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STAGES IN THE MANUFACTURE OF THE WIRE MECHANISM

V. Ryan 2009

 

The simple wire mechanism seen below needs a jig so that each piece of 4mm wire can be folded and shaped accurately.
 
The eye (see opposite) is a crucial part of the mechanism. In fact two pieces of 4mmm round section mild steel are needed to form the mechanism. For the mechanism to work smoothly the both eyes must be perfectly formed. This can only to achieved by the use of a jig.
The jig is manufactured from mild steel and is composed of the circular part called the former. Two pins are also needed.

Pin ‘A’ holds the mild steel rod in place whilst it is forced round the circular former.
Pin ‘B’ holds the rod in the second position whilst the rod is forced form its final shape.
The round section steel rod is cut to length. Two pieces are needed for the main parts of the mechanism.
   
 
   
The ends of the steel rod are filed using a hand file. This removes any burrs and sharp edges.

Alternatively, a centre lathe can be used to ‘face off’ the ends.
   
Pin ‘A’ is used to hold the steel rod in position in preparation for applying pressure to it. Pin ‘B’ is not positioned in the block at this stage.
Hand pressure is applied to the steel rod and it is forced around the former producing an accurate curve. Pin ‘B’ is still not positioned in the jig.
The steel rod is forced round the former until it reaches the position of pin ‘B’. Pin ‘B’ is then inserted in the jig.
The rod is then forced into its final position, forming an accurate eye.
   
The final stage is seen opposite. The pins can be removed and positioned in the jig as and when required. 
The final stage is to produce a 90 degree fold at the end of each of the two mild steel rods. This is produced in a vice and achieved by applying ‘hand’ force as shown in the diagrams.
 
 
 
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