the continuous stock material, wherein forming the portion of the continuous stock material comprises forming the portion of the continuous stock material while the fixed portion of the continuous stock material is clamped at a location disposed in a predetermined longitudinal direction from the formed portion of the continuous stock material, and wherein said at least partial compensation for the longitudinal growth of the continuous stock material comprises allowing movement of the continuous stock material in a longitudinal direction opposite the predetermined longitudinal direction.
- 6. A forming method according to claim 5 wherein forming the portion of the continuous stock material includes at least partially closing a plurality of dies about the continuous stock material, wherein the plurality of closed dies define a cavity of a predetermined shape which defines the shape of at least a portion of the resulting part, and wherein the plurality of at least partially closed dies define entry and exit ports through which the continuous stock material extends while the portion of the continuous stock material is formed.
- 7. A forming method according to claim 6 wherein the plurality of dies are mounted on a carriage which is adapted to move longitudinally, and wherein the forming method further comprises additionally compensating for the longitudinal growth of the continuous material by mounting the carriage such that the longitudinal growth of the continuous stock material between the formed portion of the continuous stock material and the fixed portion of the continuous stock material causes the carriage to move in a longitudinal direction opposite the predetermined longitudinal direction such that the plurality of dies remain at least partially closed about the same portion of the stock material during the formation of the portion of the continuous stock material.
- 8. A forming method according to claim 7 further comprising longitudinally biasing the carriage on which the plurality of dies are mounted with a predetermined longitudinal bias force so as to retard longitudinal movement of the carriage.
- 9. A forming method according to claim 6 further comprising:
opening the plurality of dies after forming a portion of the stock material; releasing the clamped portion of the stock material such that the continuous stock material can be advanced along the predetermined path; and repeating the method to form at least a portion of another part.
- 10. A forming method according to claim 4 further comprising:
monitoring the longitudinal growth of the continuous stock material; and terminating the formation of the portion of the continuous stock material once the longitudinal growth of the continuous stock material is at least as great as a predetermined longitudinal growth threshold.
- 11. A forming method according to claim 5 further comprising:
forming another portion of the continuous stock material into a second predetermined shape while the fixed portion of the continuous stock material is clamped; releasing the fixed portion of the continuous stock material following said forming of respective portions of the continuous stock material into first and second predetermined shapes such that the continuous stock material can be advanced along the predetermined path; and repeating the method such that the resulting parts have both the first and second predetermined shapes.
- 12. A forming method according to claim 1 further comprising:
trimming predetermined portions of each part following formation of the portion of the continuous stock material; and cutting each trimmed part from the continuous stock material to thereby separate the continuous stock material into a plurality of discrete parts.
- 13. A forming method according to claim 5 further comprising:
forming a registration feature in a predetermined portion of each part during while the continuous stock material is clamped; and trimming predetermined portions of each part which are disposed in a predetermined positional relationship to the registration feature following formation of the portion of the continuous stock material.
- 14. A forming method according to claim 1 wherein the plurality of parts comprise a plurality of spade-type boring bits, and wherein forming the portion of the continuous stock material into the first predetermined shape comprises forming a portion of the continuous stock material into a blade portion of the respective spade-type boring bit.
- 15. An apparatus for forging a plurality of parts from a continuous stock material, the apparatus comprising:
a plurality of indexers which are synchronized to intermittently advance the continuous stock material along a predetermined path such that the stock material advances longitudinally in a downstream direction through the forging apparatus; and a forge which forges a portion of the continuous stock material into a first predetermined shape following at least one intermittent advancement of the continuous stock material, wherein said plurality of indexers comprise:
an upstream indexer for intermittently pushing the continuous stock material in the downstream direction, said upstream indexer disposed upstream of said forge; and a downstream indexer for intermittently pulling the continuous stock material in the downstream direction, said downstream indexer disposed downstream of said forge, wherein said upstream and downstream indexers are synchronized to longitudinally advance the continuous stock material in the downstream direction along the predetermined path.
- 16. A forging apparatus according to claim 15 wherein said upstream indexer intermittently pushes the continuous stock material a predetermined distance in the downstream direction, and wherein said downstream indexer intermittently pulls the continuous stock material the same predetermined amount in the downstream direction such that the continuous stock material is intermittently advanced by the predetermined amount in the downstream direction.
- 17. A forging apparatus according to claim 15 wherein said upstream and downstream indexers are synchronized such that said upstream and downstream indexers concurrently pull and push the continuous stock material in the downstream direction.
- 18. A forging apparatus according to claim 15 wherein said forge comprises:
a plurality of dies disposed about the continuous stock material; and means for at least partially closing said plurality of dies about the continuous stock material, wherein said plurality of dies define a cavity of a predetermined shape which defines the shape of at least a portion of the resulting part, and wherein said plurality of dies define entry and exit ports through which the continuous stock material extends.
- 19. A forging apparatus according to claim 18, wherein at least one die includes a contact surface which defines a portion of the cavity for contacting and shaping a portion of the continuous stock material into the predetermined shape of the resulting part, wherein said means for at least partially closing said dies comprises a die housing defining an internal cavity for receiving and circumferentially encompassing said plurality of dies, wherein said plurality of dies are at least partially closed upon their insertion into said die housing such that said dies move inward in a predetermined direction, and wherein the predetermined direction is oblique to the respective contact planes of said dies such that the respective contact surfaces impart both axial and radial forces to at least portions of the continuous stock material to generate compressive and shear forces within the continuous stock material and to form at least a portion of the part within the cavity defined between said plurality of dies.
- 20. A forging apparatus according to claim 19 wherein the contact plane of at least one die and a reference plane perpendicular to the predetermined direction of movement of said at least one die define an angle of between about 10° and about 20° therebetween.
- 21. A forging apparatus according to claim 15 further comprising a clamp which clamps and securely holds a fixed portion of the continuous stock material following at least one intermittent advance of the continuous stock material, wherein said forge forges the portion of the continuous stock material while said clamp securely holds the fixed portion of the continuous stock material at a location disposed in a predetermined longitudinal direction from the forged portion of the continuous stock material, and wherein the forging apparatus at least partially compensates for longitudinal growth of the continuous stock material created by said forge by allowing movement of the continuous stock material in a longitudinal direction away from said forge and opposite the predetermined longitudinal direction.
- 22. A forging apparatus according to claim 21 wherein said forge further comprises a carriage on which said plurality of dies are mounted, and wherein said carriage is mounted so that the longitudinal growth of the continuous stock material between the forged portion of the continuous stock material and the fixed portion of the continuous stock material causes said carriage to move in a longitudinal direction opposite the predetermined longitudinal direction such that said plurality of dies remain at least partially closed about the same portion of the stock material during forming of the continuous stock material.
- 23. A forging apparatus according to claim 22 wherein said forge further comprises biasing means for longitudinally biasing said carriage with a predetermined longitudinal bias force so as to retard longitudinal movement of said carriage.
- 24. A forging apparatus according to claim 15 wherein the continuous stock material includes a plurality of longitudinally spaced apart registration features, wherein the forging apparatus further comprises:
a sensor for identifying a registration feature on the continuous stock material; and a positioner, responsive to said sensor, for positioning said forge such that the forged portion of the continuous stock material is longitudinally spaced from the registration feature by a predetermined distance.
- 25. A forging apparatus according to claim 21 wherein the continuous stock material includes a plurality of longitudinally spaced apart registration features, wherein the forging apparatus further comprises:
a sensor for identifying a registration feature on the continuous stock material; and a positioner, responsive to said sensor, for positioning said clamp such that the fixed portion of the continuous stock material which is clamped is longitudinally spaced from the registration feature by a predetermined distance.
- 26. A forging apparatus according to claim 15 wherein the continuous stock material includes a plurality of longitudinally spaced apart registration features, wherein the forging apparatus further comprises a trimming station, downstream of said forge, for trimming predetermined portions of each part, and wherein said trimming station comprises:
a trimmer for trimming predetermined portions of each part; a sensor for identifying a registration feature on the continuous stock material; and a positioner, responsive to said sensor, for positioning said trimmer such that the predetermined portions which are trimmed are longitudinally spaced from the registration feature by a predetermined distance.
- 27. A forging apparatus according to claim 15 further comprising means, upstream of said forge, for forming a registration feature in a predetermined portion of each part.
- 28. A forging apparatus according to claim 15 wherein the continuous stock material includes a plurality of longitudinally spaced apart registration features, wherein the forging apparatus further comprises a saw station, downstream of said forge, for cutting each part from the continuous stock material to thereby separate the continuous stock material into a plurality of discrete parts, and wherein said saw station comprises:
a cutter for cutting each part from the continuous stock material; a sensor for identifying a registration feature on the continuous stock material; and a positioner, responsive to said sensor, for positioning said cutter such that the portion of the continuous stock material which is cut is longitudinally spaced from the registration feature by a predetermined distance.
- 29. A forging apparatus according to claim 21 further comprising a second forge, longitudinally spaced from said first forge, which forges another portion of the continuous stock material into a second predetermined shape while said clamp securely holds the fixed portion of the continuous stock material such that the resulting parts have both the first and second predetermined shapes imparted by said first and second forges, respectively.
- 30. A forging apparatus according to claim 21 further comprising:
a longitudinal growth monitor for monitoring the longitudinal growth of the continuous stock material during forging of the continuous stock material into the first predetermined shape; and a controller, responsive to said longitudinal growth monitor, for terminating forging operations once the longitudinal growth of the continuous stock material is at least as great as a predetermined longitudinal growth threshold.
- 31. A method of controlling a process for forming a plurality of parts from a continuous stock material, the method comprising:
directing that the continuous stock material be intermittently advanced along a predetermined path such that the stock material advances longitudinally in a downstream direction; directing that a fixed portion of the continuous stock material be clamped following at least one of the intermittent advancements of the continuous stock material so as to securely hold the fixed portion of the continuous stock material; directing that a portion of the continuous stock material be formed into a first predetermined shape while the fixed portion of the continuous stock material is clamped, wherein the fixed portion of the continuous stock material is disposed in a predetermined longitudinal direction from the formed portion of the continuous stock material, and wherein formation of the continuous stock material in the fixed predetermined shape causes longitudinal growth of the continuous stock material; and directing that the longitudinal growth of the continuous stock material caused by the formation of the continuous stock material into the first predetermined shape be allowed to move in a longitudinal direction away from the formed portion of the continuous stock material and opposite the predetermined longitudinal direction so as to at least partially compensate for the longitudinal growth of the continuous stock material.
- 32. A method according to claim 31 wherein directing that a portion of the continuous stock material be formed into the first predetermined shape comprises directing that a plurality of dies be at least partially closed about the continuous stock material, wherein the plurality of closed dies define a cavity of a predetermined shape which defines the shape of at least a portion of the resulting part, and wherein the plurality of at least partially closed dies define entry and exit ports through which the continuous stock material extends.
- 33. A method according to claim 32 wherein the plurality of dies are mounted on a carriage which is adapted to move longitudinally such that the longitudinal growth of the continuous stock material between the formed portion of the continuous stock material and the fixed portion of the continuous stock material causes the carriage to move in a longitudinal direction opposite the predetermined longitudinal direction in order to at least partially compensate for the longitudinal growth of the continuous stock material, and wherein the method further comprises directing that the carriage on which the plurality of dies are mounted be longitudinally biased with a predetermined longitudinal bias force so as to retard longitudinal movement of the carriage.
- 34. A forming method according to claim 32 further comprising:
directing that the plurality of dies be opened after forming a portion of the stock material; directing that the clamped portion of the stock material be released such that the continuous stock material can be advanced along the predetermined path; and repeating the method to form at least a portion of another part.
- 35. A forming method according to claim 31 further comprising:
monitoring the longitudinal growth of the continuous stock material; and directing that the formation of the portion of the continuous stock material be once halted the longitudinal growth of the continuous stock material is at least as great as a predetermined longitudinal growth threshold.
- 36. An apparatus for trimming and separating a plurality of parts formed from a continuous stock material which includes a plurality of longitudinally spaced apart registration features, the apparatus comprising:
a trimmer for trimming predetermined portions of each part; a separator disposed downstream of said trimmer for separating each part from the continuous stock material once predetermined portions of each part are trimmed, said separator operably connected to said trimmer such that said separator and said trimmer are adapted to move together in a longitudinal direction; a sensor for identifying a registration feature on the continuous stock material; and a positioner, responsive to said sensor, for jointly positioning said trimmer and said separator such that the predetermined portions which are trimmed are longitudinally spaced from the registration feature by a predetermined distance.
- 37. An apparatus according to claim 36 wherein said separator comprises a snipper for snipping predetermined portions of the continuous stock material downstream of the trimmed portions in order to separate each part from the continuous stock material.
- 38. An apparatus according to claim 36 wherein said trimmer securely holds the continuous stock material while predetermined portions are trimmed, and wherein said positioner also advances said trimmer and said separator in a downstream longitudinal direction while said trimmer is securely holding the continuous stock material.
- 39. An apparatus according to claim 38 further comprising an indexer which intermittently advances the continuous stock material in the downstream longitudinal direction, said indexer and said positioner being synchronized such that the continuous stock material is concurrently advanced in the downstream longitudinal direction by both said indexer and said positioner.
- 40. An apparatus according to claim 36 further comprising a second positioner for positioning said separator relative to said trimmer such that said separator and trimmer are spaced by a predetermined distance.
- 41. A forge for forming a part of a predetermined shape, the forge comprising:
a head defining a passageway which extends lengthwise through at least a portion thereof; and a ram at least partially disposed within the passageway defined by said head and adapted to move lengthwise therethrough, wherein said ram has a forward end and a forward portion proximate the forward end, and wherein said ram defines a cavity opening through the forward end and adapted to receive a die assembly having a plurality of forging dies such that lengthwise advancement of said ram inserts the die assembly further into the cavity and correspondingly causes the forging dies to move inward in order to forge the part of the predetermined shape, wherein an interior surface of said head and an exterior surface of said ram cooperate to define a clearance region proximate the forward end of said ram to permit slight deflection of the forward portion of said ram in a radially outward direction as said ram is advanced and the die assembly is inserted further into the cavity, said clearance region defining a larger gap between said head and the forward portion of said ram than between said head and at least some other portions of said ram that are disposed rearward of the forward portion of said ram.
- 42. A forge according to claim 41 wherein said head defines a circumferentially extending groove opening into the passageway at a location proximate the forward end of said ram, wherein the circumferential groove provides the clearance region to permit slight radial outward deflection of the forward end of said ram during forging operations.
- 43. A forge according to claim 42 wherein the circumferential groove defined by said head extends from a first location at least as forward as the forward end of said ram following the lengthwise advancement of said ram to a second location at least as rearward as the location to which the plurality of forging dies are inserted into the cavity defined by said ram following the lengthwise advancement of said ram.
- 44. A forge according to claim 42 wherein a portion of said ram is maintained in an interference fit with a portion of said head disposed rearward of the circumferential groove in order to guide said ram during the lengthwise advancement.
- 45. A forge according to claim 44 wherein said head comprises a bronze bushing disposed rearward of the circumferential groove for engaging said ram and for providing the interference fit therewith.
- 46. A forge according to claim 41 said ram defines a lengthwise extending passageway through which a continuous stock material extends such that a plurality of parts of the predetermined shape can be forged.
- 47. A forge for forming a plurality of parts of a predetermined shape, the forge comprising:
a head defining a passageway which extends lengthwise through at least a portion thereof, wherein the passageway defines a lengthwise extending axis; a ram at least partially disposed within the passageway defined by said head and adapted to move lengthwise therethrough, wherein said ram defines a cavity opening through one end and adapted to receive a die assembly having a plurality of forging dies such that lengthwise advancement of said ram inserts the die assembly further into the cavity and correspondingly causes the forging dies to move inward in order to forge a part of the predetermined shape; and a rotator for incrementally rotating said ram about the lengthwise extending axis after at least one part has been forged, wherein said rotator repeatedly rotates said ram in increments such that a cumulative rotation of said ram eventually exceeds 360°.
- 48. A forge according to claim 47 wherein said rotator incrementally rotates said ram after a predetermined number of parts have been forged.
- 49. A forge according to claim 48 wherein said rotator incrementally rotates said ram after forging each part.
- 50. A forge according to claim 47 wherein said ram is alternately advanced to insert the die assembly further into the cavity and correspondingly cause the forging dies to move inward in order to forge a part of the predetermined shape and retracted to at least partially remove the die assembly from the cavity such that the forging dies can move outward following a forging operation, and wherein said rotator rotates said ram while said ram is retracted.
- 51. A forge according to claim 50 further comprising a lubrication system for providing lubricant between at least some of the forging dies and said ram to facilitate relative movement between said ram and the plurality of forging dies, wherein said lubrication system is adapted to provide lubricant while said ram is at least partially retracted such that the die assembly is at least partially removed from the cavity defined by said ram such that subsequent rotation of said ram circumferentially distributes the lubricant.
- 52. A forge according to claim 51 wherein said lubrication system also provides lubricant between said ram and said head to facilitate relative movement therebetween.
- 53. A forge according to claim 47 further comprising a sensor for detecting the incremental rotation of said ram.
- 54. A forge according to claim 47 wherein said rotator comprises:
a gear operably connected to said ram; and a drive member for engaging said gear and causing said gear to rotate in order to correspondingly rotate said ram, said drive member selected from the group consisting of a ratchet and a pinion gear.
- 55. A forge according to claim 47 wherein said rotator incrementally rotates said ram between 10° and 30° about the lengthwise extending axis.
- 56. A forge according to claim 55 wherein said rotator incrementally rotates said ram about 20° about the lengthwise extending axis.
- 57. A forge according to claim 47 wherein said ram defines a lengthwise extending passageway through which a continuous stock material extends such that a plurality of parts of the predetermined shape can be forged.
- 58. A forge for forming a plurality of parts of a predetermined shape, the forge comprising:
a head defining a passageway which extends lengthwise through at least a portion thereof, wherein the passageway defines a lengthwise extending axis; a ram at least partially disposed within the passageway defined by said head and adapted to move lengthwise therethrough, wherein said ram defines a cavity opening through one end; a die assembly having a plurality of forging dies, said die assembly being at least partially disposed within the cavity opening through one end of said ram such that lengthwise advancement of said ram inserts said die assembly further into the cavity and correspondingly causes the forging dies to move inward in order to forge a part of the predetermined shape; and a rotator for imparting an incremental relative rotation between said ram and said die assembly after at least one part has been forged, wherein said rotator repeatedly imparts incremental relative rotation between said ram and said die assembly such that a cumulative relative rotation between said ram and said die assembly eventually exceeds 360°.
- 59. A forge according to claim 58 wherein said rotator incrementally rotates said ram relative to said die assembly after a predetermined number of parts have been forged.
- 60. A forge according to claim 59 wherein said rotator incrementally rotates said ram relative to said die assembly after forging each part.
- 61. A forge according to claim 58 wherein said ram is alternately advanced to insert said die assembly further into the cavity and correspondingly cause said forging dies to move inward in order to forge a part of the predetermined shape and retracted to at least partially remove said die assembly from the cavity such that the forging dies can move outward following a forging operation, and wherein said rotator imparts relative rotation while said ram is retracted.
- 62. A forge according to claim 61 further comprising a lubrication system for providing lubricant between at least some of said forging dies and said ram to facilitate relative movement between said ram and said plurality of forging dies, wherein said lubrication system is adapted to provide lubricant while said ram is at least partially retracted such that said die assembly is at least partially removed from the cavity defined by said ram such that subsequent rotation of said ram circumferentially distributes the lubricant.
- 63. A forge according to claim 62 wherein said lubrication system also provides lubricant between said ram and said head to facilitate relative movement therebetween.
- 64. A forge according to claim 58 further comprising a sensor for detecting the incremental relative rotation between said ram and said die assembly.
- 65. A forge according to claim 58 wherein said rotator comprises:
a gear operably connected to said ram; and a drive member for engaging said gear and causing said gear to rotate in order to correspondingly rotate said ram relative to said die assembly, said drive member selected from the group consisting of a ratchet and a pinion gear.
- 66. A forge according to claim 58 wherein said rotator imparts an incremental relative rotation of between 10° and 30° about the lengthwise extending axis.
- 67. A forge according to claim 66 wherein said rotator imparts an incremental relative rotation of about 20° about the lengthwise extending axis.
- 68. A forge according to claim 58 wherein said ram defines a lengthwise extending passageway through which a continuous stock material extends such that a plurality of parts of the predetermined shape can be forged.
- 69. A forging method for forming a plurality of parts of a predetermined shape, the forging method comprising:
providing a head defining a passageway which extends lengthwise through at least a portion thereof, wherein the passageway defines a lengthwise extending axis; at least partially disposing a ram within the passageway defined by the head so as to move lengthwise therethrough, wherein the ram defines a cavity opening through one end and is adapted to receive a die assembly having a plurality of forging dies; advancing the ram in the lengthwise direction so as to insert the die assembly further into the cavity and correspondingly cause the forging dies to move inward in order to forge a part of the predetermined shape; and imparting an incremental relative rotation between the ram and the die assembly after at least one part has been forged such that repeated incremental relative rotation between the ram and the die assembly results in a cumulative relative rotation between the ram and the die assembly that eventually exceeds 360°.
- 70. A forging method according to claim 69 wherein the incremental relative rotation comprises incrementally rotating the ram about the lengthwise extending axis after a predetermined number of parts have been forged.
- 71. A forging method according to claim 69 wherein advancing the ram comprises alternately advancing the ram to insert the die assembly further into the cavity and correspondingly cause the forging dies to move inward in order to forge a part of the predetermined shape, wherein the forging method further comprises retracting the ram to at least partially remove the die assembly from the cavity such that the forging dies can move outward following a forging operation, and wherein imparting incremental relative rotation comprises imparting relative rotation between the ram and the die assembly.
- 72. A forging method according to claim 69 further comprising detecting the incremental relative rotation between the ram and the die assembly.
- 73. An apparatus for forging a plurality of parts from a continuous stock material, the apparatus comprising:
an indexer for intermittently advancing the continuous stock material along a predetermined path such that the stock material advances longitudinally in a downstream direction; a forge which forges a portion of the continuous stock material into a predetermined shape following at least one intermittent advance of the continuous stock material, said forge comprising:
a ram adapted to be alternately advanced and retracted during forging operations, wherein said ram defines a cavity opening through one end; and a die assembly having a plurality of forging dies, said die assembly being at least partially disposed within the cavity opening through one end of said ram such that advancement of said ram inserts said die assembly further into the cavity and correspondingly causes the forging dies to move inward in order to forge a part of the predetermined shape while retraction of said ram at least partially removes said die assembly from the cavity such that the forging dies can move outward to release the continuous stock material following a forging operation; and a lubrication system for providing lubricant between at least some of said forging dies and said ram to facilitate relative movement between said ram and said plurality of dies as a result of the alternate advancement and retraction of said ram, wherein said lubrication system is adapted to provide lubricant while said ram is at least partially retracted such that said die assembly is at least partially removed from the cavity defined by said ram.
- 74. An apparatus according to claim 73 wherein said ram defines a plurality of ports opening into the cavity through which said lubrication system injects lubricant between at least some of said forging dies and said ram.
- 75. An apparatus according to claim 73 further comprising a rotator for imparting an incremental relative rotation between said ram and said die assembly while said ram is at least partially retracted so as to circumferentially distribute the lubricant.
- 76. An apparatus according to claim 73 further comprising a head defining a lengthwise extending passageway, wherein said ram is at least partially disposed within the passageway defined by said head and adapted to move lengthwise therethrough, and wherein said lubrication system also provides lubricant between said ram and said head to facilitate relative movement therebetween.
- 77. An apparatus according to claim 76 wherein at least one of said head and said ram defines at least one circumferentially extending groove opening into the passageway defined by said head, and wherein said lubrication system injects lubricant into the circumferential groove for distribution between said head and said ram as said ram is alternately advanced and retracted during forging operations.
- 78. A method for forging a plurality of parts from a continuous stock material, the method comprising:
intermittently advancing the continuous stock material along a predetermined path such that the stock material advances longitudinally in a downstream direction; forging a portion of the continuous stock material into a predetermined shape following at least one intermittent advance of the continuous stock material, wherein forging a portion of the continuous stock material comprises:
at least partially disposing a die assembly having a plurality of forging dies within a cavity opening through one end of a ram; alternately advancing and retracting the ram during forging operations, wherein advancement of the ram inserts the die assembly further into the cavity and corresponding causes the forging dies to move inward in order to forge a part of the predetermined shape while retraction of the ram at least partially removes the die assembly from the cavity such that the forging dies can move outward to release the continuous stock material following a forging operation; and providing lubricant between at least some of the forging dies and the ram to facilitate relative movement between the ram and the plurality of dies as a result of the alternate advancement and retraction of the ram, wherein lubricant is provided while the ram is at least partially retracted such that the die assembly is at least partially removed from the cavity defined by the ram.
- 79. A method according to claim 78 further comprising at least partially disposing the ram within a passageway defined by a head such that the ram is adapted to move lengthwise therethrough, and wherein providing lubricant further comprises providing lubricant between the ram and the head to facilitate relative movement therebetween.
- 80. A forging die for forging at least a portion of a part of a predetermined shape from a workpiece, the forging die extending lengthwise between opposed first and second ends and comprising:
a contact surface adapted to contact and shape the workpiece into the predetermined shape of the resulting part; and a back surface to which forces are applied in order to urge the forging die into contact with the workpiece, wherein said back surface comprises:
a medial section having a partial conical shape; and first and second lateral sections disposed on opposite sides of said medial section, wherein each lateral section also has a partial conical shape, wherein a radius defined by said conical medial section is larger than a radius defined by said conical lateral sections at each corresponding location along the length of the forging die such that each lateral section is recessed relative to said medial section, thereby dictating that forces will be principally applied to said medial section of said back surface in order to urge the forging die into contact with the workpiece.
- 81. A forging die according to claim 80 wherein the forging die is tapered such that said contact surface is separated from said back surface by a greater amount at the first end than at the second end, and wherein said conical medial section is also tapered so as to be wider proximate the first end and narrower proximate the second end.
- 82. A forging die according to claim 81 wherein said medial section has a trapezoidally shaped surface.
- 83. A spade-type boring bit comprising:
an elongate shank defining a central longitudinal axis; and a blade portion joined at a rear end to one end of said shank along the central longitudinal axis, said blade portion including:
a pair of generally flat side segments which extend laterally in opposite directions from the central longitudinal axis, said side segments including respective forward cutting edges and respective chamfered corner portions, wherein said side segments are axially offset relative to each other such that one of said forward cutting edges is axially rearward of the other one of said forward cutting edges, and wherein each chamfered corner portion includes a chamfered edge extending both axially rearward and laterally outward from the respective forward cutting edge; and a spur extending axially from a forward end of said blade portion opposite the rear end.
- 84. A spade-type boring bit according to claim 83 wherein said forward cutting edges are axially offset relative to each other by a predetermined axial offset of about 0.010 inch to about 0.012 inch.
- 85. A spade-type boring bit according to claim 83 wherein said respective forward cutting edges of said side segments are aligned with each other along a centerline which passes through the central longitudinal axis of said elongate shaft.
- 86. A spade-type boring bit according to claim 83 wherein said spur is of a generally triangular shape extending in the central plane to a spur point on the central longitudinal axis, said spur including a pair of spur cutting edges extending along opposite sides of said spur between the spur point and the forward end of said blade portion such that each spur cutting edge extends radially outward of at least an innermost portion of the forward cutting edge of the adjacent side segment, and wherein each spur cutting edge is angularly offset from the forward cutting edge of the adjacent side segment in a predetermined direction of rotation of the spade-type boring bit when viewed along the central longitudinal axis, such that each spur cutting edge is both radially and angularly separated from the forward cutting edge of the adjacent side segment.
- 87. A spade-type boring bit according to claim 86 wherein at least a portion of each spur cutting edge extends axially rearward of the forward cutting edge of the adjacent side segment such that each spur cutting edge is axially separated from the forward cutting edge of the adjacent side segment.
- 88. A spade-type boring bit according to claim 83 wherein each chamfered corner portion includes a chamfer surface which slopes radially inward from the respective chamfered edge to a rear edge.
- 89. A spade-type boring bit according to claim 88 wherein said pair of side segments define respective lateral planes, and wherein each chamfer surface defines a chamfer plane which intersects a plane perpendicular to the lateral plane defined by the respective side segment to thereby define a chamfer clearance angle.
- 90. A spade-type boring bit according to claim 89 wherein the chamfer clearance angle is between about 10° and about 20°.
- 91. A spade-type boring bit according to claim 83 wherein a line parallel to the central longitudinal axis and the chamfered edge of each respective side segment defines a chamfer angle therebetween, the chamfer angle being between about 30° and about 60°.
- 92. A spade-type boring bit according to claim 83 wherein the forward cutting edge of each side segment extends laterally outward from an inner portion to an outer portion, and wherein the chamfered edge of the chamfered corner portion of each side segment extends both axially rearward and laterally outward from the outer portion of the respective forward cutting edge.
RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. patent application Ser. No. 09/143,630, filed Aug. 28, 1998 which is a continuation of U.S. patent application Ser. No. 08/662,665, filed Jun. 14, 1996 and now issued as U.S. Pat. No. 5,842,267 which is a continuation-in-part of U.S. patent application Ser. No. 08/366,986, filed Dec. 30, 1995 and now issued as U.S. Pat. No. 5,700,113 and U.S. patent application Ser. No. 08/514,071, filed Aug. 11, 1995 and now issued as U.S. Pat. No. 5,697,738, the contents of each being expressly incorporated in their entirety herein.
Divisions (1)
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Number |
Date |
Country |
Parent |
09215159 |
Dec 1998 |
US |
Child |
09953746 |
Sep 2001 |
US |
Continuations (1)
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Number |
Date |
Country |
Parent |
08662665 |
Jun 1996 |
US |
Child |
09143630 |
Aug 1998 |
US |
Continuation in Parts (3)
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Number |
Date |
Country |
Parent |
09143630 |
Aug 1998 |
US |
Child |
09215159 |
Dec 1998 |
US |
Parent |
08366986 |
Dec 1994 |
US |
Child |
08662665 |
Jun 1996 |
US |
Parent |
08514071 |
Aug 1995 |
US |
Child |
08662665 |
Jun 1996 |
US |