Improvements in the Manufacture of Axle Boxes and in Apparatus for the Purpose.
Year: 1892

page_text: Date of Application, 2nd July, 1892
Complete Specification Left, 4th Apr., 1893-Accepted, 20th May, 1893
PROVISIONAL SPECIFICATION.
Improvements in the Manufacture of Axle Boxes and in Apparatus
for the Purpose.
I, SAMSON FOX, of The Leeds Forge, New Wortley, Leeds, in the County of
York, Civil Engineer, do hereby declare the nature of this invention to be as
follows:-
This invention relates to the manufacture or construction of axle boxes for
railway and other vehicles from wrought iron or steel blooms, half wroughts, rolled
sections, and pressed or forged parts, and from metallic plate such as wrought iron
or steel.
According thereto suitable metal such as mild steel or iron in one or other of the
forms referred to is first converted into a tube the external and internal dimensions
of which correspond roughly to that of the required axle box and then welded,
after which it is compressed to complete the formation of the axle box. For this
purpose I employ a collapsible mandrel or core die the exterior of which corresponds
in shape and dimensions with the interior of the finished axle box, and male and
female dies the interior of which correspond in shape and dimensions with the
exterior of the finished axle box.
The collapsible mandrel or core die comprises a number of outer parts or
segments suitably fitted together and a central boss or bearing spindle the form of
which is such that it can be readily withdrawn immediately the axle box is pressed.
The construction of this mandrel or core die can be variously modified. Thus the
When made in
central boss or bearing spindle may be made in one or more parts.
more than one part it can be so constructed as to act as a cotter or screw bolt in
order that its several parts can be readily held together. It may also be formed
with raised or sunk parts to admit of the outer parts or segments being held in
position for use. Wedge pieces may also be arranged within or between the outer
segments or parts in such a manner that they will become loose or can be readily
loosened, after the central boss or bearing spindle has been withdrawn.
According to another construction supplementary segmental pieces either plain :
or of dovetail form in cross section, are arranged between the outer segmental
pieces and the central boss or bearing spindle. In another arrangement the central
boss or bearing spindle is in one piece grooved and fitted with loose segmental
pieces which in turn hold the outer segmental pieces in place. The male and
female dies comprise metallic plates or parts so formed and arranged as to form in
conjunction with the before mentioned mandrel or core die the sides top and bottom
of the required axle box, when the tube is pressed between them.
Instead of using the before mentioned collapsible mandrel or core die I use in
conjunction with the outer dies molten fluid such as lead under pressure or any
metallic substance that can be caused to flow by hydraulic or other pressure,
According to this method a suitable metal tube as before described after being
heated is placed between the outer dies before described which correspond with the
outer form of the axle box to be produced, and after being closed the metallic fluid
under pressure is forced into the interior of the tube, so as to expand the tube
against the outer dies and is thereby caused to assume the desired form of axle
box. The lead or other substance is afterwards melted and run out of the finished
axle box.
The male and female dies may be actuated by any suitable means as for example
a hydraulic press or similar apparatus.
:

page_text: The compressing of the box or tube to the required shape can be effected by one
or more operations as may be desired.
Dated this 2nd day of July 1892.
W. LLOYD WISE,
Per F. J. Brougham,
46, Lincoln's Inn Fields, London, W.C., Agent for the Applicant.
COMPLETE SPECIFICATION.
Improvements in the Manufacture of Axle Boxes and in Apparatus
for the Purpose.
1, SAMSON Fox, of the Leeds Forge, New Wortley, Leeds, in the County of
York, Civil Engineer, 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
in and by the following statement :-
This invention relates to the manufacture or construction of axle boxes for
railway and other vehicles from wrought iron or steel blooms, half wroughts, rolled
sections, and pressed or forged parts, and from metallic plate such as wrought iron
or steel.
According thereto suitable metal such as mild steel or iron, in one or other of
the forms referred to, is first converted into a tube the external and internal
dimensions of which correspond roughly to that of the required axle box, after
which it is compressed to complete the formation of the axle box. For this latter
purpose there is employed a collapsible mandrel or core die (hereinafter called the
collapsible mandrel) the exterior of which corresponds in shape and dimensions
with the interior of the finished axle box to be produced, and movable male and
female dies (hereinafter called the outer dies) the interiors of which correspond in
shape and dimensions with the exterior of the finished axle box.
The collapsible mandrel comprises a number of outer parts or segments suitably
fitted together, and a central boss or bearing spindle the form of which is such that
it can be readily withdrawn immediately the axle box is pressed. The con-
struction of this mandrel can be variously modified.
The outer or closing dies comprise metallic plates or parts so formed and
arranged as to form in conjunction with the before mentioned collapsible mandrel,
the sides, top, and bottom of the required axle box when the tube is pressed between
them.
The outer dies may be actuated by any suitable means as for example by a
hydraulic press or similar apparatus.
The compressing of the box or tube to the required shape can be effected by one
or more operations as may be desired.
In the accompanying drawings,
Fig. 1 is a longitudinal section partly in elevation ;
Fig. 2 is a plan; and
Fig. 3 is an end elevation, to a larger scale, of one form of collapsible mandrel
constructed according to this invention.
Figs. 4, 5 and 6 are respectively a longitudinal section, partly in elevation, a
plan, and a side elevation, illustrating a modified construction of collapsible
mandrel; and
Figs. 7 and 8 are respectively left and right hand elevations thereof.
Fig. 9 is a cross section on the line A B (Fig. 5).
Fig. 10 shows partly in cross section and partly in end elevation, the outer dies,
which, in conjunction with the collapsible mandrel, shown in elevation, serve for 5
pressing the tube placed between them, and shown in cross section, into an axle
box; the various parts are shown in the position they occupy preparatory to
pressing the said tube to shape.

page_text: a Fig. 10.
Fig. 10A is a cross section on the line
Fig. 11 is a longitudinal section on the line CD of Fig. 10, the collapsible
imandrel and tube being shown in the positions they occupy after the pressing
operation; the mandrel being shown in side elevation and the pressed axle box in
longitudinal section.
Fig. 12 is a horizontal section on the line EF Fig. 10.
Figs. 13 to 29 inclusive illustrate various forms of welded tubes suitable for
conversion into axle boxes.
Figs. 13, 14 and 15 are respectively a plan, side elevation, and end elevation, of
an open ended tube suitable for conversion into an axle box having side grooves for
axle guards.
Figs. 16, 17 and 18 are similar views to Figs. 13 14 and 15 respectively,
illustrating a slightly modified form of tube in which there is no depression at the
top of the tube as in the latter figures.
Figs. 19, 20 and 21 are similar views to Figs. 16, 17 and 18 respectively, but the
smaller end of the tube is shown partly closed.
Figs. 22, 23 and 24 are respectively a plan, side elevation and end elevation of a
tube that is of uniformn cross section for part of its length and of a gradually
decreasing cross section for the remainder of its length.
Figs. 25 26 and 27 are similar views to Figs. 22 23 and 24 respectively showing
a tube of gradually decreasing cross section or tapered form from one end to the
other.
Figs. 28 and 29 are respectively a plan and end elevation of a cylindrical tube.
The exterior of the collapsible mandrel shown in Figs. 1 and 2 is of a form
corresponding to the interior of the required axle box, being for this purpose formed
at each side with projections 1, 1" between which is a groove 2 which in conjunction
with corresponding recesses and projections on the outer side dies hereinafter described
form the axle guard grooves in the sides of the axle box. The top of the mandrel
is formed with a recess 2 which, in conjunction with a correspondingly formed outer
top die hereinafter described, forms the top of the axle box with a recessed spring
seat on the outer side, and it may be a bearing on the inside for a journal brass.
The outer portion of this collapsible mandrel comprises four corner segments 3, 4,
5 and 6 (Fig. 3) and four intermediate segments 7, 8, 9 and 10, these segments
being fitted around a central tapered boss or spindle 11 (hereinafter called the core)
and interlocked with each other in the manner indicated by the zig-zag lines 12.
13 and 13 are wedge-shaped plates inserted between the upper and lower intermediate
pieces 7 and 9 and the core 11, which in the example shown, is of rectangular form
in cross section. 14 is a collar fixed to one of the outer end portions 11* of the
core. 14 is another collar loosely mounted upon the smaller tapered end of the core
whereon it is held by a cotter 15. The exterior form of the collars 14 and 14" is
such as to suit the shape and size of the openings required in the ends of the axle
box thus they may be of square, round or oval form in end view, and of parallel
or of taper form in side view. In the example now being described they are
approximately of oval form in end view, and of tapered form in side view.
:
As will be seen the arrangement is such that when the core is in place and the
cotter is tightened up the outer portions of the mandrel will be firmly keyed
together so that they cannot be detached, but upon removing the cotter and
coliar 14ª, the core can be withdrawn from the outer portions of the mandrel, the
wedge-shaped plates will be released and can be removed, after which the outer
portions of the mandrel can be readily detached from each other by first with-
drawing the intermediate parts 8 and 10.
The outer end portions 11* of the core may advantageously be made square as
shown in order that the mandrel may be readily held in position, as hereinafter
described, with its sides vertical ready for the pressing operation. One of these end
portious is formed at two opposite sides with vertical recesses 16 (Fig. 2) for the
reception of a holding device whereby the mandrel is held longitudinally in the
required position within the outer dies. 17 is a gauge plate of taper form in cross

page_text: section it is fixed in the outer end of the removable collar 14", and permits of the
mandrel, or the mandrel and the tube from which the axle box is to be formed, being
placed in proper position within the outer dies.
In the modified construction of collapsible mandrel shown in Figs. 4 to 9 inclusive,
the core is made in two parts 11, 11" of which the former (11) is partly cylindrical
and partly taper, and the latter (11) which is tapered both externally and
internally, is arranged to fit the tapered portion of the former, the arrangement
being such that the two portions of the core can be withdrawn from opposite ends
of the mandrel. Between the corner segments 3, 4, 5 and 6, and the intermediate
wedge-shaped segments 7, 8, 9 and 10 there are in this arrangement, additional
wedge-shaped segments 7, 8, 9 and 10 that are interlocked as shown with each
other and with the corner segments. The corner segments are formed with dove-
tailed shaped projections 3", 4", 5", and 6 respectively, that take into corre-
spondingly formed recesses in the exterior of the two parts 11, 11* of the core, as
also does a projection 7 on the intermediate segment 7.
As will be seen the
arrangement is such that when the two parts of the core are inserted in place, the
outer segments, some of which may be made in two lengths as shown in Figs. 4 and 5
will be firmly locked together and to the core, and that upon withdrawal of the
core, the intermediate segments 7, 8 9 and 10 will be released and can be readily
removed from the inside, after which the additional segments can be removed,
thereby leaving the corner segments free.
The collar 14 in this arrangement is shown formed in one with the part 11" of
the core, the outer end of the other part 11 of the core in conjunction with
projecting portions of the segments 3, 7, 7, 7" and 4 serving as the equivalent of
the collar 14 shown in Figs. 12 and 3. The outer segments, or some of them, may
be made in two lengths with bevel joints in order to allow for contraction of the
axle box when cooling.
The outer dies are constructed as follows: reference being had to Figs. 10, 11
and 12 of the drawings.
18 is a hollow base plate or support the sides and ends of which are formed
with inwardly projecting vertical extensions, 19, 19" respectively, the upper
surfaces 19* of which are horizontal. Its ends are also formed with strong
vertical extensions 20, 20 extending above the sides. Each of these extensions
is formed with a vertical groove 21 and is strengthened by side flanges 22 and
ribs 23. 24, 24" are blocks each formed with lateral extensions 24 arranged to
slide on the horizontal surfaces 19* of the extensions 19". Each of these blocks is
formed with a downwardly inclined outer surface 25 bounded by side cheeks 24*
and in which is formed a dove-tail shaped groove 25".
or 20º.
26 is a vertically movable plate (hereinafter called the cap piece) provided
with two depending extensions 26". The outer side of each of these extensions
is vertical and arranged to slide in the groove 21 in the corresponding extension 20
The inner side of each extension 26" is inclined to correspond with the
outer inclined surface 25 of the corresponding block 24 or 24ª against which it
slides, and is provided with a dove-tail shaped projection 27 arranged to slide in
the correspondingly formed groove 25 in the adjacent slide block. 28 28" are
side dies secured in any convenient manner as by set screws as indicated in dotted
lines in Fig. 12, to the inner vertical surfaces of the blocks 24, 24" respectively.
The inner surfaces of each of these side dies is formed with grooves and pro-
jections as shown to correspond to the external formation which it is desired to
impart to the sides of the tube to convert the same into the required axle box.
29, 29 (Fig. 10) are inwardly extending projections formed on the side dies 28 28
for a purpose hereinafter mentioned. 30, 30" are hard steel formers fixed in the
side dies 28, 28" respectively, as shown more clearly in Fig. 10 and so as to
extend through the ribs 28* of the side dies. They are each formed with square
lower edges and corners 30* that are arranged to project slightly beyond the sides
of the rib 28* below them the arrangement being such that when the formers are
forced downward with the side dies, as hereinafter described, they act to square

page_text: out the corners of the axle guard grooves 2* (Fig. 12) previously formed in the
sides of the pressed axle box by the lower portions of the said ribs. 31 is a plate
forming the bottom die and the upper surface of which corresponds to that of the
bottom of the 'required axle-box. This bottom die is carried by a support 32
which may be made in one with the base plate 18 as shown in Figure 11, or
separate therefrom as shown in Fig. 10. In each case the bottom die is fixed
in place by set screws 33. 34 is the top die secured within the cap piece 26 in any
suitable manner as for instance by set screws as shown and the under surface of
which is so formed that, in conjunction with the top surface of the mandrel it will
impart the desired formation to the upper part of the tube to form a recessed
spring seat and internal bearing to receive a brass for an axle journal. 35, 35 are
slotted guides carried. by plates 35 fixed to the sides of the base plate, and
serving to receive the square ends 11* of the mandrel core for the purpose of
keeping the sides of the mandrel, shown at 36, vertical, whilst the tube 37 around
the same is being operated upon by the side dies 28, 28". 38 38 are side bearers
secured one to each of the side dies; they serve to carry the ends of the core and
keep the mandrel level ready for the pressing operation. 39, 39 are lateral
projections formed on the lower outer part of each of the side dies 28 28°; these
projections are arranged to slide upon the upper surfaces 19* of the extensions 19.
and support the side dies during the formation of the sides of the axle box; they
also aid in withdrawing the pressed axle-box from the top die 34. 40, 40 are
projections extending inwardly from the sides of the base plate 18 to which they
are fixed. These projections which are shown more clearly in Fig. 104 and may
be fixed to the slotted guides 35 serve as stops to limit the upward movement of
the projections 39 and the side dies attached thereto as hereinafter described.
To the outer side of each block 24, 24" is fixed a stud 41 corresponding to which
is a weighted lever 42 and a fixed bar 43 formed with an inclined surface at 43".
Each lever 42, which is pivoted to the cap piece as shown, is formed with a recess 44.
adapted to receive the corresponding stud 41, and is provided with a stud 45 that is
caused by the action of the weighted lever to bear against the adjacent side of the
corresponding bar 43.
A tube say of the form shown in Figs. 13, 14 and 15 and produced from plate
metal or a rolled section in a manner well understood is pressed to the form
of an axle box by means of apparatus of the kind described in the following
manner :-
The several dies are first moved into their open position shown in Fig. 10. The
metal tube 37 shown in full lines in Fig. 10 and in dotted lines in Fig. 12, is
heated to a suitable temperature, say a bright red heat, and slipped over the
mandrel, and the two are placed in position between the side dies 28, 28* as shown
in Figs. 10 and 12. The cap piece 26 is then at once forced downward by any
suitable means, preferably by the ram of a hydraulic press. As the cap piece
descends its wedge shaped side portions 26" by acting against the two blocks 24 24ª
cause them and the side dies 28, 28° to slide on the extensions 19, 19* and move
horizontally inwards thus causing the said dies to close upon the tube and mandrel.
By this means the sides of the tube are caused to assume the form of the inner
surfaces of the side dies and the outer vertical sides of the mandrel between which
they are pressed, thereby forming the side projections 1* with intermediate
grooves 2 for axle guards. At the same time the ends of the tube are bent
inward and partly around the collars 14 and 14 so as to partly produce the desired
formation of the ends of the axle box. When the blocks and side dies have
finished their inward movement and completed the formation of the sides of the
axle box as described, they will have left the sliding faces 19* upon which they
were previously supported, and will have been brought over the recessed portion
of the base plate 18. The side levers 42 will also at this same time have each
closed in upon and clasped the corresponding stud 41 so as to hold the blocks and
side dies, which on the further descent of the cap piece will move downward into
the hollow base plate together with the extensions 26" of the cap piece. By this

page_text: downward movement of the side dies, the two steel formers 30 30° carried thereby
will be caused to descend the axle guard grooves 2* in the sides of the partly
pressed tube, whilst the same are still hot, and cause the grooves to become square
in cross section so as to suit the axle guards of a wagon or car. When the said
grooves have been thus squared and finished the top and bottom dies 34 and 31
respectively will come into action, these dies acting simultaneously upon the top
and bottom of the tube, whilst the sides thereof are rigidly held between the side
dies, thereby completing the pressing of the tube into an axle box of the required
formation.
Immediately the tube has been thus pressed to shape, the cap piece 26 is raised
whereby the side dies, blocks, axle box and mandrel will be carried up with it
until the studs 45 on the levers 42 come into contact with the inclined portions 43*
of the fixed bars 43 which will then act to press the levers outward and cause
them to release the studs 41 and leave the side dies and blocks ready to be moved
laterally. Immediately this disengagement of the levers takes place, the pro-
jections 39 on the side dies come into contact with the projections or stops 40
which prevent the side dies and blocks ascending any further with the cap piece,
the wedge shaped extensions 26" of which then cause the side dies and blocks to
slide outwards on the slide surfaces 19* (onto which they descend when stopped by
the projections 40) and into the positions shown in Fig. 10. The pressed axle
box, with mandrel will however continue to ascend with the top die 34 (in which
it will have become fixed) until the projecting ends of the mandrel come in con-
tact with the projecting portions 29 of the side dies which, being now prevented from
ascending, act by pressing upon the top of the said projecting ends of the mandrel
to release the axle box and mandrel from the top die so as to permit of their
easy withdrawal from between the outer dies when these have assumed the positions
shown in Fig. 10. The cotter 15 of the collapsible mandrel is then removed and
the core of the mandrel withdrawn, whereupon the intermediate wedge shaped
segments of the outer portion of the mandrel will fall, or can be moved
inwards and are removed thus freeing the corner segments which are then
withdrawn.
The axle box thus pressed to shape is ready after the ends have been suitably
trimmed if necessary to receive the journal brass, grease box or other desired
attachments as well understood.
As will be obvious axle boxes can be constructed in various forms in the manner
hereinbefore described the tubes from which they are to be formed, and the
mandrel and outer dies being suitably formed for the purpose.
Having now particularly described and ascertained the nature of the said inven-
tion and in what manner the same is to be performed I declare that what I
claim is :-
1. The manufacture of axle boxes in the improved manner hereinabove
described that is to say by converting suitable metal such as mild steel or wrought
iron into a tube having roughly the general form of the required axle box and
compressing or closing the tube whilst at a suitable temperature upon and around
a collapsible mandrel or inner die, the external form of which corresponds to the
external form of the desired axle box by means of outer dies capable of being
moved towards and closed upon the said tube and mandrel or inner die and the
acting surfaces of which correspond in form to the external shape of the required
axle box substantially as hereinabove described.
2. In apparatus for the manufacture of axle boxes in the improved manner herein-
above described, a collapsible mandrel or inner die the external form of which
corresponds to the internal form of the required axle box and composed of a
number of outer segments or parts interlocked with each other and mounted upon a
.core made in one or more parts, the arrangement being such that upon removal
of the core the outer segments or parts can be readily detached from each
other to permit of their removal from within a pressed axle box substantially as

page_text: herein before described with reference to the examples illustrated in Figs. 1 2 and 3,
and in Figs. 4 to 9 inclusive of the accompanying drawings.
3. For the manufacture of axle boxes in the improved manner herein before
described, apparatus comprising a fixed collapsible mandrel or inner die adapted
to support the plate metal tube from which an axle box is to be made, and movable
outer dies adapted to be closed upon and around the tube and mandrel or inner die,
the acting surfaces of the said mandrel or inner die and of the outer dies corre-
sponding respectively to the interior and exterior of the required axle box,
substantially as herein described.
4. For the manufacture of axle boxes in the improved manner hereinabove
described, apparatus comprising a collapsible mandrel or inner die, and movable
outer dies constructed arranged and operating substantially as hereinbefore
described with reference to and shown in Figs. 10, 11 and 12 of the accompanying
drawings.
Dated this 4th day of April 1893.
W. LLOYD WISE,
Per F. J. Brougham,
46, Lincoln's Inn Fields, London, W.C., Agent for the Applicant.