ERIE SINGLE FRAME FORGING HAMMERSERIE SINGLE FRAME FORGING HAMMERS « SELF-CONTAINED AND STANDARD TYPES Erie single frame forging hammers are built in two types—self-contained and standard. ‘The self- contained, in sizes from 50 Ibs. to 300 Ibs, includes the anvil as an integral part of the frame. The stand- ard type, in sizes from 250 Ibs, to 6000 Ibs, has separately mounted anvil. Larger Brie single frame hammers have been built to special order. The range of sizes given is usually adequate where a single frame forging hammer is desired, Larger size flat die hammers are usually built as double frame forging hammers, describee in a separate bulletin. Forging hammers are rated by the nominal scale weight of the reciprocating parts including the ram, top die, piston rod, and piston. In all sizes of Erie forging hammers, actual weight of these parts is great- er than the nominal size, Erie single frame forging hammers are double- acting, They take steam both above and below the piston, ERIE IS SUPERIOR IN COMPARISON WITH OTHER TYPES Wherever steam or compressed air is available, Erie single frame forging hammers are first choice. ‘They have low first cost, low operating cost, flexibility of control, ability to strike light or heavy blows, single blows or rapid automatic strokes, maximum force of blow for special jobs and adaptability for various heights of work between the dies. Where hammer use is intermittent and work peri- ‘ods comparatively short, the hammer can usually be connected without increasing compressor or boiler capacity, ‘The maximum energy of the blow of the Erie single frame hammer exceeds that of any other type, the weight of the reciprocating parts of the two ham. mers being the same. Various types of mechanical or power hammers ‘and pneumatic hammers are sometimes considered in comparison with steam forging hammers, However, mechanical hammers are built only in smaller sizes and compere only with very small steam hammers. Pneumatic hammers can be built larger than me- chanical hammers but maximum size is limited by design factors and in many instances there is a tend eney to overrate pneumatic hammers. HAMMER CAPACITY Forging capacity of Erie steam hammers is almost unlimited. The hammer cannot be damaged or over- loaded by work of any size, A small hammer on very large work may require several heats to reduce the bar the desired amount. Capacity, therefore, involves good judgment as to the time which can profitably be spent for work of any size. Operating conditions affect the decision and the cost. Each case must be considered separately. For example, a small hammer used most of the time for tool dressing might be used occasionally for working down a 4 by 4-inch bar. If the hammer were used almost constantly on work requiring 4 by 4-inch stock, a larger hammer would be much more economical. The production would be higher and the labor cost less, In forging soft steels, the hammer should have about 100 Ibs. of falling weight for each two square inches of cross section of the bar. This applies to Beneral blacksmithing work. It is the average work to be handled at maximum efficiency and not the Erie hammers exceed the above capacity as the following table indicates: Size of Hammer Diameter of Stock 50-100 ths. 14" 100-200 Ibs, 2M" 200-400 Ibs. 3%" 400-600 tbs a" 600 - 800 Ibs. aye 800 - 1100 Ibs, 5” 1100 - 1500 Ibs. 6%" 1500-2500 Ibs. 8" 3000 - 4000 Ibs. 10” For an occasional large job the ratio may be as high es four or five square inches for each 100 Ths, of falling weight.EFFECTIVENESS OF THE BLOW Effectiveness of the blow depends on what percentage of available energy can be used to deform the piece being worked. Factors affecting this are: plasticity of the metal; weight of upper works of the hammer; and anvil weight. Weight, strength and rigidity in the frame and cylinder prevent deffection and con- centrate all energy on the forging. ‘These parts in Erie hammers are often 20 to 25° heavier than in com- petitive hammers. ANVIL RATIO Any Erie single frame hammer can be furnished with any desired anvil ratio. In the past, an anvil ratio fie Single Frame Hammer of the Standord type with sep ‘ote anvil, This design user steam cushion” safety head ‘ond is typical ot sizes trom 800 fs. 16-2500 Tos, neluive of 8 to 1 was considered satisfactory for average work, Because of the trend to alloy and high strength steels, a higher anvil ratio is desirable. Erie's standard anvil ratio is 15:1 to permit efficient forging of mod- cern steels. Erie engineers design all parts for the loads that come on them; add weight to provide stability; and concentrate the mass of the anvil in Tine with the blow. This is one reason for the high efficiency of Erie hammers and the low maintenance costs in forge shops using them. CLEARANCES Hammer size required is often indicated by the clear- lance it provides for the work. Erie hammers are of the guided ram type most suitable for heavy work. Ample clearances are pro- vided between the working point and frame to handle forgings of awkward shape. Erie hammer dies are set at an angle 35 degrees from the center line of the frame. Long bars can be worked through the long or short way of the dies and still clear the frames and hammer driver ‘The hammer driver can stand in a comfortable position at the levers and have a clear view of work between the dies. ‘The ram and top die never go out of sight. This is a factor of great importance to the safety and con- venience of the blacksmith. It is speciall in utilization of high hammer speed. OPERATE ON STEAM ‘OR COMPRESSED AIR Erie hammers, referred to as steam hammers, operate just as effectively on compressed air. Relative economy of the two mediums depends on local conditions. Steam is logical if used for other machines or processes. If steam is required for heating, hammer exhaust can be utilized for that purpose be- cause the hammer will operate against a back pressure of five pounds per square inch. This is ordinarily suitable for any type of heating system and is par- ticularly economical for heating purposes because the pulsating flow of the hammer’s exhaust is practically as useful as the same weight of high pressure steam, POWER REQUIREMENTS FOR STEAM OPERATIONS Steam operation requires pressure of about 80 to 100 Ibs. per square inch diry saturated steam. Higher pres- sures are sometimes used, but they increase the possi- bility of hammer abuse by the operator. If pressureis greatly in excess of 80 to 100 psig installation of a reducing valve is recommended. Large cylinder areas permit Erie hammers to oper- ate readily on pressures as low as 60 Ibs. per square inch, This advantage is appreciated particularly if boiler pressure drops, due to a sudden increase in the Toad. From the hammer standpoint, there is no ob- jection to a moderate amount of super-heat. For average size hammers, where miscellaneous forging work is handled, installation of one boiler horsepower for each 100 Ibs. of installed hammer rat- ing is satisfactory. For small hammers, or when a Erie Single Frome Fo tyre. Typical ef all izer except the 300: which Mor a Boxsection frome. single hammer is operated, the ratio must be inereased. On quantity production work, where the hammer operates steadily, the ratio must be increased to about three boiler horsepower for each 100 tbs. of rated size. POWER REQUIREMENTS — COMPRESSED AIR OPERATION For compressed air operation, normal pressure re- quired is about 90 to 100 Ibs. psi. For average work oF light duty, air consumption is about 25 to 30 cubic feot of free air per minute for each 100 Ibs. of rated size of hammer. For steady production work, such as cogging down ingots, air consumption will be higher. If service is intermittent and operating periods short, compressor size can be reduced through use of a large receiver to supply some air during brief periods of peak operation. It is recommended that no after-cooler be used and air be piped as directly fas possible from the compressor to the hammer through insulated piping. CYLINDER CONSTRUCTION Erie hammers are designed with large cylinder bores compared to the rated size. They are exceptionally fast in operation and strike @ heavier blow because of the increased steam force above the piston. Ample cylinder areas and large steam ports make it possible to operate on low pressures not suited to competitive hammers. This is why Erie hammers are more adapt- able to forge shop conditions where intermittent ham- ‘mer operation produces fluctuating steam demands and wide pressure variances, SAFETY HEAD All Erie forging hammers have a cushion head to pre- vent cylinder damage if the hammer is stroked too high or the rod comes out of the ram, This cushion acts on top of the piston, rather than against the ram, and is effective even if the rod pulls out of the ram. ‘On hammers rated at 800 Ibs. and larger, cushion- ing is provided by steam at boiler pressure which is trapped above an auxiliary piston in the head, and compressed to even higher pressure to stop the up- ward movement of the rod. In sizes rated at 600 Tbs. and smaller, the cushion is a safety spring which backs up a plunger extending through the top cylinder head. ‘The spring is held by a eross bar and side bolts run- hing to lugs cast integral with the cylinder. GUIDES ‘The ram works between multiple V-guides, of large area, to minimize wear. An adjusting wedge is inter-posed between each guide and the frame, and is moved and locked by a screw. This permits a very fine adjustment. The wedges are in compression back of the guides. The guides are held against the frames by heavy through bolts. When they are locked in place, the construction is as rigid as though the guides ‘were integral with the frames. Guides are adjusted without disturbing their contact with the ram through- out their full length. Alignment is preserved by means of horizontal tongues on the backs of the guides which fit into horizontal grooves on the front face of the frame. (On hammers rated at $000 Ibs. and larger, guides are completely enclosed in the frames, with an ad- justing wedge back of each guide. heed shown is used on this type hammer in sizes Through 600 Ibs FRAME AND ANVIL Frames of the smaller self-contained hammers are of I-beam construction with the anvil cast integral with the frame and bed plate. The bottom die is seated directly in the anvil Large size, self-contained hammers and forging hammers have thick-walled, box section, heavily rib- bed frames. The bed plate is cast separate from the frame for ease in erecting in hammers larger than 3000 Ibs. Bed plate and frame fasten with body-bound bolts in reamed holes. In the standard type hammer the anvil is separate from the frame. It extends through the bed plate and rests in a pocket in the foundation, The anvil can be held in position or shifted slightly to align dies with impressions. ‘The horizontal cross section of the anvil is relative- ly small. The vertical height is great, to concentrate ‘the weight directly under the blow. At the bottom, the anvil is flanged out, to provide proper bearing on the timbers of the foundation. A steel cap protects the top of the anvil and holds the bottom die. The three parts are held together by Note the two-piece frame constuction used on Ere Single Frame Hammer, sed et 3000 ths. ond Terger, tapered keys and dovetailed tongue-and-groove con- struction, The anvil-cap key is located above the bed plate and can be removed without disturbing any other part. In all sizes, the bottom of the frame or the bottom of the bed plate is machined to a true surface, The installation cost is greatly reduced, and the alignment of the hammer is maintained indefinitely.DIES One pair of plain, flatfaced dies, suited for ordinary, miscellaneous forging, is furnished with the hammer. Dies are special analysis high carbon cast steel or forged steel. They allow the blacksmith to perform an infinite variety of operations. CONTROL ‘Two control levers, one for the throttle or admission valve, and one for the motion, or distribution valve, ‘are placed side by side and pivot around the same shaft. Each lever has a ratehet grip and works on a, separate rack, Each lever can be sot at any desired point. The operator can stand or sit comfortably. Work between the dies is in full view, yet the operator need not in- terfere with the smith In self-contained hammers a foot treadle is pro- vided in connection with the hand lever. The motion valve lever, which controls the length of the stroke, can be set any desired point. The throttle valve, which controls starting and stopping of the hammer, can be operated through the foot treadle, No helper is re- quired to run the hammer. Standard type hammers can be furnished with a treadle for controlling the throttle valve. The hand lever is arranged beside the motion valve lever. Use of the treadle is not recommended on hammers larger than the 800-Ib. size, since the work done in such hammers is usually heavy enough to require the full attention of the blacksmith, On such work a help- er is usually available. All joints in the valve mechanism are clevis type made with hardened pins working in reamed holes. Pins are in double shear. There is no tendency for wear to throw the pins out of line and cause the mechanism. to bind. Hore is @MATERIAL SPECIFICATIONS ANVIL BLOCKS, FRAMES, BED PLATES: Standard type— Open hearth steel castings. (Cast steel is most suitable for hammer parts subject to shock because of its higher impact strength. It may also be welded, fa- cilitating the mounting attachments if needed.) Cylin. ders may also be made of cast stee! bushed with cast iron as an extra if specified. Self contained type (one piece frame and anvil) — Semi-steel casting (Semi-steel is used on hammers of this type because of the less severe service to which they are subjected). CYLINDER AND GUIDE! RAMS: Open hearth forged steel, PISTON AND RODS: Open hearth forged stecl. On all except the smaller sizes the two parts are forged inte- jemi-stee] castings. gral with each other. On the smaller sizes, the head is 1a separate piece shrunk onto the rod. ANVIL CAPS: Open hearth steel for DIES: Special high carbon steel, either forgings or cast- ings depending on size and shape. GUIDE ADJUSTING WEDGES: Forged steel KEYS: Special heat-treated steel, tough to prevent splintering when being driven, but hard enough to prevent upsetting, VALVE GEARING: Forged steel levers and connections and cast steel rocker arm, motion atm, and motion valve crank. SAFETY STOP CUSHION HEAD OR CROSS BAR: Cost steel CYLINDER PARTS: Cast iron, semi-steel, or brass de- pending on the service. ngs. These specifications and dimensions regularly apply, but will be altered when unusual conditions demand, and we reserve the right to make changes for the improvement of the design or construction, PRINCIPAL DIMENSIONS SELF-CONTAINED TYPE Height Size, Diameter | stroke, | Face Face Center of Floor to pee, | ot [Berges of of Die to Steam Exhaust Floor Top of Cylinder, Rim Die, Frame, Pipe, Pipe, Space, ‘Hammer, Tnches Inches Inehés __Tnehes’_ Inches Inches Inches___Tnches 50 3% | 10 3 x5 Dax 8 % 1 16% 30 79 100 3% | 13° 3%4x6%e | 3 x6 10 1 1% | 22x37 o1 150 4 13 | 4x64 | avx6 10 1 1% | 22x37 on 200 44 | 105 x7 4 x6% 12 1% 2 | 24x41 104 300 5 10 6 xTM | A¥ex7 12% 1% 2 36x45 108 STANDARD TYPE Height Size, Diameter stroke, Face Face Center of Floor to rere, | oooh [SESE of of Die to” Steam Exhaust Floor Top of cylinder, Ram, Die, Frame, Pipe, Pipe, Space, Harmer, inches Inches Inches Inches! inches Inches Tuches__ Inches 250 5 16° «5Mx 7% aax 7 1% Ih 2 30x47 102 400 6 9 6 «9 S$ x 8% 15 1, 2 38x57 120 600 7 2200°«7~«xil | 5 x10 «17% | 2 24 41x64 130 800 8 25 8 x13 6 xI2% 20 2 2% 43x70 135 1100 10 30 B%x13% 64x13 23 2M 50x81 161 1500 2 330-9 x10 7 x14) 25 We 53x82 171 2000 13 30° -10%4x17 BB x1G 27% 56x87 180 2500 4 39-11 x17% 8 x17 | 30 3 62x96 191 3000 15 42 12 x18 9 9 x17 | 34 3 64x109 205 3500 10 42 12 x18 10 x17 | 34 3% 604x109 205 4000 a7 4213 x18 10 x17 | 34 3% 064x109 205 5000 19 42° 13%x18 x18 48. 5 972x156 250 6090 20 42 1Stex18 13 x18 | 48 5 72x156 250ERIE FOUNDRY COMPANY ra AIL