Improvements in the Manufacture of Railway Axles and the like.
Year: 1890

page_text: Date of Application, 29th Apr., 1890-Accepted, 12th July, 1890
COMPLETE SPECIFICATION.
Improvements in the Manufacture of Railway Axles and the like.
I, HENRY AIKEN, of Pittsburgh, in the County of Allegheny, State of Pennsylvania,
and United States of America, Engineer, do hereby declare the nature of this inven-
tion and in what manner the same is to be performed, to be particularly described
and ascertained in and by the following statement :-
The invention described herein relates to certain improvements in the manufacture
of axles for vehicles such as railway cars, etc., and other like articles of circular or
nearly circular contour in cross-section, as described in English Letters Patent
No. 9287, dated November 20, 1889. The method described in said Patent consists,
generally stated, in forming a bar or blank of uniform cross-sectional area, having a
diameter equal to or slightly less than the diameter of the smallest part of the axle to
be formed, and of a length greater than that of the axle, and then upsetting such
blank by endwise pressure while enclosed in a suitable die. This method is more
especially applicable to the manufacture of axles from steel or non-fibrous metal, but
the distortion of the fibres of wrought iron when subjected to the above operation is
liable to render the completed axle unreliable. In order to avoid a distortion of the
fibres when manufacturing articles of this class of wrought iron or fibrous material,
a blank of irregular cross-section, but of practically uniform size from end to end is
formed by rolling or forging, this blank is then enclosed in a die cavity and then
subjected to lateral pressure, thereby causing the metal to flow longitudinally and
laterally and fill the die cavity.
In the accompanying drawings forming a part of this specification,
Fig. 1 is a view in side elevation, of my improved machine;
Fig. 2 is a sectional plan view, the plane of section being indicated by the line a, a,
Fig. 1;
Fig. 3, is a sectional elevation, the plane of section being indicated by the line y, y,
Figs. 1 and 2;
Fig. 4 is a sectional elevation, the section being taken on the line z, z, Fig. 3;
Figs. 5 and 6 are views similar to Figs. 3 and 4, of modification of the apparatus,
the feed mechanism being omitted ;
Figs. 7 and 8 are plan views of lower dies used in the machine shown in Figs. 5
and 6;
Figs. 9, 10 and 11 are detail views of the blanks and a finished axle respectively;
and
Fig. 12, is a transverse section of a modified arrangement of the apparatus designed
to form axles by lateral pressure.
The frame of the machine consists of a base 1, cheek pieces 2, supported by the
base and a cap 3 resting upon the cheek pieces, the said parts being firmly held
together by the horizontal bolts 4, 5 and 6, and by the vertical bolts 7 and 8. The
horizontal bolts 4 and 6 pass through the cap and base respectively, as well as through
the cheek-pieces, but the bolt 5 passes through the cheek pieces only, and as said
pieces serve as guides for the carrier block 10, a section of pipe 9 is, placed around
the bolt 5 and bears at its ends against the cheek pieces, so as to prevent the latter
from being sprung inwardly when the nuts on the ends of the bolt 5 are tightened up.
Between the
The same function can be effected by forming shoulders on the bolt 5.
cheek pieces is arranged a heavy casting forming the carrier 10, guided at its ends by
the cheek pieces as hereinbefore stated. This carrier is vertically slotted as shown in
Fig. 3, so as to permit of the passage of the bolt 5 without interference with its
vertical movements, which are effected by the piston 12 of the fluid pressure cylinder 13,
arranged as shown in Figs. 1, 3 and 4, upon the base 1, and held in position laterally
by a stud 14 formed thereon and fitting in a socket in the base. The dies 15 and 16

page_text: These
having suitable matrices formed therein are secured to the cap 3 and carrier 10, and
in the adjacent faces of the dies at the ends of the matrices are cut grooves 17, which,
when the dies are closed, form passages for the upsetting plungers 18.
plungers are attached to the stems 19 of the pistons 20 of the fluid pressure cylinders 21,
which are preferably secured to the cheek pieces 2 by the bolts 4 and 5, as shown in
Fig. 4. For convenience of operation, the machine is so arranged in a pit, as shown
in Figs. 1, 2 and 3, that the dies will be readily accessible from the floor level, and
when operating the blanks are placed upon rails 22, pivoted at their inner ends to
ears 23 on one side of the lower movable die 16 and at their outer ends to posts 24
also pivoted to shoes 25, secured to the floor of the mill, as shown in Figs. 2 and 3.
The posts 24 are made of such a height that when the die 16 is raised, the rails 22
will be level or approximately level, so that any blanks placed upon the rails may not
roll off, but will either roll or slide down towards the die 16 when it is lowered or will
remain in position until forced toward and into the die by the dogs 26. These dogs
are pivoted to blocks 27 mounted in dovetailed grooves in the inner walls of the
rails 22, as shown in Fig. 1, and have their outer ends weighted so as to hold their
inner ends normally above the rails and to permit said inner ends to be depressed and
passed under a blank during the outward movement of the sliding blocks. In order
to prevent too great movement of the dogs, lugs 28 are formed on their outer ends, so
as to engage pins 29 on the sliding blocks. These blocks 27 are connected by links 30
to the upper ends of arms 31, which are attached to a rock shaft 32 mounted in
brackets 33, bolted to the base 1 as shown in Figs. 1 and 3. A crank 34 projecting
from the shaft 32, is connected by a link 35 to a bracket 36 bolted to the carrier 10,
so that when the carrier is raised, the rock-shaft is so turned as to move the blocks
and dogs outwardly, the latter passing under and behind the blank on the rails, and
when the carrier is lowered separating the dies, the dogs are moved inward pushing
a blank before them into the matrix of the lower die, thereby displacing a completed
axle. In the lower die are formed sockets 37 for the reception of the crutches 38,
which fill the sockets and have a firm solid bearing in the bottoms thereof, and have
their upper faces shaped to form a part of the matrix and register therewith during
the blank shaping operation. These crutches are provided with stems 39 extending
down through the die and adapted to engage the bolt 5 or the pipe surrounding the
same, when the carrier is lowered thereby holding the crutches and the finished axle
stationary, while the die 16 continues its downward movement. The stems are so
proportioned as to length, that the axle will be held clear of its matrix, when the die
has reached the lower limit of its movement, and can therefore be readily pushed
from between the dies onto the receiving rails 40, by the incoming blank. The
receiving rails 40 are pivoted at their inner ends to ears 41 formed on the side of the
lower die 16, and have their outer ends supported on a friction roller 42, mounted in
suitable bearings formed in the upper end of standards 43, secured to the floor plate
of the mill. These standards are made of such a height, that the rails 40 will be level
or approximately so when the die 16 carrying the inner ends of the rails, is at the
lower limit of its movement, but will have a downward inclination toward their outer
ends, when the die is raised so that the finished axle may be automatically discharged
therefrom.
In order to prevent the blanks from being pushed beyond the matrices of the dies
by the dogs 26, pins 44 are placed on the discharge side of the die 16 as shown in
Figs. 2 and 3, and that the stop pins may not interfere with the discharge of the
finished axle, they are located beyond the ends of the matrices, so as to engage the
ends of the blank which as described in English Patent No. 9287, is longer than
the axle to be formed, while permitting the finished axle to pass between them.
The machine thus far described is applicable to the practice of the method described
and claimed in English Patent No. 9287, herein before referred to, wherein a blank
of uniform cross-sectional size approximately equal to the smallest sectional size of the
axle to be formed and of a length greater than that required in such axle, is subjected
to end compression or upsetting thereby reducing the blank in length and enlarging
its ends and intermediate portions.

page_text: My improved method consists in subjecting a blank b, Fig. 10, oblong or oval in
cross-section, to lateral pressure while in a closed die, thereby causing the metal to
flow longitudinally and laterally and fill the die cavity. For the manufacture of axles
in accordance with this method, slight changes are required in the machine herein
before described. As for example, two cylinders 13 are employed for operating the
carrier block, said cylinders being arranged on the base 1 so as to engage the carrier
block at the ends thereof, and afford room between them for a third fluid pressure
cylinder 45, which is employed for operating a vertically moving plunger 46. This
plunger which is arranged in a vertical slot formed through the carrier block 10 and
through the lower die 16, is made of a width equal to the matrix in the die 16. and
has its operative edge so constructed as to complete the shaping face of the die 16, as
shown in Figs. 6 and 8. The plunger 46 may be made of a thickness not greater
than the smallest diameter of the matrix in the die 16, the slot having a corresponding
width in which case the plunger has a uniform width throughout and its side walls
are made plain or straight as shown in Figs. 5 and 6, or the plunger may be made to
correspond in transverse dimensions, to the diameters of the matrix in the die 16, or
of the finished axle, the slots in the carrier and die having correspondingly varying
transverse dimensions, as shown in Fig. 8. The matrices of the dies 15 and 16 are
closed at their ends, when shaping the blank by lateral pressure, either by the
plungers 18 as shown in Fig. 6, or by solid walls as shown in Fig. 7, so that the
metal, when subjected to lateral pressure by the plunger 46, may flow longitudinally
against the end closing abutments whether formed by the plungers or solid walls,
and then flow radially into and fill the collar forming grooves adjacent to the abut-
ments. While the axles can be readily formed in dies having solid abutments, I
prefer to employ movable abutments in the shape of the plungers 18, as by their use
a compacting or condensation of the metal may be effected after the axle has been
shaped by the plunger 46, and further in case the blank is a little short of metal to
completely fill the matrix, the plunger 18 can supplement the shaping operation of the
plunger 46, and complete the axle. As these plungers 18 have only a finishing or
supplemental action, their movements are very small, hence the cylinders 21 are made
very much shorter than is required for the machine when shaping blanks by end
pressure alone. The cylinders 13 and 45 are so constructed that a longer stroke or
greater vertical movement is imparted to the carrier block and die 16, thereby per-
mitting of such downward movement of the die 16 along the plunger 46, that an
axle will be stripped from the die matrix and held on a level with the face of the die
or approximately so, from which position it can be readily removed by an incoming
blank. The blanks b, Fig. 10, which are oval or oblong in cross-section are fed into
position between the die, by the feed mechanism hereinbefore described, the move-
ments of the dogs 26 being so regulated that the forward edge of the blank will
project over the matrix of the die 16, by an amount a little greater than half its
longer diameter, as shown in Fig. 5, in order that such forward edge, which is sub-
ported when the blank is fed in, by the projecting plunger 46, may drop down by
reason of its over balancing weight, when the die 16 is raised towards the die 15.
When the blank has been placed in the position described, the die 16 is raised up
against the die 15, the plunger 46 remaining stationary. During this upward move-
ment of the die 16, the rear edge of the blank is raised, its forward edge resting on
the plunger enters the slot in the die with the plunger. As the die 16 continues its
upward movement, the blank will gradually turn until its longer diameter is vertical,
the lower edge of the blank resting on the plunger in the slot in the die. After the
dies have been closed, the plunger 46 is forced up, subjecting the blank to lateral
pressure throughout its entire length, causing the metal to flow longitudinally and
laterally filling the die cavity. As soon as the plunger 46 has completed its move-
ment, the plungers 18 are forced inward, subjecting the axle to end compression, as
hereinbefore stated.
In Fig. 12, is shown a form of apparatus wherein the slot through which the
plunger 46 operates, is formed by recesses cut in the adjacent or meeting faces of the .
dies 15 and 16, the plunger 46 and its operating cylinder 45 being supported in a

page_text: horizontal position by brackets 47, secured to the cap or top piece of the machine.
In this construction of machine there will not be any rotation of the blank as the
lower die is raised, and said die has sufficient movement to afford space when the die
is at the lower limit of its movement to permit of the insertion of the blank or the
removal of the finished axle, under the plunger 46. As the plunger does not in this
arrangement afford means for the removal of the axle the crutches or strippers 38,
are employed as hereinbefore described.
It will be observed that the blank is entirely enclosed in the die matrix and slot
leading therefrom before any flow of the metal' occurs, and also that the operative
face of the plunger 46 is so constructed that its edges are merged into the walls of the
die matrix and that therefore, there will not be any liability of forming a fin or other
projection on the axle. The meeting faces of the dies being held in close contact no
metal can be forced between them, and the plunger fitting snugly in the slot in the
die 16, and the edges of its operative faces being made like a knife, and merging its
walls into the wall of the matrix, no projection or excresence can be formed on the
axle.
It will be observed that the plunger 46 operates as regards the lifting of the
finished axle from the matrix of the die 16, exactly the same as the crutches 38, the
movement of the plunger being arrested by its lower end coming in contact with
the cylinders 13, while the carrier and die 16 continue their downward movement.
Having now particularly described and ascertained the nature of my said inven-
tion and in what manner the same is to be performed, I declare that what
I claim is:
1. As an improvement in the art of manufacturing axles and other like articles of
circular or nearly circular contour in cross-section, the method herein described con-
sisting in first rolling or forging a blank of irregular cross-section, but of practically
uniform size from end to end, then enclosing such blank in a die cavity where under
a subsequently applied lateral compression the metal may have a longitudinal and
lateral flow or motion and while so enclosed, applying through a wall of such cavity
a laterally acting compressive force thereto sufficient in amount to change the shape
of the portions so compressed and cause it to fill and take the form of the die cavity,
substantially as set forth.
2. As an improvement in the art of manufacturing axles and other like articles of
circular or nearly circular contour in cross-section, the method herein described, con-
sisting in rolling or forging a blank of irregular cross-section, but of practically
uniform size from end to end, enclosing such blank in a die cavity where under
lateral compression, the metal may have a longitudinal and lateral flow or motion,
and while so enclosed applying a laterally and a longitudinally acting compressive
force thereto, sufficient in amount to cause it to fill and take the form of the cavity,
substantially as set forth.
3. In an apparatus for the manufacture of axles, the combination of a stationary
die, a movable die, said dies having in their adjacent faces recesses suitably shaped
for the formation of an axle, a fluid pressure cylinder for operating the movable
die, and plungers operative in opposite directions between the adjacent faces of said
dies, substantially as set forth.
4. In an apparatus for the manufacture of axles, the combination of a stationary
die, a movable die, said dies having in their adjacent faces, recesses suitably shaped
for the formation of an axle, a carrier block mounted in suitable guides and having
the movable die secured thereto, a fluid pressure cylinder for moving said carrier,
plungers operative in opposite directions between the adjacent faces of said dies,
substantially as set forth.
5. In an apparatus for the manufacture of axles, the combination of a stationary, a
movable die, said dies having in their adjacent faces recesses suitably shaped for the
formation of an axle and provided with a longitudinal slot, and a plunger operative
through said slot for exerting a lateral pressure in a blank enclosed by said dies,
substantially as set forth.

page_text: 6. In an apparatus for the manufacture of axles, the combination of a stationary
die, a die movable toward and from the stationary die, said dies having in their
adjacent faces recesses suitably shaped for the formation of an axle, one of said dies
having a longitudinal slot formed therethrough, and a plunger operative through
said slot for exerting a lateral pressure on a blank held in the recesses in the dies,
substantially as set forth.
7. In an apparatus for the manufacture of axles, the combination of separable dies,
having in their adjacent faces recesses suitably shaped for the formation of an axle,
one of said dies being longitudinally slotted, a plunger operative through said slot
for exerting a lateral pressure on a blank enclosed in said dies, and plungers operative
in opposite directions against the ends of the blank, substantially as set forth.
8. In an apparatus for the manufacture of axles, the combination of an upper
stationary die, a movable die, said dies having suitable shaping recesses formed in
their adjacent faces, rails having their inner ends arranged on a level with the face
of the movable die when at the lower limit of its movement, and reciprocating dogs
for moving a blank along said rails between the dies, substantially as set forth.
9. In an apparatus for the manufacture of axles, the combination of an upper
stationary die, a lower movable die, said dies having their adjacent faces suitably
recessed, rails having their inner ends on a level with the face of the movable die
when at the lower limit of its movement, movable dogs mounted on said rails, and
interposed mechanism whereby the die in its movements may reciprocate the dogs,
substantially as set forth.
10. In an apparatus for the manufacture of axles, the combination of a stationary
upper die, a movable lower die, crutches or strippers arranged in recesses or slots in
the lower die and capable of vertical movement and a stop for arresting the down-
ward movement of the crutches before the lower die reaches the lower limit of its
movement, substantially as set forth.
Signed at Pittsburgh, Pa., U.S.A., this 26th day of March, A.D. 1890.
Witnesses:
R. H. WHITTLESEY.
DARWIN S. WOLCOTT.
HENRY AIKEN.