A method for manufacturing a bell

Abstract

The application discloses a bell chime manufacturing method, which comprises the following steps: designing a mechanical processing drawing and a sample for blanking; preparing enough raw materials and blanking, wherein the Morse taper of the Yong is between 1.6-1.3 degrees; processing the parts by using modern processes such as laser cutting; welding; tuning, measuring the original pitch of each bell double sound, and then arranging the pitch sequence. The bell chime manufactured by using the method can fully exert the characteristics of modern metal processing equipment, such as high efficiency and short work cycle, so that the product has the advantages of accurate shape, low cost, beautiful tone and accurate pitch. The product manufactured by using the method can be popularized due to the low cost.

Description

Technical Field

[0001] This invention relates to the field of musical instrument manufacturing technology, specifically to a method for manufacturing a set of chime bells. Background Technology

[0002] Chinese chime bells can be traced back to the ancient Bronze Age. Ancient chime bells were cast in bronze using various casting techniques, including clay casting and paraffin casting. They are categorized into three types: *yong* bells, *bo* bells, and *niu* bells. Each bell consists of a *yong* (nose), a *wu* (dance), a tile-shaped body, *mei* (nipple-shaped studs), a *zheng* (gong), a lip, a *xian* (millet), and a *sui* (tunnel). Modern chime bells are mostly based on excavated chime bells, cast using plaster molds; this method will be referred to below as the "casting method." In ancient times, chime bells were made using casting methods, employing a process of selecting the best and discarding the worst. If a bell's sound was unsatisfactory, it often needed to be melted down and recast multiple times. The production of a large chime bell could take several years, even decades. The time and expense involved are unimaginable to modern people. Take a bell weighing over 300 jin (approximately 150 kg) as an example. From mold making and copper melting to casting, if one mortar and pestle could melt 20 jin (approximately 10 catties) of copper, 20 mortars would be needed simultaneously to melt copper for the entire bell. Unified command and uninterrupted casting were crucial; if insufficient copper was poured in at once, the bell was ruined. After casting, the sound was checked by ear; if the tone was off, the bell had to be destroyed and recast. This demonstrates the immense difficulty of casting chime bells in ancient times.

[0003] Currently, the chime bells replicated using plaster molds and casting methods on the original artifacts suffer from significant errors due to the multiple molding processes. Consequently, their shape and pitch are greatly altered. As for chime bell ornaments that can be placed on a table and chime bell-shaped vessels such as wine bottles, these are purely decorative items rather than practical musical instruments. The question that this application aims to address is whether a completely new method for making chime bells can be developed. Summary of the Invention

[0004] To address the aforementioned problems, the purpose of this invention is to provide a method for manufacturing chime bells that, based on modern processing technology and using carbon steel profiles as raw materials, shortens the manufacturing process while ensuring the sound quality of the chime bells.

[0005] To achieve the above objectives, the technical solution adopted by this invention is: a method for manufacturing a set of chime bells, the chime bells comprising a bell body (shaped like a sash), a bell body (shaped like a tile), bells (shaped like a bell), a bell (shaped like a bell), a lip (shaped like a lip), a milling machine, a tunneling machine, and a spinning machine, comprising the following steps: S1. Design the machining drawings and the templates used for material cutting; S2. Prepare sufficient raw materials and cut them: cut the bell and the piece according to the closed dimensions of the length and diameter shown in the drawings; the bell is thinner at the top and thicker at the bottom, and its Morse taper is between 1.6 and 1.3 degrees; the ratio of milling to finishing is between 10:8 and 10:8.5; cut the bell body and the finishing part according to the template; S3. Component Processing: The bell body is made of steel pipes of the same diameter. After marking the lines on the template, it is formed by plasma cutting. According to the templates for the dancing part and the milling part, the required curvature of the two ends of the tile is calibrated by a press. The dancing part is then formed by laser cutting according to the template. The tube and the part are processed into components by lathe according to the drawings. For the rotating parts, the rotating blank can be welded to the tube first, and then turned. Before the tube is welded, the bell body does not distinguish between the front and back. S4, Welding and Forming: (1) Weld the two tile-shaped bodies processed in S3 into a combined tile-shaped barrel-shaped bell body with a smaller upper part and a larger lower part. The weld is made by internal and external welding. After welding, the outer corner is ground into an acute angle. (2) Weld the tong and wu together. (3) Connect the bell body and wu, and then use thin steel strips to weld grids on the bell body to engrave the seal and zheng. (4) Weld the mei firmly to the bell body. The bell tong and zheng on the inner wall of the bell cavity, as well as the lower protrusion, are welded by overlay welding. (5) The bell lip is filled and formed by repair welding. (6) Carve patterns: First, polish the surface of the bell body until the smoothness reaches ▽4 or above, and then carve manually. S5. Tuning: After the bell bodies and bell frame of a set of bells are completed, each bell body is hung on the frame; from large to small, the original pitch of each bell's double tone is measured first, and then the scale sequence is arranged.

[0006] Preferably, the materials used for processing the chime bells are seamless steel pipes, steel plates, and round steel.

[0007] The manufacturing method of this invention has the following advantages: Unlike the casting method, this invention uses a component assembly and welding method. The carbon steel profiles used as raw materials—seamless steel pipes, steel plates, round steel, etc.—are processed using modern machining methods to create the components of the chime bells. Then, advanced modern welding technology is used to weld them into shape. After grinding, tuning, and engraving, each bell is made into a single bell. Multiple bells are then strung together to form a frame, completing the production process of the entire large chime bell set. Chime bells made using the component assembly and welding method have a uniform material density and do not suffer from insufficient filling or honeycomb phenomena like those found in cast bells. Therefore, their tone, sound quality, and volume are superior to those of cast bells. Due to the price difference between steel and copper materials and the use of modern machining and welding technology, the cost is significantly reduced. Therefore, the cost of making steel chime bells using the "welding method" is much lower than the cost of bronze chime bells made using the "casting method."

[0008] Using this method to manufacture chime bells can fully utilize the high efficiency and short production cycle of modern metal processing equipment, resulting in products with advantages such as precise shape, low cost, beautiful tone, and accurate pitch. Products produced by this method can be widely promoted due to their low cost. Attached Figure Description

[0009] Figure 1 This is a front view of the chime bells described in this invention; Figure 2 yes Figure 1 Side view; Figure 3 yes Figure 1 A bottom view; Figure 4 yes Figure 1 Top view. Detailed Implementation

[0010] Reference Figure 1-4 As shown, a method for making a set of chime bells, which includes a 10-piece bell, a 11-piece bell, a tile-shaped bell body, a 12-piece bell, a 13-piece bell, a 14-piece bell, a 15-piece lip, a 16-piece bell, a 17-piece bell, and a 18-piece bell, includes the following steps: S1. Design the machining drawings and the templates used for material cutting; S2. Prepare sufficient raw materials and cut them: cut the bell and the piece according to the closed dimensions of the length and diameter shown in the drawings; the bell is thinner at the top and thicker at the bottom, and its Morse taper is between 1.6 and 1.3 degrees; the ratio of milling section 19 and dance section 20 is between 10:8 and 10:8.5; cut the bell body and the dance section according to the template; S3. Component Processing: The bell body is made of steel pipes of the same diameter, which are drawn according to templates and formed by plasma cutting. The required curvature of the two ends of the tile-shaped parts is calibrated by a press according to the templates for the dancing part and the milling part. The dancing part is then formed by laser cutting according to the templates. The tube and the part are processed into components by lathe according to the drawings. For the rotating parts, the rotating blank can be welded to the tube first and then turned. Before the tube 21 is welded, the bell body does not distinguish between the front and back. S4, Welding and Forming: (1) Weld the two tile-shaped bodies processed in S3 into a combined tile-shaped barrel-shaped bell body with a smaller upper part and a larger lower part. The weld is made by internal and external welding. After welding, the outer corner is ground into an acute angle. (2) Weld the tong and wu together. (3) Connect the bell body and wu, and then use thin steel strips to weld grids on the bell body to engrave the seal and zheng. (4) Weld the mei firmly to the bell body. The bell tong and zheng on the inner wall of the bell cavity, as well as the lower protrusion, are welded by overlay welding. (5) The bell lip is filled and formed by repair welding. (6) Carve patterns: First, polish the surface of the bell body until the smoothness reaches ▽4 or above, and then carve manually. S5. Tuning: After the bell bodies and bell frame of a set of bells are completed, each bell body is hung on the frame; from large to small, the original pitch of each bell's double tone is measured first, and then the scale sequence is arranged.

[0011] In the preferred embodiment, the materials used for processing the chime bells are seamless steel pipes, steel plates, and round steel.

[0012] In step S3, the required curvature of the two ends of the two tiles of the bell is calibrated using a press. This means that when making the bell body, a steel cylinder must first be divided into two symmetrical parts from top to bottom. The curvature of the upper and lower ends of the bell is different, and the required curvature needs to be processed by a press. After forming, it is a tile-shaped body. The two tile-shaped bodies are joined together to form the bell body.

[0013] In step S4, the number of bells is 36. Since for the large-sized chime bells unearthed archaeologically, the number of bells on each is 36, the steel bells manufactured by this method still follow this. Because the sizes and arcs of each bell are different, it is very difficult to engrave them with a plate engraving machine, so manual engraving is still used.

[0014] In step S5, tuning is the final process of the whole set of chime bells and also the most difficult one. Since the pitch adjustment range of the steel chime bells can reach ±300 cents, in the embodiment of the present invention, the temperament of the chime bells adopts the equal temperament. For the large bells in the lower layer, only taking the tone at the center of the inner wall of the bell mouth (the tunneling tone) can form the "pentatonic scale", and taking the tone at the center of the outer wall of the bell mouth (the drum tone) can form the "heptatonic scale", with two additional changing tones. For the small bells in the upper layer, only taking the tunneling tone can form the "heptatonic scale", and taking the drum tone can make the twelve-tone temperament complete. There are two main tones with the same pitch, and their pitch accuracy can all reach within the range of ±6 cents, which the ancient chime bells could not achieve.

[0015] The process of tuning is a process of increasing or decreasing the thickness of the bell wall. When the wall thickness increases, the pitch is higher, and vice versa. When using a tuning instrument, a special caliper is also needed to measure the thickness of the bell wall. By grinding the inner wall of the bell, the pitch of the bell can be made lower, or welding can be carried out on the inner wall of the bell to make its pitch accuracy higher. Temperature also has an impact on the pitch of the chime bells. When tuning the bells, if grinding is carried out for a long time, high temperature will be generated. At this time, if the pitch is calibrated, after cooling, the pitch will be much higher. It is later found that the chime bells are in a cavity vibration mode, and its reaction to heat and cold is exactly opposite to that of the air column vibration mode of wind instruments.

[0016] As a preferred solution, the processing material of the chime bells of the present invention is carbon steel profiles, specifically seamless steel pipes, steel plates, round steel, etc. The material density of carbon steel is uniform, and there will be no phenomena such as insufficient casting and honeycombing like those in cast bells. Therefore, the timbre, pitch quality, and volume are all better than those of cast bells. Due to the price difference between steel materials and copper materials and the use of modern mechanical processing and modern welding techniques, the manufacturing cost is greatly reduced. Therefore, the cost of manufacturing steel chime bells by the welding method is much lower than the cost of manufacturing bronze chime bells by the casting method.

[0017] The structure of the chime bells is rigorous. Taking the yongzhong (a type of bell) as an example, it consists of parts such as the yong 10, wo 21, xuan 18, wu 11, bell body 12, mei 13, zhuan 22, zheng 14, etc. The yong is used to balance the inclination of the hanging bell (the yongzhong is hung obliquely), the wo and xuan are used to hang the bell. The tile-shaped bell body is unique to Chinese chime bells and is also the key and basis for a single bell to produce two tones. The wu part is used to connect the yong and the bell body, and it is also an inevitable setting to隔断 the upper vibration and promote the sound to be emitted from the bell mouth. The zhuan and zheng are the boundaries for distinguishing the tunneling tone and the drum tone, and the mei is an important setting to accelerate the attenuation of the aftertone to prevent the aftertone from being too long and affecting the played melody.

[0018] In the embodiment of the present invention, the first set of steel chime bells is manufactured by the above method. The number of bells is twelve in total, and the total weight is 613 kilograms.

[0019] The entire set of chime bells uses the twelve-tone equal temperament. The lower register (lower layer of large bells) has five bells, each producing a pitch that forms a pentatonic scale. Combined with the sound of the drum, it forms a heptatonic scale with two altered notes. The upper register (upper layer of small bells) has seven bells, each producing a heptatonic scale. Combined with the sound of the drum, it forms the twelve-tone equal temperament with two unison notes.

[0020] The basic key of this clock is D.

Claims

1. A method for manufacturing a set of chime bells, the chime bells comprising a bell body in the shape of a sash, a bell base, a bell ring, a rim, a bell ferrule, a bell shaft, and a bell mechanism, characterized in that, Includes the following steps: S1. Design the machining drawings and the templates used for material cutting; S2. Prepare sufficient raw materials and cut them: cut the bell and the piece according to the closed dimensions of the length and diameter shown in the drawings; the bell is thinner at the top and thicker at the bottom, and its Morse taper is between 1.6 and 1.3 degrees; the ratio of milling to finishing is between 10:8 and 10:8.5; cut the bell body and the finishing part according to the template; S3. Component Processing: The bell body is made of steel pipes of the same diameter. After marking the lines on the template, it is formed by plasma cutting. According to the templates for the dancing part and the milling part, the required curvature of the two ends of the tile is calibrated by a press. The dancing part is then formed by laser cutting according to the template. The tube and the part are processed into components by lathe according to the drawings. For the rotating parts, the rotating blank can be welded to the tube first, and then turned. Before the tube is welded, the bell body does not distinguish between the front and back. S4, Welding and Forming: (1) Weld the two tile-shaped bodies processed in S3 into a combined tile-shaped barrel-shaped bell body with a smaller upper part and a larger lower part. The weld is made by internal and external welding. After welding, the outer corner is ground into an acute angle. (2) Weld the tong and wu together. (3) Connect the bell body and wu, and then use thin steel strips to weld grids on the bell body to engrave the seal and zheng. (4) Weld the mei firmly to the bell body. The bell tong and zheng on the inner wall of the bell cavity, as well as the lower protrusion, are welded by overlay welding. (5) The bell lip is filled and formed by repair welding. (6) Carve patterns: First, polish the surface of the bell body until the smoothness reaches ▽4 or above, and then carve manually. S5. Tuning: After the bell bodies and bell frame of a set of bells are completed, each bell body is hung on the frame; from large to small, the original pitch of each bell's double tone is measured first, and then the scale sequence is arranged.

2. The method for manufacturing chime bells according to claim 1, characterized in that, The materials used for processing the chime bells are seamless steel pipes, steel plates, and round steel.

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