Improvements in the Manufacture of Metal Bars or Rails and in Apparatus therefor.
Year: 1889

page_text: Date of Application, 16th July, 1889-Accepted, 17th Aug., 1889
VUMI LE DIMULTICATION.
Improvements in the Manufacture of Metal Bars or Rails and in
Apparatus therefor.
We, EDWIN NORTON and JOHN GEORGE HODGSON, residing in Maywood, in the
County of Cook, in the State of Illinois, United States of America, Manufacturers do
hereby declare the nature of this invention and in what manner the same is to be
performed, to be particularly described and ascertained in and by the following
statement:
By the method or process heretofore generally in use for manufacturing rail road
rails and other metal bars, the molten metal is first cast into an ingot which is then
reheated and rolled until reduced to the required size and shape. By this method the
molten metal is not subjected to compression in the mold while it is in the act of
setting, though it is well known to those skilled in the art that the compressing of the
molten or setting metal while it is in the fluid or setting state, tends to greatly
improve the character and quality of the steel produced, and to give the castings or
ingots a very dense, solid and homogenous structure. And where, as heretofore, the
metal is cast in a closed mold confined on all sides, excepting at the top or runner, air
or gases confined in the molten metal have little opportunity to escape, so that it is
difficult in this way to produce an ingot entirely free from air holes and imperfections.
The rolling and rerolling to shape of the finished bar or rail tends to densify the metal
to a greater or less extent, but this rolling operation does not entirely remove the
flaws or imperfections produced in the ingot at the time it is cast. The manufacture
of metal bars or rails by this old process also involves considerable time, labor and
expense in the several steps of the process, and requires an extensive and costly plant
of machinery.
The object of our invention is to provide a more simple and expeditious method or
process of and apparatus for manufacturing metal bars or rails, whereby the molten
metal will be compressed or subjected to pressure while it is still in the fluid or
setting state, whereby the air or gases in the metal will be free to escape therefrom as
the metal is compressed and set, so as to thus densify and improve the quality of the
metal, render it free from flaws, air holes or imperfections, and of a solid and homo-
genous structure, and thereby increase the strength, durability and wearing qualities
of the rails or bars produced.
Our invention consists in the method or process and apparatus which we employ to
accomplish this result that is to say it consists in pouring a continuous stream of
molten metal from a suitable vessel, and simultaneously compressing, setting and
shaping the metal by its contact with chilling and compressing surfaces or rolls which
confine or surround the stream on all sides as it passes such continuously moving,
chilling surfaces or rolls. The chilling surfaces or rolls which shape, compress and
set the metal, and thus convert the molten stream of metal into a bar or rail, travel or
move at the same surface speed as the velocity of the flowing stream of molten metal,
so that the molten metal will not dam up or collect between the rolls, and so that the
molten metal or bar produced will come in contact with the rolls or chilling surfaces
only at a single point, so to speak, at a time.
By our invention tho metal bars or rails, it will be thus seen, are produced directly
from the molten metal, and without first casting the metal into an ingot and heating
and rolling and rerolling it. And as the molten is poured in a continuous solid stream
into what may be termed a continuously revolving or traveling metal chilling and
compressing mold which comes in contact with only one point, or a very limited
length, of the metal stream or bar at a time, and is continuously traveling in the same
direction with the stream or bar, point after point in the whole length of the metal

page_text: stream or bar coming successively in contact with this traveling or revolving com-
pressing and chilling mold, the metal bars or rails are of course produced in
continuous lengths, and the process or operation is continuous so long as the stream of
metal flows.
In practicing our invention the molten metal is poured in a continuous solid stream
from a suitable bowl or pouring vessel between a series of rolls, preferably four in
number, having their axes arranged in the same horizontal plane and having a pocket.
or space between their peripheries at their common meeting point for the reception of
the stream of molten metal, so that the stream of molten metal as it passes between
the rolls will be compressed by the wedging action of the rolls and the molten metal
at the same time chilled or set by contact with the rolls. The fluid metal is thus rolled
by the rails compressing and setting it. The rolls are made hollow and filled with
water which is made to constantly flow through them so as to keep them cool or at the
proper temperature for chilling or setting the stream of molten metal as it flows
between the rolls. The pouring bowl or nozzle is arranged directly over the common
meeting point of the series of rolls so that the stream of molten metal will flow in a
direction tangential to all the rolls. Each roll thus comes in contact with the stream
of molten metal, or with the metal bar produced, only at a single point so to speak, of
its periphery at a time, thus making it practicable to easily keep the rolls cool or at a
proper temperature for chilling or setting the stream of molten metal as it passes
between the rolls. The rolls are revolved at a sufficiently great surface speed, in
respect to the velocity of the stream of molten metal and in respect to the space
between the rolls or the size of the bar being produced, as to prevent the molten metal
collecting or damming up in the space between the rolls. We thus prevent a large
surface contact between the molten metal and the chilling rolls which would tend to
heat the rolls rapidly and render it difficult to keep them cool or at the proper tempe-
rature, on the one hand; and which on the other hand, would tend to chill or set the
molten metal before it reaclics the meeting line or plane joining the axes of the rolls
and where the passage between them is most contracted, thus subjecting the
apparatus to greater strain and requiring greater force to revolve the rolls and inter-
fering to a greater or less extent with the proper compression of the metal while yet
in a molten or setting state. By employing a series of rolls the fluid or setting stream
of metal, passing between the rolls, is compressed on all sides thus densifying or
compressing the metal by the wedging action of the rolls. And this densifying or
compressing action of the rolls upon the metal aids in solidifying or setting the molten
metal, as well as to greatly improve the quality of the steel or metal bar produced.
The compressing and rolling action of the rolls upon the fluid or setting stream of
metal passing between the rolls also tends to give the metal bar a superior texture,
grain, or fibre, and thereby to increase the strength of the bar produced.
Our invention in its most improved or perfected form also consists in pouring a
stream of molten metal and simultaneously compressing, setting and shaping it into a
bar, and then further rolling and finishing the bar as it is produced and while it is
still at a high heat. In practicing this latter feature of our invention we preferably
arrange directly beneath the first series of rolling, chilling and compressing rolls or
molds, a second series of revolving rolls which serve to further chill, compress, shape
and roll the rail or bar as it issues. The continuous rail or bar produced is delivered
from this second series of rolls to a horizontal carrier or series of rolls by an inter-
mediate curved passage or conveyor, consisting preferably, of a series of rolls
arranged in a curve. As the rail or bar is conveyed out horizontally it may, while
still hot, be passed through finishing and straightening rolls and further rolled to a
greater or less extent as desired.
In the drawing, which forms a part of this specification, we have shown at Fig.
a plan view of the apparatus embodying four convergent rolls, suitable for use in
practicing our invention; Fig. 2 is a central horizontal section taken through the
axes of the rolls; Fig. 3 is a vertical section taken on line 3-3 of Fig. 1. The
section of Fig. 2 is indicated on Fig. 3 by the line 2-2. Fig. 4 is a side elevation,
partly in section, showing the horizontal conveyor and intermediate curved conveyor

page_text: for receiving the rail or bar as it issues from the series of rolls. Fig. 5 illustrates a
modification wherein a series of three rolls is employed for compressing and shaping
the fluid or setting stream of metal passing between them. These rolls are shaped
to produce ordinary angle bars...
Similar letters of reference indicate like parts in all the figures.
b
In the drawing A represents the frame of the machine on which is journaled a
series of converging rolls B, preferably four in number, revolving together and
having their peripheries shaped or grooved to form a passage or way b between them
to receive the stream of molten metal as it flows down from the pouring bowl or
nozzle C. As indicated in Figs. 1, 2, 3 and 4 of the drawing, the working or meeting
faces of the rolls B are given a shape or configuration to form an ordinary rail road
rail; they may however be shaped to give the space or passage bany desired cross
section and thus produce a bar of any form desired. The rolls B have beveled
faces which meet or roll against each other and serve as stops for the several rolls
against each other, so that the space or passage for the metal will always be main-
tained of a uniform size, and thus produce the rail or bar of a uniform cross section
throughout. The rolls B are each made hollow and preferably with a central web B¹,
and the shafts B2 are also made hollow so that the water or other cooling fluid or
liquid may be made to circulate through each of the rolls for the purpose of keeping
them cool or of the desired temperature. The hollow shafts B2 are each furnished
with a packing or stuffing box at each end by which they are connected with the
inlet and outlet water pipers D D'. The pouring bowl or vessel C is supported by
any suitable means above the rolls B during the pouring operation, preferably by
standards C furnished with adjusting screws C². The pouring nozzle C is, prefer-
ably, furnished with a valve or device c for opening and closing the discharge passage.
The hollow shafts B2 of the rolls are all geared together so that they revolve or roll
together at the same surface speed. The gearing employed may preferably be
bevel gears, such as indicated at B3. Two of the shafts B2 are also geared together by
spur gears B.
E is the driving shaft having a gear E which meshes with a gear E'
on one of the shafts B. The pouring bowl or nozzle is furnished with a guide or
shield extending down to near the meeting point of the rolls. This is designed to
prevent the metal from splattering at the beginning of the pouring operation. For
doing this work a greater or less number of rolls than four may obviously be
employed. In the modification shown in Fig. 5, for example, three rolls B, B, B, are
made to roll together, their working faces or peripheries being shaped to produce
an angle bar, and the rolling or bevel faces 6 of the three rolls being arranged to form
a closed passage between the rolls.
b
F represents a second series of converging rolls, arranged, preferably, directly
below the chilling rolls B, and between which the bar a passes as it issues from the
chilling rolls B. The series of rolls Fare, preferably, of the same form and construc-
tion as the rolls B, being hollow and having the same connections for passing water
through them so that they may operate as chilling rolls as well as to further roll,
compress, and finish the rail or bar produced. The roll F may, however, be of any
ordinary or known construction. The series of rolls F is, preferably, like the series B
composed of four rolls revolving together.
G is a curved guide or conveyor consisting, preferably, of a series of rolls, or
idle pulley wheels arranged in a curved path, to curve and guide the bar as it
issues from the rolls F to the horizontal conveyor or series of rolls H. Some of
the rolls H are preferably driven and operate to further roll and straighten the rail
or bar as well as to convey it along or away. The curved guide G also affords some
slack in the rail or bar between the chilling rolls and rolls H H to compensate for
difference in speed or slipping.
Having now particularly described and ascertained the nature of our said inven-
tion, and in what manner the same is to bo performed, we declare that what we
claim is:
1st. The process of manufacturing metal bars directly from molten metal, consisting

page_text: in pouring a continuous stream of molten metal and compressing, setting and
shaping the metal on all sides into a bar by contact with continuously moving chilling
and compressing surfaces or rolls traveling at an equal or greater surface speed than
the velocity of the flowing stream of metal, substantially as specified.
2nd. The process of manufacturing metal bars directly from molten metal, consisting
in pouring a continuous stream of molten metal and compressing, setting and shaping
the metal on all sides into a bar by contact with continuously moving chilling and
compressing surfaces or rolls traveling at an equal or greater surface speed than the
velocity of the flowing stream of metal, and then rolling the bar as it issues and while
still at a high heat, substantially as specified.
3rd. The process of manufacturing metal bars directly from molten metal, consisting
in pouring a continuous stream of molten metal between three or more continuously
revolving chilling rolls revolving together and surrounding the passing stream on all
sides and thus compressing, setting and shaping the constantly moving stream into a
bar or ruil, substantially as specified.
4th. The process of manufacturing metal bars directly from molten metal, consisting
in pouring a continuous stream of inolten metal between three or more continuously
revolving chilling rolls revolving together and surrounding the passing stream on all
sides and thus compressing, setting and shaping the constantly moving stream into a
bar or rail, and then further rolling the bar as it issues and while still at a high
heat, substantially as specified.
5th. The process of manufacturing metal bars directly from molten metal consisting
in pouring a continuous stream of molten metal directly downwards between con-
tinuously revolving chilling rolls and thereby compressing, setting and shaping the
metal stream into a bar and then deflecting or curving the hot bar as it issues into
a horizontal direction, and finally rolling and straightening it while it is still hot,
substantially as specified.
6th. The combination with a series of three or more chilling rolls revolving together
with a space or passage between them of a pouring vessel or nozzle for directing a
stream of molten metal between said rolls, substantially as specified.
7th. The combination with a pouring vessel of a series of chilling rolls having
working faces and bevel rolling or stop faces to limit the extent to which said rolls may
approach each other, substantially as specified.
Sth. The combination with a pouring vessel of a series of hollow chilling rolls
revolving together and having a space or passage for the stream of molten metal
between them, and means for causing water to circulate through said hollow rolls,
substantially as specified.
9th. The combination with a pouring vessel of a series of three or more chilling
rolls revolving together, and a second series of rolls between which the rail or bar
passes as it issues from said chilling rolls, substantially as specified.
10th. The apparatus for producing metal bars directly from molten metal consisting
in a series of three or more rolls revolving together with a space or passage between
them and having their axes in a common horizontal plane so that a vertical stream
of metal may pass between them tangentially and be compressed and set thereby,
substantially as specified.
11th. The combination with three or more chilling rolls arranged to revolve
together with their axes in a horizontal plane, of means for directing
a continuous
stream of molten metal tangentially between said rolls, so that the stream of metal
will be compressed from all sides while in a fluid or setting state, substantially as
specified.
12th. The combination with a series of tiree or more chilling rolls revolving
together with a space or passage between them of a pouring vessel or nozzle for
directing a stream of molten metal between said rolls, said rolls revolving at an
equal or greater surface speed than the velocity of the flowing metal, substantially as
specified.
13th. The combination with a pouring vessel of a series of chilling rolls having working
faces and bevel rolling or stop faces to limit the extent to which said rolls may

page_text: approach each other, said rolls revolving at an equal or greater surface speed than
the velocity of the flowing metal, substantially as specified.
14th. The combination with a pouring vessel of a series of hollow chilling rolls revolv
ing together and having space or passage for the stream of molten metal between them,
and means for causing water to circulate through said hollow rolls, said rolls revolving
at an equal or greater surface speed than the velocity of the flowing metal, substantially
as specified.
15th. The combination with a pouring vessel of a series of three or more chilling
rolls revolving together, and a second series or rolls between which the rail or bar
passes as it issues from said chilling rolls, said rolls revolving at an equal or greater
surface speed than the velocity of the flowing metal, substantially as specified.
16th. The combination with three or more chilling rolls arranged to revolve together
with their axes in a horizontal plane, of means for directing a continuous stream of
molten metal tangentially between said rolls, so that the stream of metal will be
compressed from all sides while in a fluid or setting state, said rolls revolving at an
equal or greater surface speed than the flowing metal, substantially as specified.
17th. The combination with a pouring vessel of a series of three or more rolls
revolving together, a second series of rolls between which the rail or har passes as it
issues from said first series or rolls, a curved guide and a horizontal series of rolls,
substantially as specified.
18th. The combination with a series of three or more rolls having their axes arranged
in a horizontal plane, a pouring vessel arranged above and between them in a direction
tangential to the peripheries of all of said rolls, and a second series of rolls arranged
directly beneath the first series, a curved guide consisting of a series of rolls arranged
in a curve, and a horizontal conveyor consisting of a horizontal series of rolls,
substantially as specified.
19th. In an apparatus for rolling fluid metal, the combination with chilling rolls of
a pouring nozzle or vessel above and between them and a guide or shield C³
surrounding said pouring vessel and extending down to near the meeting point of the
rolls, substantially as specified.
111
TY GA
L
OL 1000
Witnesses:
EDWIN NORTON.
JOHN GEORGE HODGSON.
Haseltine, Lake & Co.,
45, Southampton Buildings, London, Agents for the Applicants.
H. M. MUNDAY.
a