Heat treatment of helical springs or similarly shaped articles by electric resistance heating

Abstract

Apparatus is provided for metallurgical heat treatment of coil springs, or similarly shaped workpieces and articles of manufacture, by electric resistance heating along the entire length of the workpiece so that the ends of the workpiece can be heat treated to the same degree and quality as the section of the workpiece between its two ends.

Claims

1. An electric resistance heat treatment apparatus for an elongated workpiece having an opposing ends disposed at an angle to an axial length of the elongated workpiece, the electric resistance heat treatment apparatus comprising: a pair of end insert contacts, each one of the pair of end insert contacts formed from a solid electrically conductive material and being cylindrical in shape, each one of the pair of end insert contacts having a seating notch, a cross section of the seating notch being at least partially semicircular in shape, the pair of end insert contacts spaced apart from each other so that the opposing ends of the elongated workpiece can be at least partially inserted in the seating notches of the pair of end insert contacts; an electric power source for a supply of an electric current to the pair of end insert contacts; an electrical conductor for connection of each one of the pair of end insert contacts to the electric power source to heat by Joule heating each one of the pair of end insert contacts to approximately a heat treatment temperature when the opposing ends of the elongated workpiece are at least partially inserted in the seating notches of the pair of end insert contacts; and a driver for moving at least one of the pair of end insert contacts along the axial length of the elongated workpiece when the opposing ends of the elongated workpiece are at least partially inserted in the seating notches of the pair of end insert contacts to apply a compression force or a tension force to the elongated workpiece during the supply of the electric current from the electric power source.

2. The electric resistance heat treatment apparatus of claim 1 wherein an interior surface area of the seating notch is at least 40 percent of an outer perimeter surface area of the one of the opposing ends of the elongated workpiece at least partially inserted in the seating notch.

3. The electric resistance heat treatment apparatus of claim 1 further comprising an end clamp for at least one of the pair of end insert contacts, the end clamp applying a compression force against an exposed surface area of the one of the opposing ends of the elongated workpiece at least partially inserted into the seating notch to force an outer perimeter surface area of the at least partially inserted one of the opposing ends of the elongated workpiece against an interior surface area of the seating notch during the supply of the electric current from the electric power source.

4. The electric resistance heat treatment apparatus of claim 1 where the elongated workpiece is a coil spring with the opposing ends having a circular cross section.

5. The electric resistance heat treatment apparatus of claim 1 wherein the elongated workpiece has a hollow interior and the electric resistance heat treatment apparatus further comprises a supply of a cooling medium through the hollow interior.

6. An apparatus for selectively resistance heat treating a plurality of diverse elongated workpieces, each one of the plurality of diverse elongated workpieces having an opposing ends at an angle to an axial length of the one of the plurality of diverse elongated workpieces, the apparatus comprising: a plurality of alternative pairs of end insert contacts, an appropriate one of the plurality of alternative pairs of end insert contacts provided for a diverse one of the plurality of diverse elongated workpieces, each one of the plurality of alternative pairs of end insert contacts formed from a solid electrically conductive material and having a seating notch, each one of the plurality of alternative pairs of end insert contacts spaced apart from each other so that the opposing ends of each one of the plurality of diverse elongated workpieces can be at least partially inserted in the seating notches of an appropriate one of the plurality of alternative pairs of end insert contacts, the seating notches in at least one of the plurality of alternative pairs of end insert contacts having an appropriate cross sectional shape different from a cross sectional shape of the seating notches in at least one other of the plurality of alternative pairs of end insert contacts to accommodate the plurality of diverse elongated workpieces; a first and a second spaced apart opposing plates, a first end insert contact of each one of the alternative pairs of end insert contacts mounted on the first spaced apart opposing plate, and a second end insert contact of each one of the plurality of alternative pairs of end insert contacts mounted on the second spaced apart opposing plate; a drive for rotating the first and the second spaced apart opposing plates to alternatively position the first and the second end insert contacts of each one of the plurality of alternative pairs of end insert contacts at a diverse elongated workpiece insertion and removal station; and an electric power source for a supply of a current to the first and the second end insert contacts of the one of the plurality of alternative pairs of end insert contacts alternatively positioned at the diverse elongated workpiece insertion and removal station to heat by Joule heating the first and second end insert contacts of the one of the plurality of alternative pairs of end insert contacts alternatively positioned at the diverse elongated workpiece insertion and removal station when the opposing ends of the diverse one of the plurality of diverse elongated workpieces are at least partially inserted into the seating notches of the one of the plurality of alternative pairs of end insert contacts alternatively positioned at the diverse elongated workpiece insertion and removal station.

7. The apparatus of claim 6 wherein an interior surface area of the seating notches of the appropriate one of the plurality of alternative pairs of end insert contacts is at least 40 percent of an outer perimeter surface area of the opposing ends of the diverse one of the plurality of diverse elongated workpieces at least partially inserted in the seating notches at the diverse elongated workpiece insertion and removal station.

8. The apparatus of claim 6 where each one of the plurality of alternative pairs of end insert contacts is cylindrical in shape and the cross sectional shape of all seating notches in the plurality of alternative pairs of end insert contacts is at least partially semicircular in shape.

9. The apparatus of claim 6 where the plurality of diverse elongated workpieces comprises a plurality of diverse coil springs.

10. The apparatus of claim 6 wherein at least one of the plurality of diverse elongated workpiece has a hollow interior and the electric resistance heat treatment apparatus further comprises a supply of a cooling medium through the hollow interior.

11. An electric resistance heat treatment apparatus for a coil spring having a circular cross sectional opposing ends disposed at an angle to an axial length of the coil spring, the electric resistance heat treatment apparatus comprising: a pair of cylindrically shaped end insert contacts, each one of the pair of cylindrically shaped end insert contacts formed from a solid electrically conductive material and having a seating notch at least partially semicircular in cross section, the pair of cylindrically shaped end insert contacts spaced apart from each other so that the circular cross sectional opposing ends of the coil spring can be at least partially inserted in the seating notches of the pair of cylindrically shaped end insert contacts; an electric power source for a supply of an electric current to the pair of cylindrically shaped end insert contacts; an electrical conductor for connection of each one of the pair of cylindrically shaped end insert contacts to the electric power source to heat by Joule heating each one of the pair of cylindrically shaped end insert contacts to approximately a heat treatment temperature when the circular cross sectional opposing ends of the coil spring are at least partially inserted in the seating notches of the pair of cylindrically shaped end insert contacts; and an end clamp for at least one of the pair of cylindrically shaped end insert contacts, the end clamp applying a compression force against an exposed surface area of the one of the opposing ends of the coil spring at least partially inserted into the seating notch to force an outer perimeter surface area of the at least partially inserted one of the opposing ends of the coil spring against an interior surface area of the seating notch during the supply of the electric current from the electric power source.

12. The electric resistance heat treatment apparatus of claim 11 wherein the interior surface area of the seating notch is at least 40 percent of an outer perimeter surface area of the one of the opposing ends of the coil spring at least partially inserted in the seating notch.

13. The electric resistance heat treatment apparatus of claim 11 further comprising a driver for moving at least one of the pair of cylindrically shaped end insert contacts along the axial length of the coil spring when the opposing ends of the coil spring are at least partially inserted in the seating notches of the pair of cylindrically shaped end insert contacts to apply a compression force or a tension force to the coil spring during the supply of the electric current from the electric power source.

14. The electric resistance heat treatment apparatus of claim 11 wherein the coil spring has a hollow interior and the electric resistance heat treatment apparatus further comprises a supply of a cooling medium through the hollow interior.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) For the purpose of illustrating the invention, there is shown in the drawings a form which is presently preferred. It being understood, however, that this invention is not limited to the precise arrangements and instrumentalities shown.

(2) FIG. 1(a) is an elevational view of one example of a prior art apparatus for electric resistance heating of a coil spring.

(3) FIG. 1(b) is a partial side view through line A-A in FIG. 1(a) of a coil spring end section and adjacent electrical contact of the apparatus shown in FIG. 1.

(4) FIG. 2 is an elevational view of one example of an apparatus of the present invention for heat treatment of a workpiece.

(5) FIG. 3(a) through FIG. 3(g) are detail views of one example of a workpiece end insert contact utilized in the apparatus shown in FIG. 2, and FIG. 3(h) is a detail view of the interface surfaces between an end-of workpiece and a seating notch in an end insert contact utilized in the present invention.

(6) FIG. 4 is an elevational view of an example of another apparatus of the present invention for heat treatment of a workpiece.

(7) FIG. 5(a) and FIG. 5(b) are detail views of one example of the workpiece end contacts utilized in the apparatus shown in FIG. 4.

(8) FIG. 6(a) is an elevational view of one example of an end-of-workpiece clamping device used in some examples of the invention to retain the end-of-workpiece in an end insert contact.

(9) FIG. 6(b) is an elevational view of one example of a driver for moving an end insert contact along the axial length of a workpiece inserted in the end insert contact.

(10) FIG. 7(a) is a cross sectional elevational view of one example of an apparatus of the present invention for resistance heat treatment of diverse workpieces.

(11) FIG. 7(b) and FIG. 7(c) are plan views of bottom and top mounting plates that are used in the apparatus shown in FIG. 7(a).

(12) FIG. 8 is one example of an elongated workpiece similar to a coil spring that can be heat treated in some examples of the apparatus of the present invention.

(13) FIG. 9(a) is another example of an elongated workpiece similar to a coil spring that can be heat treated in some examples of the apparatus of the present invention.

(14) FIG. 9(b) is the elongated workpiece shown in FIG. 9(a) in an apparatus of the present invention where a compression force is applied to the ends of the workpiece during the resistance heat treatment process.

(15) FIG. 10 is a cross sectional view of a workpiece having an end with a square cross section that is inserted into an end insert contact utilized in an apparatus of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

(16) While the present invention will be described in connection with a preferred embodiment, it will be understood that it is not intended to limit the invention to that embodiment. On the contrary, it is intended to cover all alternatives, modifications and equivalents as may be included within the scope of the invention.

(17) In one non-limiting example of the apparatus, and method, of the present invention, as illustrated in FIG. 2, apparatus 10 comprises end insert contacts 12a and 12b which are connected to a suitable power source (PS) via electrical conductors 14a and 14b, and interfacing electrical conductors 14a′ and 14b′ whereby an electric potential is applied across the end insert contacts and causes a heat treatment current flow through a workpiece positioned in the end insert contacts. Conductors 14a, 14a′, 14b and 14b′ represent one typical, but non-limiting method, or means, of supplying power from the power source to end insert contacts 12a and 12b, which may also be described as end-of-workpiece electrical contacts. For example conductors 14a′ and 14b′ may be in the form of electrical bus bars or conductive plates, and conductors 14a and 14b may be in the form of electrical cables.

(18) Workpiece 90 (shown in dashed lines FIG. 2) that is to be heat treated in apparatus 10 may be a helical (coil) spring or other article of manufacture formed from a longitudinally-oriented feedstock such as a length of wire or rectangular bar. A coil spring represents one type of such elongated workpieces that can be metallurgically heat treated with the apparatus and method of the present invention. While workpiece 90 is described as being generally circular in cross section, workpieces of other shapes, for example an elongated bar, or spring formed with a rectangular or square cross section, can be heat treated with the apparatus and method of the present invention. More generally, the elongated workpiece has opposing ends disposed at an angle to the axial length of the elongated workpiece. For example, as shown in FIG. 8, elongated workpiece 90a has an axial length of Z.sub.2 with opposing ends 90a′ disposed at an angle, α.sub.1, of approximately 90 degrees from the longitudinal axis of the workpiece. The elongated workpiece 90b in FIG. 9(a) has opposing ends 90b′ disposed at an angle, α.sub.2, at an angle greater than 90 degrees from the longitudinal axis of the workpiece. Optionally when workpiece 90b is inserted in an apparatus of the present invention, its ends (and axial length) may be compressed by the end insert contacts 12a and 12b, as shown in FIG. 9(b) and as further described below.

(19) In one non-limiting example of the invention, as shown in FIG. 3(a), FIG. 3(b) and FIG. 3(c), each end insert contact (12a, 12b) comprises a solid, cylindrically shaped electrical conductor with an end-of-workpiece seating notch 12′ in which an end of the workpiece is seated during the resistance heat treatment process of the workpiece.

(20) In a preferred embodiment of the invention, during the resistance heat treatment process of the workpiece, each end insert contact is resistance (Joule) heated to a temperature that is approximately the same as the resistance heat treatment temperature required at each end of the workpiece to ensure uniform heat treatment at the ends of the workpiece. Otherwise a significant temperature gradient can exist throughout an end insert contact during the resistance heat treatment process, for example from 100° F. to 1600° F., which would negatively affect uniform heat treatment of the ends of the workpiece. As a preferred minimum, an interface region (shown cross hatched in FIG. 3(d)) in the seating notch of an end insert contact that is adjacent to the end-of-workpiece inserted in the seating notch should be at a temperature that is approximately the same as the resistance heat treatment temperature required at each end of the workpiece. The term “resistance heat treatment temperature” is the temperature versus time profile of resistance heat treatment temperature that is required for heat treatment of a particular workpiece; the heat treatment temperature may be a constant temperature or varied over the heat treatment time period. Controlling the shape or form of the end insert contact relative to the shape or form of the particular end-of-workpiece will ensure the desired resistance heating of the end insert contact and sufficient heating of the end insert contact boundary region around an end-of-workpiece inserted in the seating notch. For example the cross sectional form of the end insert contact or the resistivity of the end insert contact can be selected based on the resistance heat treatment temperature required for a particular end-of-workpiece positioned in the end insert contact.

(21) Preferably, but not by way of limitation, an end insert contact is formed from a high temperature resistant, electrically conductive material composition. One suitable but non-limiting choice for an end insert contact composition is HAYNES® 230® with a resistivity ranging from 125.0 microhm-cm at room temperature to 127.1 at 1,800° F.

(22) When the workpiece has a circular end-of-workpiece cross section the notch is preferably semicircular with a radius approximately equal to the cross sectional radius of the end of the workpiece to be heat treated as shown in FIG. 3(a) through FIG. 3(c). In one preferred embodiment of the invention, the seating notch is shaped so that the interior surfaces of the notch make contact with at least 40 percent of the outer perimeter surface of the end-of-workpiece seated in the notch. For example, as shown in FIG. 3(e), the end of workpiece 90 is inserted for length L.sub.1 into the seating notch, and the surface area of this inserted workpiece length interfacing (in contact) with the interior surface area of the seating notch (shown in cross hatch in FIG. 3(f) and by thick interface boundary curve “I” in FIG. 3(g) and FIG. 3(h)) is at least 40 percent of the outer perimeter surface area of workpiece length L.sub.1 that is inserted in the seating notch.

(23) The shape of the end-of-workpiece seating notch in an end insert contact will change depending upon the shape of the end of a particular workpiece. For example, an apparatus of the present invention used to resistance heat treat a workpiece with a rectangularly-shaped cross sectional end 90e′ will have a rectangularly-shaped seating notch for seating of the end of the workpiece in end insert contact 12e as shown, for example, in FIG. 10. That is, the interior of the seating notch in an end insert contact is selected to accommodate the configuration of the end of the particular workpiece being heat treated.

(24) Referring to FIG. 2, clamps 16a and 16b represent one type of clamping device that can be optionally used to hold an end-of-workpiece in a seating notch during the resistance heat treatment process. Fingertips 16a′ and 16b′ of clamps 16a and 16b, respectively, can be applied with a compressive force against the surface of the ends of the workpiece opposite the end-of-workpiece surfaces seated in the notches to enhance physical contact between the interfacing end-of-workpiece and seating notch interior surfaces for an evenly distributed current density across this interface during the resistance heat treatment process. At least the fingertip of each clamp is formed from a high temperature resistant material composition, such as a ceramic composition, as shown, for example, in detail for alternative clamp 16c in FIG. 6(a) with ceramic fingertip 16c′.

(25) Preferably the moveable clamping mechanism is arranged to automatically clamp an end of the workpiece inserted in the seating notch of each end insert contact. For example as shown in FIG. 6(a) a linear driver 19, such as an electric or hydraulic cylinder or screw drive, can be used to lower or raise the clamp in the Z-direction, to or from its clamping position shown in FIG. 6(a). Optionally, in addition to, or as an alternative to, vertically oriented clamp fingertip 16c′, horizontally oriented clamp fingertip 16c″ may be provided as shown in FIG. 6(a) to apply a compression force to the extreme end-of-workpiece against the rear wall 12″ in the seating notch.

(26) In another embodiment of the present invention complementary electrical contacts 12c and 12d can be provided as shown in FIG. 4. In this alternative arrangement, in addition to the electric current supplied to end insert contacts 12a and 12b during the heat treatment process described in a previous embodiment of the invention, electric current can be supplied to complementary electrical contacts 12c and 12d via electrical conductors 11a and 11b from power source (PS) to ensure approximately 360 degrees of uniform current density around the perimeter of each end-of-workpiece located in an end insert contact. The notch, or cutout, in each complementary contact 12c or 12d can be configured to surround the outer perimeter surface area of length L.sub.1 inserted in the seating notch of an end insert contact as illustrated in FIG. 5(a) and FIG. 5(b) for end insert contact 12a and complementary electrical contact 12c. Complementary contact drive mechanisms 22a and 22b may be similar to a clamp drive mechanism as described above and are provided to move a complementary electrical contact away from an end insert contact as shown in FIG. 5(a) and to move the complementary electrical contact adjacent to an end insert contact as shown in FIG. 5(b) during the resistance heat treatment process.

(27) A plurality of alternative paired end insert contacts having different configurations can be provided in an apparatus of the present invention to accommodate resistance heat treatment of diverse workpieces according to the process of the present invention. The diversity of workpieces can include differences in axial length and/or end cross sections. FIG. 7(a) illustrates, in cross section, one example of an apparatus 30 of the present invention for selectively resistance heat treating of diverse workpieces. FIG. 7(b) and FIG. 7(c) illustrate bottom and top mounting plates 44 and 42 utilized in apparatus 30. Referring to FIG. 7(b) and FIG. 7(c), eight paired top and bottom end insert contacts, pairs 13a-15a through 13h-15h, provide eight heat treatment stations for the heating of diverse workpieces. The cross section of apparatus 30 in FIG. 7(a) is through line B-B in FIG. 7(b) and FIG. 7(c) so that top and bottom insert pairs 13f-15f through 13h-15h are not seen in FIG. 7(a). In this non-limiting example of the invention, electrical conductors 17a through 17e are connected to top end insert contacts 13a through 13e, respectively, and electrical conductors 18a through 18e are connected to bottom end insert contacts 15a through 15e. Each of the eight pairs of top and bottom insert contacts may have seating notches with different cross sectional shapes to accommodate eight diverse workpieces with different end cross sectional shapes. Two or more of the paired top and bottom insert contacts may be spaced apart at different distances to accommodate diverse workpieces having different axial lengths. For example as shown in FIG. 7(a), workpiece 90d positioned in end insert contacts 13c and 15c has a shorter axial length than workpiece 90c positioned in end insert contacts 13e and 15e. In the arrangement shown in FIG. 7(a) top electrical conductor 17c is laterally extended downwards to accommodate the shorter spaced apart distance between top and bottom end insert contacts 13c and 15c.

(28) In this non-limiting example of the invention, top and bottom mounting plates 42 and 44 are spaced apart from each other and rotatable via driver 40 to form a rotating carousel apparatus. One location around the carousel (LOC) can be designated a workpiece load and unload station. While top and bottom end insert contact pair 13e-15e are presently in location (LOC) in the figures, rotational driver 40 can rotate the carousel apparatus to position the appropriate top and bottom end insert contact pair in location (LOC) to perform the resistance heat treatment process for a particular diverse workpiece. Electrical connecting means can be provided for connecting the top and bottom electrical conductors associated with the top and bottom end insert contact pair in location (LOC) to a suitable power source so that the heat treatment process can be performed. In some examples of the invention, interchangeable carousel apparatus 30 can be provided to accommodate resistance heat treatment of additional diverse workpieces, for example, with axial lengths and/or different end cross sections that can not be accommodated by the end insert contacts on a single carousel apparatus.

(29) An automated robotic workpiece transfer apparatus may be provided to transfer a workpiece from a supply stock of workpieces to be heat treated in an apparatus of the present invention with the robotic workpiece transfer apparatus programmed to grasp the workpiece at appropriate locations and transfer the ends of the workpiece automatically into the seating notches of the end insert contacts without human operator intervention. Further in some examples of the invention, the end clamp mechanism and function may be incorporated into the robotic workpiece transfer apparatus so that the robotic workpiece transfer apparatus holds the ends of the workpiece in the seating notches of the end insert contacts during the heat treatment process.

(30) In some examples of the invention if the workpiece requires quench treatment, an apparatus of the present invention may also comprise quench features. For example after completion of workpiece heating, an automated robotic workpiece transfer apparatus can transfer the workpiece to a quench station where the heat treated workpiece is either sprayed with a quenchant or dipped in a quench bath. Alternatively, one or both end insert contacts of the apparatus may be arranged to move after completion of workpiece heat treatment to cause the workpiece to initiate a gravity free fall directly to a quench station or quench bath, or indirectly, for example, via a transfer chute or conveyor. Alternatively the workpiece may be quench treated while still being held in place by the end insert contacts after completion of heat treatment by positioning quench supply apparatus (for example, one or more complete or partial quench rings) around the workpiece.

(31) A direct current (DC) power source (PS) is preferred to eliminate current skin effect through the length of the workpiece although an alternating current (AC) power source may be appropriate for a particular workpiece configuration.

(32) In all examples of the invention, an opposing pair of end insert contacts may be spaced apart at a fixed distance (for example, distance Z.sub.1 in FIG. 2 for contacts 12a and 12b) along the Z-axis, or one or both of the contacts may be moveable mounted in the Z-direction to accommodate different axial lengths of workpieces, or to apply a compressive or tensile force to the workpiece during the resistance heat treatment process. For example, as illustrated in FIG. 6(b) driver 19′, such as an electric or hydraulic cylinder or screw drive, may be used to move end insert contact 12a in the Z-direction to compress or tension workpiece 90 while it is being resistance heat treated. End insert contact 12a may move independently from associated conductor 14a′, or the combination of contact 12a and conductor 14a′ may move together. If insert contact 12a moves independently from conductor 14a′ then a flexible electrical extension conductor can be provided between conductor 14a′ and contact 12a to maintain an electrical path between conductor 14a′ and contact 12a as contact 12a moves away from conductor 14a′.

(33) Although the electrical contacts shown in the figures are vertically oriented to each other, the orientation may be in any other direction, such as but not limited to horizontal orientation, in other examples of the invention.

(34) If the workpiece is a hollow workpiece an apparatus of the present invention may also include provisions for supply of a cooling medium through the hollow interior of the workpiece while the workpiece is mounted in the end insert contacts.

(35) The present invention may be embodied in other specific forms without departing from the essential attributes thereof and, accordingly, reference should be made to the appended claims, rather than to the foregoing specification, as indicating the scope of the invention. The above examples of the invention have been provided merely for the purpose of explanation, and are in no way to be construed as limiting of the present invention. While the invention has been described with reference to various embodiments and examples, the words used herein are words of description and illustration, rather than words of limitations. Although the invention has been described herein with reference to particular means, materials and embodiments, the invention is not intended to be limited to the particulars disclosed herein; rather, the invention extends to all functionally equivalent structures, methods and uses. Those skilled in the art, having the benefit of the teachings of this specification, may effect numerous modifications thereto, and changes may be made without departing from the scope of the invention in its aspects.