Method and Apparatus for the Manufacture of Rails, Girders, and Rolled Bars of Various Sections and similar Objects.
Year: 1891

page_text: Date of Application, 22nd Aug., 1891
Complete Specification Left, 22nd Feb., 1892-Accepted, 26th Mar.,
1892
PROVISIONAL SPECIFICATION.
Method and Apparatus for the Manufacture of Rails, Girders, and
Rolled Bars of Various Sections and similar Objects.
I, TOUSSAINT BICHEROUX, of Dusseldorf, in the German Empire, Smelting
Works Proprietor, do hereby declare the nature of this invention to be as
ollows:-
This invention relates to a process and apparatus for manufacturing rails,
girders, rolled bars and the like of various shapes and sizes and of any desired
netal.
It has hitherto been a great disadvantage attending processes at present in use
that it has been impossible to enlarge the dimensions beyond a certain limit of rails,
girders, or bars of various section or of their parts. For instance it was not possible
to roll rails with any desired breadth of base.
By the new process all these difficulties are got over, and moreover this process
has the advantage that the system of rollers is simplified and the rolling of the
desired profile is rendered more exact.
The new process consists of a series of operations.
The blank to be worked is in the first place rolled, forged, pressed, cast or in any
In this blank is
suitable manner brought to a rectangular or similar section.
formed a deep groove or several of these, which can be done by rolling, or may be
cast in the first instance.
The grooved blank is then drawn out by grooved rollers to the desired suitable
shape. The sides of the grooves are thus pressed together. The welding of these
sides cannot then take place.
Finally the sides of the grooves are bent apart sufficiently for the intended
purpose.
The following is a description of the rolling of a rail by the new process. The
apparatus is shewn by Figs. 1 to 6 inclusive. A blank of suitable dimensions is first
rolled to rectangular section, and in this a groove is rolled by one pair or several
pairs of rollers; the depth of this groove corresponds with the desired breadth of
the base of the rail. The blank thus prepared is then suitably shaped by other
sets of rollers.
During the drawing out the head of the rail is formed, the two sides of the
groove are pressed together, and at the same time the desired shape is approximately
given to the base.
Figs. 1 and 2 shew the sets of rollers by which the above operations are effected.
The sides are then bent away from each other to form the base of the rail. For
this bending operation the arrangement shewn by Figs. 3, 4 and 5 is most suitable.
Fig. 3 is a side view partly in section,
Fig. 4 is an end view partly in section, and
Fig. 5 is a plan.
The frame a of the finishing rollers has fixed to it a bed plate c on which a
slide d can move horizontally. This slide carries a bracket f having a changeable
facing which serves to guide the head of the rail.
A cover is fixed on the bracket f. At the side and under the slide ar
hydraulic cylinders by which the bending and separation of the rail base are effected,
and the rail is fed forwards to the finishing rollers. The rail being introduced in
the slide the plunger i of the cylinder pushes the rail up against a guide projecting
down from the cover h, and thus the head and rib of the rail cannot be altered.
The side plunger k now advances and drives a wedge between the two sides of the
base groove which had been pressed together so as to bend them apart.

page_text: When the base is thus partly shaped, the end plunger advances pushing the
slide towards the rollers and feeding the rail between them, the plungers i and
continuing to serve as guides. The rollers 6 then seize the rail and draw it through,
the base completely flattened and the rail finished.
Fig. 6 shews a more simple arrangement for bending out the flanges of the rail
base.
In front of the finishing rollers m by which the rail head and rib are shaped, is
mounted a shaft n carrying three rollers.
The first o is grooved to the shape of the upper sides of the base flanges, the
second roller p is doubly conical to spread out the sides of the groove, the third
roller is smooth to finish the base.
This treatment for rails is applicable for the manufacture of bars of other
shapes.
Figs. 7 to 15 shew the gradually altered forms of the blanks during the chief
stages of the process. As will be seen these blanks are grooved to suitable depth
for the profile to be formed. The sides of the grooves are pressed together by
rolling and the form of the body is approximately produced. The sides of the
grooves are then spread apart, and the bar is finished as described with reference to
Figs. 3 to 6.
Fig. 7 shews the process applied for a rail of narrow base.
Fig. 8 shews it for a very broad base, such as may be spread out by the
arrangement shewn in Fig. 16, by the use of hydraulic presses as already
described.
By simply bending round the foot is obtained a longitudinal sleeper, which
hitherto could not be got in one piece but had to be made in two pieces.
Thus the new process is of great advantage applied in this particular case. A
special arrangement for production of such longitudinal sleeper rails is shewn in
Fig. 17.
The rails receive their finished shape from the three rollers s, s¹ s¹. From the
shaft u motion is conveyed by the cog wheels t t to the roller s, whilst bevel
wheels, serve to drive the rollers s¹. The roller s is mounted in the
frame 1', the rollers s¹s are mounted in the frame w.
Figs. 9 and 10 shew the production of H iron bars or girders of various sizes,
for which may be used the rollers shewn in Figs. 18 and 19.
The upper and lower rollers being adjustable, the six rollers are sufficient to roll
the blank to profile.
For producing girders a yard in depth, only two sets of rollers are necessary, one
set working to a depth of about half a yard and the other from half to a whole
yard.
For spreading out the flanges on both sides of the H iron, the arrangement shewn
by Figs. 20 and 21 may be employed,
Fig. 20 being a plan and Fig. 21 an end view of the apparatus which acts in a
manner similar to that for spreading out the base flanges of a rail or like section;
it is only necessary to add a hydraulic press on the opposite side in order that both
flanges may be spread out simultaneously, the process of spreading out and guiding
to the finishing rollers being otherwise the same.
Fig. 11 shews the production of angle iron, Fig. 12 of T iron, and Fig. 13 of
cross iron.
Figs. 14 and 15 shew the production of trough iron and Z iron. On the
sides a¹ at the points c¹ where the bend is to take place small ribs are provided;
on separating the sides of the groove an angle is first produced.
Finally, may be specially mentioned the production of a rail such as is shewn in
Fig. 22 having its base widened out where it rests on a sleeper. This highly useful
form is produced by the new process, the finishing rollers by which the flanges are
spread out and finished to shape, being recessed where the widening takes place.
The circumference of the rollers must therefore be equal to the distance from centre
to centre of the widened parts.

page_text: The arrangement shewn in Fig. 6 can be applied with advantage in the
production of these rails.
By the new process for the production of rails, girders and bars of various profiles
great advantages are obtained, and it is therefore to be considered a great
improvement, a most important feature being the great simplicity of the roller
plant, and the consequent economy of manufacture.
Dated this 22nd day of August 1891.
ABEL & IMKAI,
Agents for the Applicant.
COMPLETE SPECIFICATION.
Method and Apparatus for the Manufacture of Rails, Girders, and
Rolled Bars of Various Sections and similar Objects.
I, TOUSSAINT BICHEROUX, of Dusseldorf in the German Empire, Smelting
Works Proprietor, 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 a process and apparatus for manufacturing rails,
girders, rolled bars and the like of various shapes and sizes and of any desired
metal.
It has hitherto been a great disadvantage attending processes at present in use
that it has been impossible to enlarge the dimensions beyond a certain limit, of rails,
girders, or bars of various section or of their parts. For instance, it was not
possible to roll rails with any desired breadth of base.
By the new process all these difficulties are got over, and moreover this process has
the advantage, that the system of rollers is simplified and the rolling of the desired
profile is rendered more exact.
The new process consists of a series of operations :-
The blank to be worked is in the first place rolled, forged, pressed, cast or in
In this blank
any suitable manner brought to a rectangular or similar section.
is formed a deep groove or several of these, which can be done by rolling, or may
be cast in the first instance.
The grooved blank is then drawn out by grooved rollers to the desired suitable
shape. The sides of the grooves are thus pressed together. The welding of these
sides cannot then take place.
Finally the sides of the grooves are bent apart sufficiently for the intended
purpose.
The following is a description of the rolling of a rail by the new process.
The apparatus is shewn by Figs. 1 to 6 inclusive referring to the drawings filed
with my Provisional Specification.
A blank of suitable dimensions is first rolled to rectangular section, and in this
groove is rolled by one pair or several pairs of rollers; the depth of this groove
corresponds with the desired breadth of the base of the rail. The blank thus
prepared is then suitably shaped by other sets of rollers. During the drawing out
the head of the rail is formed, the two sides of the groove are pressed together,
and at the same time the desired shape is approximately given to the base.
Figs. 1 and 2 shew the sets of rollers by which the above operations are effected.
The sides are then bent away from each other to form the base of the rail.
For this bending operation the arrangement shewn by Figs. 3, 4 and 5 is most
suitable.
Fig. 3 is a side view partly in section.
Fig. 4 is an end view partly in section and
Fig. 5 is a plan.
The frame a of the finishing rollers has fixed to it a bed plate c, on which a
slide can move horizontally. This slide carries a bracket f having a changeable

page_text: facing g which serves to guide the head of the rail. A cover his fixed on the
bracket f. At the side and under the slide are hydraulic cylinders, by which the
bending and separation of the rail base are effected, and the rail is fed forwards to
the finishing rollers. The rail being introduced in the slide the plunger i of the
cylinder under the slide pushes the rail up against a guide projecting down from
the cover h, and thus the head aud rib of the rail cannot be altered. The side
plunger know advances and drives a wedge between the two sides of the base
groove which had been pressed together so as to bend them apart.
When the base is thus partly shaped, the end plunger l'advances pushing the
slide towards the rollers and feeding the rail between them, the plungers i and k
continuing to serve as guides. The rollers & then seize the rail and draw it through,
the base is completely flattened and the rail finished.
Figure 6 shews a more simple arrangement for bending out the flanges of the
rail base.
In front of the finishing rollers m, by which the rail head and rib are shaped, is
mounted a shaft n carrying three rollers. The first o is grooved to the shape of
the upper sides of the base flanges, the second roller p is doubly conical to spread
out the sides of the groove, the third roller is smooth to finish the base.
9
This treatment for rails is applicable for the manufacture of bars of other
shapes.
Figs. 7 to 15 shew the gradually altered forms of the blanks during the chief
stages of the process.
As will be seen, these blanks are grooved to suitable depth for the profile to be
formed.
The sides of the grooves are pressed together by rolling and the form of the
body is approximately produced. The sides of the grooves are then spread apart,
and the bar is finished as described with reference to Figs. 3 to 6.
Fig. 7. shews the process applied for a rail of narrow base.
Fig. 8. shews it for a very broad base, such as may be spread out by the
arrangement shewn in Fig. 16 by the use of hydraulic presses as already described.
By simply bending round the foot is obtained a longitudinal sleeper, which
hitherto could not be got in one piece but had to be made in two pieces.
Thus the new process is of great advantage applied in this particular case.
special arrangement for production of such longitudinal sleeper rails is shewn in
Fig. 17.
A
The rails receive their finished shape from the three rollerssss'. From the
shaft u motion is conveyed by the cog wheels t t to the roller s, whilst bevel
wheels vvv serve to drive the rollers & s¹. The roller s is mounted in the frame r,
the rollers s¹ are mounted in the frame w.
Figs. 9 and 10 shew the production of H iron bars or girders of various sizes, for
which may be used the rollers shewn in Figs. 18 and 19. The upper and lower
rollers being adjustable, the six rollers are sufficient to roll the blank to profile.
For producing girders a yard in depth, only two sets of rollers are necessary, one
set working to a depth of about half a yard and the other from half to a whole
yard.
For spreading out the flanges on both sides of the H iron, the arrangement
shewn by Figs. 20 and 21 may be employed.
Fig. 20 being a plan and Fig. 21 an end view of the apparatus, which acts in a
manner similar to that for spreading out the base flanges of a rail or like section ;
it is only necessary to add a hydraulic press on the opposite side in order that
both flanges may be spread out simultaneously, the process of spreading out and
guiding to the finishing rollers being otherwise the same.
Fig. 11 shews the production of angle iron, Fig. 12 of T iron and Fig. 13 of
cross iron.
Figs. 14 and 15 shew the production of trough iron and Z iron.
On the sides a b¹ at the points c¹ where the bend is to take place small ribs are
provided on separating the sides of the groove an angle is first produced.
;

page_text: Finally may be specially mentioned the production of a rail such as is shewn in
Fig. 22, having its base widened out where it rests on a sleeper. This highly useful
orm is produced by the new process, the finishing rollers by which the flanges are
spread out and finished to shape being recessed where the widening takes place.
The circumference of the rollers must therefore be equal to the distance from
centre to centre of the widened parts.
The arrangement shewn in Fig. 6, can be applied with advantage in the
production of these rails.
By the new process for the production of rails, girders and bars of various
profiles great advantages are obtained, and it is therefore to be considered a great
improvement, a most important feature being the great simplicity of the roller
plant, and the consequent economy of manufacture.
Having now particularly described and ascertained the nature of this inven-
tion and in what manner the same is to be performed, 1 declare that what 1
claim is
1. The method of manufacturing rails, girders and rolled bars or the like of
various profiles and dimensions, consisting in first producing blanks of suitable size:
approximately rectangular in section by rolling, forging or the like, in giving this
blank a groove corresponding to the profile to be produced by one pair or several
pairs of rollers or otherwise, in drawing out by successive rollers the grooved blank
until the profile is approximately of the shape desired with the flanges pressed
together, in spreading the flanges apart and finally finishing the rails or other
objects by rolling.
2. In the process above referred to, the use of blanks cast with grooves, rendering
the grooving by rollers unnecessary.
3. For bending out the sides of the grooves above referred to, the arrangement
consisting of a combination of hydraulic presses with a pair of rollers, such that the
rolled bar is pressed into a guide by the first press, a wedge is forced between the
flanges by the second press, and the bar is pushed by the third press between
the rollers, by which it is finished.
4. For spreading out the flanges of H iron, an arrangement consisting of four
hydraulic presses, two side ones of which spread out by wedging the flanges on both
sides.
5. For spreading out the sides of the grooves to form flanges, another arrange-
ment consisting of the shaft n carrying three rollers o p q acting in front of the
finishing rollers, the roller o giving the flanges approximately their finished shape,
the double cone roller p partly spreading out the flanges, and the smooth roller
completing the flattening of the base.
6. For finish-rolling longitudinal sleeper rails a set of rollers consisting of three
profile rollers sss, in which the motion of the roller s is communicated to the
rollers ss by cog wheels t t and bevel wheels v v¹ v¹.
7. In the process referred to in Claim 1 the use of rollers having recesses for
producing rails having their bases locally widened where resting on sleepers.
Daund this und dar of February 1892.
ABEL & IMKAT,
Agents for the Applicant.