Another child trims the eyes, which he does by laying the needle upon a lump of lead, and driving a proper punch through its eye; then laying it sidewise upon a flat piece of steel, with the punch sticking in it, he gives it a tap on each side with his hammer, and causes the eye to take the shape of the punch. The operation of piercing and trimming the eyes, is performed by clever children with astonishing rapidity; who become so dexterous as to pierce with their punch a human hair, and thread it with another, for the amusement of visitors.
The next operative makes the groove at the eye, and rounds the head. He fixes the needle in pincers, [fig. 761.], so that the eye corresponds to their flat side; he then rests the head of the needle in an angular groove, cut in a piece of hard wood fixed in a vice, with the eye in an upright position. He now forms the groove with a single stroke of a small file, dexterously applied, first to the one side of the needle, and then to the other. He next rounds and smooths the head with a small flat file. Having finished, he opens the pincers, throws the needle upon the bench, and puts another in its place. A still more expeditious method of making the grooves and finishing the heads has been long used in most English factories. A small ram is so mounted as to be made to rise and fall by a pedal lever, so that the child works the tool with his foot; in the same way as the heads of pins are fixed. A small die of tempered steel bears the form of the one channel or groove, another similar die, that of the other, both being in relief; these being worked by the lever pedal, finish the grooving of the eye at a single blow, by striking against each other, with the head of the needle between them.
The whole of the needles thus prepared are thrown pell-mell into a sort of drawer or box, in which they are by a few dexterous jerks of the workman’s hand made to arrange themselves parallel to each other.
The needles are now ready for the tempering; for which purpose they are weighed out in quantities of about 30 pounds, which contain from 250,000 to 500,000 needles, and are carried in boxes to the temperer. He arranges these upon sheet-iron plates, about 10 inches long, and 5 inches broad, having borders only upon the two longer sides. These plates are heated in a proper furnace to bright redness for the larger needles, and to a less intense degree for the smaller; they are taken out, and inverted smartly over a cistern of water, so that all the needles may be immersed at the same moment, yet distinct from one another. The water being run off from the cistern, the needles are removed, and arranged by agitation in a box, as above described. Instead of heating the needles in a furnace, some manufacturers heat them by means of a bath of melted lead in a state of ignition.
After being suddenly plunged in the cold water, they are very hard and excessively brittle. The following mode of tempering them is practised at Neustadt. The needles are thrown into a sort of frying-pan along with a quantity of grease. The pan being placed on the fire, the fatty matter soon inflames, and is allowed to burn out; the needles are now found to be sufficiently well tempered. They must, however, be re-adjusted upon the steel anvil, because many of them get twisted in the hardening and tempering.
Polishing is the longest, and not the least expensive process in the needle manufacture. This is done upon bundles containing 500,000 needles; and the same machine under the guidance of one man, polishes from 20 to 30 bundles at a time; either by water or steam power. The needles are rolled up in canvas along with some quartzose sand interstratified between their layers, and the mixture is besmeared with rape-seed oil. [Fig. 762.] represents one of the rolls or packets of needles 12 inches long, strongly bound with cords. These packets are exposed to the to-and-fro pressure of wooden tables, by which they are rolled about, with the effect of causing every needle in the bundle to rub against its fellow, and against the siliceous matter, or emery, enclosed in the bag. [Fig. 763.] represents an improved table for polishing the needles by attrition-bags. The lower table M M is movable, whereas in the old constructions it was fixed; the table C has merely a vertical motion, of pressure upon the bundles, whereas formerly it had both a vertical and horizontal motion. Several bundles may obviously be polished at once in the present machine. The table M M may be of any length that is required, and from 24 to 27 inches broad; resting upon the wooden rollers B, B, B, placed at suitable distances, it receives a horizontal motion, either by hand or other convenient power; the packets of needles A, A, A, are laid upon it, and over them the tables C, C, C, which are lifted by means of the chains K, K, K, and the levers L, L, L, in order to allow the needles to be introduced or removed. The see-saw motion forces the rouleaux to turn upon their own axes, and thereby creates such attrition among their contents as to polish them. The workman has merely to distribute these rolls upon the table M, in a direction perpendicular to that in which the table moves; and whenever one of them gets displaced, he sets it right, lifting by the help of the chain the loaded table. The table makes about 20 horizontal double vibrations in the minute; whereby each bundle, running over 24 inches each time, passes through 40 feet per minute, or 800 yards in the hour.