Improvements in and relating to Metal Rolling.
Year: 1898

page_text: PROVISIONAL SPECIFICATION.
Improvements in and relating to Metal Rolling.
I, WILLIAM HENRY DUNKLEY, of 127, Derwentwater Road, Gateshead-on-Tyne,
in the County of Durham, Forge Roller, do hereby declare the nature of this
invention to be as follows:-
This invention relates to metal rolling and more particularly to the utilization
of worn out ordinary double headed rails by the re-rolling of the same, and its
object is to provide an improved arrangement of the rolls and grooves in a rolling
mill whereby the old rails are rapidly transformed into billets suitable for rolling
bars of small channelled T, H, or other section.
The invention consists generally in arranging a mill with three rolls one above
the other instead of two rolls as at present, thus providing two sets of grooves
between the respective rolls instead of one set, and, further in so arranging these
grooves in dimensions that the whole double headed rail instead of being lapped
over and welded, as is at present the case, is reduced in depth step by step through
successive grooves and the metal compressed and caused to flow into the new
sections during the rolling process. A further improvement consists in arranging
between the sliding bearings of each set of rolls transverse wedges operated upon
by screw nuts and screws.
In carrying the invention into effect three rolls are provided superimposed one
above the other and arranged to run in bearings upon sliding blocks arranged
in cast iron or steel standards. These blocks slide vertically in suitable guides
and between the centre and the top and bottom sets iwo transverse wedges are
placed, the transverse wedges having suitable guides transversely placed across
the standards. A pair of wedges, of course, are applied to each standard. The
narrow end (preferably) of each wedge is formed with a screw passing through a
slot in the standard in such a manner that by means of an exterior nut and a lock
nut upon this screw the wedge can be drawn forward and adjusted to a nicety.
By the screw adjustments upon these wedges the spacing of the rolls can be
altered without the usual method of driving up by hammer.
At one end of the rolls and between the bottom and centre one a groove is
formed of such a size that the worn rail after being passed through is reduced in
depth while the one head is compressed or flattened to add to the thickness of the
central web at either side. Immediately above this groove and between the
centre and top roll another groove is formed still less in depth and greater in
thickness and the rail is passed through this groove to be further reduced in
depth and increased in thickness. Further along the rolls a second groove is
formed between the middle and bottom roll and it repeats the opera-
tion of decreasing in depth and increasing in thickness, the metal
also generally, flowing towards the bottom horizontal web. Further
along again another groove is formed between the top and middle
Toll still repeating the same operation of decreasing in depth and increasing in
thickness and also causing the metal to flow towards the bottom horizontal web.
LD071

page_text: Further along the roll again and between the middle and bottom roll a groove
increasing the same process is again formed and so on alternately between the
middle and top roll and middle and bottom roll grooves are formed, which, through
the action of rolling, gradually compress and decrease the rail in the direction of
its vertical web and bottom horizontal web. By this means after the fifth, sixth,
seventh, or eight groove has been passed a longitudinal billet is formed from which
it is possible to easily roll small tee rails H, T, channel, sections, fire-bars, or light
vails.
To complete the sections by rolling the billets so formed, the applicant prefers
to use a rolling mill similarly arranged to the rolls employed to produce the billets,
that is to say, with three rolls and two sets of grooves instead of with only two
rolls and one set of grooves.
The arrangement of grooves or channels formed in the rolls as hereinbefore
described to give the required successive decreasing contour or cross section pro-
duces a longitudinal billet by causing the metal to compress instead of by lapping
and not properly welding as is usual in processes in use at the present time and
thus a much stronger and more reliable channel is produced. Also the capacity
of any mill is greatly increased as the amount of heating requisite in this method
is less owing to the rapidity of reduction of the original rail, and from calculations
the applicant has made he will be enabled roughly to turn out 40 to 50 tons of
rails or other small sections in twelve hours, instead of from 18 to 20 tons in the
same time as is at present the case.
It is to be clearly understood that the number of successive grooves in any one
rolling mill or set of rolls may be increased or decreased without departing from
the subject of the present invention.
+000
MARKS & CLERK,
18, Southampton Buildings, London, W.C., and
13, Temple Street, Birmingham, Agents.
I, WILLIAM HENRY DUNKLEY, of 127, Derwentwater Road, Gateshead-on-Tyne,
in the County of Durham, Forge Roller, 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:-
This invention relates to metal rolling and more particularly to the utilization
of worn out ordinary double headed rails by the re-rolling of the same, and its
object is to provide an improved arrangement of the grooves in a rolling
mill whereby the old rails are rapidly transformed into billets suitable for rolling
bars of small channelled T, H, or other section.
The invention consists generally in arranging a mill with three rolls one above
the other instead of two rolls as at present, thus providing two sets of grooves
between the respective rolls instead of one set, and, further in se arranging these
grooves in dimensions that the whole double headed rail instead of being lapped
over and welded is altered in shape step by step through successive
to flow into the new
grooves and the metal compressed and caused
sections during the rolling process. A further improvement consists in arranging
between the sliding bearing of each set of rolls transverse wedges operated
by screw nuts and screws.
A method of carrying the invention into effect is illustrated in the accompany-
ing drawings as follows;-

page_text: Figure 1 is a vertical section through c, d, Fig. 3 showing one standard with
the roll bearings and transverse wedges.
Figure 2 is a horizontal section on the line a, b, Figure 1.
Figure 3 is a front elevation of the rolls with the standards and bed plate in
section.
In carrying the invention into effect as illustrated in the drawings three rolls
lettered respectively A, B, and C are provided superimposed one above the other
and arranged to run in bearings D, D1, D2, carried upon sliding blocks EEE,
arranged in the cast iron or steel standards F. These blocks E, E E slide verti-
cally in the standards F. Between the bottom block E and the middle block E¹
a steel wedge H is placed while similarly between E¹ and E a second wedge H¹ is
also arranged to act in lieu of liners. In the constructions shown on Figure 1,
the taper sides of the wedges H, H₁ face inwards and fit between planed surfaces
on the blocks while the ends of the wedges pass through clearance holes in the
standards F, a pair of wedges of course being applied to each standard. The
narrow end (preferably) of each wedge is formed with a screw I passing through
a hole in the standard as shown so that by means of the exterior nut and lock nut
upon this screw I the wedge can be drawn forward and adjusted to a nicety. All
three bearings blocks E, EI E², are also secured firmly in position by a hand wheel
and screw arranged in the cover K of each standard F. It is evident that the
arrangement of wedges just described allow the spacing of the rolls to be altered
thus dispensing with the usual method of driving up by hammer.
The process for producing billets and given sections from worn out rails (and
referring more particularly to Figure 3) is as follows:-Between the rolls A
and B and at one end thereof a groove L is formed of such a size that the worn
rail after being passed through from one side of the rolls is compressed or flattened.
Adjacent to the groove L and between the rolls B and C another groove Mis
formed less in depth and greater in thickness than the groove L, and the rail is
passed through it from the other side of the rolls thus further displacing and
compressing the metal. This process is repeated in the groove N between the
rolls A and B and by the action of this progressive rolling the rail is decreased in
the direction of its vertical web and the metal caused to flow and finally assume
the shape shown in the groove N. Billets suitable for rolling into any required
cross section are thus produced.
In producing bridge or channel sections from the billets, it is preferred to pass
the billet in the first instance through edging or forming grooves such as that
shown at 0. To produce an H iron or girder the billet is now passed successively
through the grooves P and Q from either side of the rolls, while on the other hand
when a channel section is required the billet is passed through the groove R.
When fire bars are required the billet is passed through an edging or tapering
groove T and then through the groove S.
The arrangement of grooves or channels formed in the rolls as hereinbefore
described to give the required successive decreasing container or cross section
produces a longitudinal billet by causing the metal to compress and flow instead
of by lapping and sometimes improper welding as in processes in use at the
present time. The actual cross section of the grooves may be varied according to
the section of the billet required though in all cases the gradually altering shape
of the groove is employed.
A stronger and more reliable section is thus produced. Again the capacity of
the mill is greatly increased as the amount of heating requisite in the present
improved process is less owing to the rapidity of reduction of the original rail
and from experimental calculations it is expected that from 40 to 50 tons of rails
or other small sections will be manufactured in 12 hours against 18 to 20 tons in
the same time when ordinary methods are employed.
It is to be clearly understood that the number of successive grooves in any one
rolling mill or set of rolls may be increased or decreased without departing from
the subject of the present invention.

page_text: To operate the rolls any suitable form or train of gearing mounted upon or con-
nected to the roll shafts may be employed.
Having now particularly described and ascertained the nature of my said
invention and in what manner the same is to be performed, I declare that what
I claim is:
1.) In metal rolling mills having three superimposed rolls the arrangement and
shape of two sets of grooves between their adjacent surfaces which are proportioned
in such a manner that worn out rails or like articles are gradually fashioned into
billets of a suitable shape to be worked up into any required section substantially
as and for the purposes herein before described.
2.) In metal rolling mills having three superimposed rolls providing the trans-
verse wedges between the bearings of the rolls with screw nuts and screws as a
means of accurate and ready adjustment substantially as hereinbefore described.
3.) The improved metal rolling mill hereinbefore described with reference to
the accompanying drawings.
Dated this 19th day of Santamber 1899
MARKS & CLERK,
18, Southampton Buildings, London, W.C., Agents.