IMPROVEMENTS IN THE MANUFACTURE OF LONGITUDINALLY CORRUGATED BEANS OR RAILS OF STEEL OR IRON FOR RAILWAYS AND FOR ARCHITECTURAL AND OTHER PURPOSES."
Year: 1870

page_text: LETTERS PATENT to Richard Montgomery, of the City, County, and
State of New York, and United States of America, Engineer, for
the Invention of "IMPROVEMENTS IN THE MANUFACTURE OF LONGITUDINALLY
CORRUGATED BEANS OR RAILS OF STEEL OR IRON FOR RAILWAYS AND FOR
ARCHITECTURAL AND OTHER PURPOSES."
COMPLETE SPECIFICATION filed by the said Richard Montgomery
at the Office of the Commissioners of Patents, with his Petition
and Declaration, on the 30th November 1870, pursuant to the 9th
Section of the Patent Law Amendment Act, 1852.
TO ALL TO WHOM THESE PRESENTS SHALL COME, I, RICHARD
MONTGOMERY, of the City, County, and State of New York, and United
States of America, Engineer, send greeting.
WHEREAS I am in possession of an Invention for "IMPROVEMENTS
IN THE MANUFACTURE OF LONGITUDINALLY CORRUGATED BEANS OR RAILS OF STEEL
OR IRON FOR RAILWAYS AND FOR ARCHITECTURAL AND OTHER PURPOSES," and
have petitioned Her Majesty to grant unto me, my executors, ad-

page_text: ministrators, and assigns, Her Royal Letters Patent for the same, and
have made solemn Declaration that I am the first and true Inventor
thereof.
NOW KNOW YE, that I, the said Richard Montgomery, do hereby
declare that the following Complete Specification, under my hand and 5
seal, fully describes and ascertains the nature of the said Invention,
and in what manner the same is to be performed, in and by the follow-
ing statement, reference being had to the accompanying Drawings
forming a part of this Specification :-
NATURE AND OBJECTS OF THE INVENTION.
It is well known that a bar or beam of metal bent or rolled to present
one or more longitudinal flat and parallel sides connected by inverted
or uninverted arches will possess the greatest possible amount of
transverse strength, and consequently support a greater weight or resist
a higher degree of pressure in comparison with its own weight than 1
a bar or beam of any other form.
The first part of my Invention relates to an improvement in the shape
of ingot to be used in the manufacture of such a longitudinally corru-
gated or folded beam, bar, or rail of steel, wherein an ingot of good
steel is passed at a suitable temperature between rolls constructed 2
specially for the purpose and herein-after described: It consists in
casting the ingot in a mold so fashioned as to form or produce longi-
tudinal grooves in the ingot corresponding in their number and relative
position with those required in the finished beam or rail. To convert
the ingot thus formed into a beam, bar, or rall it is passed at a proper
heat through a rolling mill provided with a series of finishing grooves,
the first of which correspond very nearly with those of the ingot. The
object of this part of my Invention is to diminish the number of passes
required in the reduction of an ingot of ordinary shape to a finished
beam, and thereby not only save time in the manufacture of the beam,
but also save the expense involved in the use of longer rolls, and the
loss of power and the wear and tear of machinery expended in making
the preliminary passes, which by means of my Invention are dispensed
with.
The second part of my Invention relates to the combination of bars of
:. peculiar novel shape in the formation of a "pile" for the production
a longitudinally corrugated beam, bar, or rail of iron. Heretofore in
e manufacture of longitudinally corrugated beams or rails of wrought

page_text: iron a "pile" has first been formed of ordinary flat bars, which being
duly heated and passed between a series of roughing and shaping rolls,
usually two or three in number, is gradually reduced to a form approxi-
mating that of the finished beam. At this stage of the process the
metal generally requires reheating. The object of this second part of
my Invention is to avoid all these laborious and expensive preliminary
steps in the manufacture of the beam, and attain the same end by
forming a "pile" having the same shape as the bar thereby produced,
from which with the same rolls and the same number of passes I
manufacture as perfect a beam as can be produced from said bar.
The third part of my Invention relates to the combination of a steel
head, cap plate, or bar with a longitudinally corrugated beam or rail of
wrought iron, to produce a novel and exceedingly light, elastic, and
durable railway rail, combining in itself the advantages of the economy
of weight and the strength of a longitudinally corrugated beam, the
endurance of the best steel rail, the freedom from jar and concussion of
a continuous unbroken rail, the novel advantage of a detachable head,
easily removed and replaced when worn without disturbance of its base,
and in the use of which all fish plates, joint bars, and the like are
entirely dispensed with and fewer cross ties are required.
The fourth part of my Invention relates to the form of steel ingot to
be used in producing the cap plate or bar which I combine with a
longitudinally corrugated wrought-iron beam in manufacturing my
improved railway rail, and it consists in casting the ingot into a shape
approximating a form in cross section, the object of this part of my
Invention being to facilitate and economize the rolling out of the desired
cap plate or bar.
I use in rolling out longitudinally corrugated beams or rails from the
steel ingots or wrought-iron "piles" herein-before mentioned a rolling
mill consisting of three superimposed peculiarly grooved and flanged
rolls so arranged and disposed one upon the other in a vertical plane as
that the ingot or pile may be passed consecutively back and forth
between the rolls through a series of gradually diminishing grooves
alternately above and below the centre roll, the peculiar forms of the
several grooves being novel and of my Invention.
The longitudinally corrugated beam which I produce from a steel
ingot combines with the superior form and disposition of metal found in
a longitudinally corrugated beam of wrought iron the superior advan-

page_text: tages of the metal, steel, and it presents in and of itself a new article of
manufacture which I believe to be as novel as it is useful. The singular
lightness of such a beam of steel in comparison with its strength, its
great elasticity, the character of its surface presenting a film or coat
which does not readily oxidize, and its superior durability, are among the t
important advantages thereof.
DESCRIPTION OF THE ACCOMPANYING DRAWINGS.
Figure 1 (Sheet 1) is an elevation in perspective, and Figure 2 a
transverse section of an ingot cast of "Bessemer" or other good steel
preparatory to the production of a longitudinally corrugated steel beam 1
or rail; Figure 4 a view in perspective, and Figure 5 an end view of
one of the wrought-iron bars which I employ in the formation of my
improved "pile" for the manufacture of longitudinally corrugated iron
beams or rails; Figures 6 and 7 being corresponding views of the second
bar completing the "pile." Figures 8 and 9 are respectively a view in 1
perspective and an end view of the wrought-iron "pile" complete ready
to be passed at a welding heat through the rolling mill.
Figure 10 (Sheet 2) is an elevation in perspective of my improved
longitudinally corrugated beam or rail produced from my improved ingot
(illustrated in Figures 1 and 2), or from my wrought iron pile (illustrated 2
in Figures 8 and 9); Figure 11, a transverse section of the beam
illustrated in Figure 10; and Fig. 12, a transverse section of a beam
of the same description but made of a uniform thickness of metal
throughout. Figure 13 represents a longitudinal central vertical section
of my improved rolling mill; Figure 14 is an elevation in perspective a
of my improved longitudinally corrugated steel-capped railway rail;
Figure 15, a transverse section of said rail; Figures 16, 17, and 18 are
similar sections illustrating modifications in the combination of the cap
and base of the rail; Figure 19 an end view, and Figure 20 an elevation
of the ingot which I cast preparatory to rolling a steel cap for the rail
illustrated in Figures 14 and 15.

page_text: :
longitudinal cliannel or groove 6 is formed centrally on one side (the
upper), and two similar channels c, c, of less depth are formed at equal
distances from the centre in the opposite side thereof; the two remaining
sides of the ingot are recessed or cut away so as to leave longitudinal
5 projections d, d, on each side of the double grooves c, c, to constitute
the flanges on the base of the finished, beam, all' as clearly shown in
Figure 2.
I claim as my Invention this improved form of cast steel ingot for
use in manufacturing a longitudinally corrugated steel beam, by means
) whereof I am enabled to produce the beam with fewer passes in the
rolling mill than with the ordinary ingot, and to complete the same at a
single heat, and I contemplate simple modifications thereof.
-
:
B, C, Figure 8, is my improved "pile" for the production of a
corrugated beam of wrought iron of the general form illustrated in
Figures 10, 11, and 12. This "pile" is formed of two bars B (Figures 4
and 5) and O (Figures 6 and 7), which are rolled out directly from the
bloom with no more labor or expense than is required in rolling out the
bars used in forming a "pile" of the description heretofore in use for
this purpose. To produce these bars B and O the roughing rolls by
which the blooms are shaped and rolled out into the flat extended bars
of commerce are grooved so as to form bars longitudinally channeled on.
one side and flattened on the other, and otherwise outwardly shaped
(substantially as illustrated in Figures 4 to 7 of the Drawings) to:
correspond with one or the other longitudinal half or division of a bar.
such as is produced in the old process by passing a "pile" of flat bars
several times between a series of "roughing" rolls, the uso whereof I
dispense with.
My improved "pile". formed by the bars B and O brought together in
pairs and superimposed as shown in Figures 8 and 9 is heated to a
welding temperature and then completed into a perfect beam by passing.
it through a suitable rolling mill as herein-after described without the
necessity of reheating it. It is manifest that a beam may be thus
produced irrespective of the number of longitudinal folds or channels
therein by imparting a proper shape to the two bars B, O, which are to
constitute the pile. from which it is to be rolled and that the shape
of the bars B, C, may be varied at pleasure by varying the shape of the
roughing rolls employed in reducing the blooms. It is also evident that
the longitudinal division of the "pile," Figure 8, might be made vertical
=

page_text: instead of longitudinal as therein illustrated, in which case the two
divisions could each be produced by the same rolls. Instead of forming
the pile of two bars or longitudinal divisions B, C, as described, I con-
template the possibility of building it up of three or more bars each
fashioned so as to correspond to a definite longitudinal division of a bar i
having substantially the form shown in Figures 8 and 9, so that when
brought together they will form a pile of that shape.
"
I claim as my Invention a wrought-iron "pile" for beams or rails
composed of two or more bars grooved longitudinally and of such shape
as that when put together they will constitute a "pile" of the general 1
configuration which I have just described. The rolling mill in which
I reduce and fashion the steel ingot A, Figure 2 (Sheet 1) or the
wrought-iron "pile" B, C, Figure 8, into my improved longitudinally
corrugated beam H, Figure 10 (Sheet 2) is illustrated in Figure 13
(Sheet 2) of the Drawings. D, E, F, are the solid cast-iron rolls of the 1
mill, having suitable journals at each end thereof revolving in bearings
formed in the "housings or frame G of the apparatus. Said rolls are
geared together outside of the frame so as to revolve in unison. Parallel
annular recesses alternating with parallel projections are cut in the
circumference of the central roll E, and counterpart annular recesses and 2
projections are out or formed alternately in the upper roll D and lower
roll F. The first annular recess e in the sories is cut near one end of
the roll E of the full width of the wrought-iron "pile" B, C, Figure 8,
a similar recess e' is also cut opposite thereto in the lower roll F. These
opposite annular recesses e, e¹, are so grooved and flanged, as illustrated?
in the Drawing, as that the opening 1 formed thereby between the
rolls E, F, as they revolve in contact will be nearly the counterpart of
a cross section of the pile B, C, (see Figure 9) varying therefrom only to
such an extent as shall not only elongate the "pile" in passing through
the same, but cause it to approximate to the shape required in the
finished beam H. The second annular recess & cut in the central roll E
is met by an annular recess 6¹ cut opposite thereto in the upper roll D,
the two recesses being grooved and flanged as illustrated in the Drawings
so that the opening 2 thereby left between the rolls E, F, will receivo
the "
'pile as it comes from between the rolls through the aperture 1, :
and compress and extend it to a form still more closely approximating
that required in the finished beam H. Thus a complete series of seven
(7) annular, grooved, and flanged recesses e, f, g, h, i, j, and ⁄ are cut in
"

page_text: the central roll E and counterpart grooved and flanged recesses
e', ƒ³, g³, h', i̇'‚ ƒ', and are cut alternately in the upper and lower
rolls D and F to form alternately between the upper and central and the
lower and central rolls as they revolve in unison a series of forming and
shaping apertures 1, 2, 3, 4, 5, 6, and 7, whereby the iron pile or the steel
ingot shall in being passed through said apertures be gradually extended,
grooved, and furrowed, causing it to assume the shape and proportions
required in the finished beam. The intervals m, m, m, between the series
of annular, grooved, and flanged recesses e, f, g, h, i, j, and k, at the spaces
1, 2, 3, 4, 5, 6, and 7 in the central roll E are deeply grooved circum-
ferentially, with recesses having an angular section as shown in the
Drawing, and counterpart angular flanges m³, m³, m³, projecting both
from the upper and lower rolls D and F, fit into and engage closely
therewith, preventing any longitudinal movement or displacement of the
rolls D, E, F, and intimately connecting them. In using this com-
bination of triple rolls D, E, F, wherein the upper and lower rolls D and
F alternately present counterpart forming spaces in coincidence with
those formed consecutively upon the central roll E, the "pile” B, C, or
the "ingot" A, passed through from one side between the rolls E, F, at 1,
and thereby partially rolled, is immediately returned between the rolls E,
D, at 2, which continues the reduction and formation of the bar or beam,
and then again passed back between the rolls E, F, at 3, to be again
returned between E and D at 4, and thus sucessively from opposite sides
through the forming spaces 5, 6, and 7, until it has finally attained its
complete form, each successive pass from 1 to 7 causing it to approximate
as herein-before stated more closely in size and shape in the finished
beam. The series of forming apertures 1 to 7 between the rolls may
bo
diminished or increased in number to meet the requirements involved in
rolling a small and comparatively light bar, or a thick and heavy beam.
In rolling out my improved steel ingot illustrated in Figures 1 and 2,
the passes 1 and 2 may be omitted, and the ingot introduced between the
rolls at the forming aperture 3, and the beam be rolled out and finished
with the four succeeding passes. By returning the heated "pile" B, C,
or ingot A, from side to side between the rolls without delay as herein set
forth, the conversion thereof into a corrugated beam is effected in about
one half the time required with the old rolling mills having but two rolls.
Hence longer bars may be rolled in the same time, or as the bar
may be
finished in so much less time and can be consequently entirely formed
'
and finished at a single heat and at a much higher degree of temperature,

page_text: cheaper iron may be used, thinner bars manufactured, and a more perfect
and intimate weld, and union of the particles and fibres of the metal be
produced in the beam than with the old mills.
One of the adaptations of my improved corrugated beam to railway
purposes is illustrated in Figures 14 to 18 of the Drawings.
P is a beam, bar, or extended plate of iron or steel longitudinally
corrugated into two folds, whose edges are bent outward in a plane with
the arch of the central fold to form a base for the rail thus produced.
This corrugated rail is manufactured as herein-before described by
passing a pile of iron or ingot of steel at proper temperature through a
series of suitably ground rolls, and I prefer to make it thicker in the
crown of each arch or fold to obtain thereby greater strength in the parts
most fully exposed to tension and strain with the utmost economy of
metal. Upon the upper surface of this corrugated beam I secure a cap
plate of hardened iron or steel, by preference thic latter, made to span
the two arches or folds of the corrugated beam P, and clasp the saine
firmly with its overlapping edges, as shown in the Drawing. R is the
cap plate or capping, and p, p, the overlapping edges thereof. This
hardened capping R is by preference provided with a central longitudinal
flange S, Figures 14 and 15, projecting from its under side to fit in
between the folds of the base beam and facilitate its secure attachment
thereto. It is produced by passing the metal between suitable rolls until
it is so shaped as to fit very exactly upon the arches of the corrugated
beam overlapping and embracing them closely, its central flange passing
down closely between them, as illustrated in the Drawings, Figures 14
and 15. When this flanged capping R is used it is secured upon the corru-
gated base rail by means of transverse bolts r, ", passing through the
sides or web of the corrugated rail and through the flange of the capping,
as shown in Figure 15. By causing the cap plate R to break joints with
the base beams P, P, as shown in Figure 14, a continuous even rail is
obtained, and the use of fish plates or joint plates of any description
avoided. As fast as the capping wears away it may be readily removed
and replaced by simply detaching the bolts by which it is held. Where
superior elasticity is required in the rail a lining of india-rubber or
gutta percha may be inserted between the cap and beam. From the;
superior rigidity and strength of the corrugated base beams P, P, fewer
cross ties by one half will be required in a railway track laid therewith
than when the ordinary iron or steel Trails are employed.

page_text: Although I prefer for the sake of convenience and economy a ready
detachment and removal of the capping when worn without a disturbance
of the base beam I contemplate welding, cementing, or otherwise per-
manently securing the capping upon the corrugated base beam by any of
the well-known processes for capping iron rails.
Figure 16 illustrates one of the forms of my improved rail in which
the capping is thus permanently united to the base without bolts by
cementation in a suitable furnace to a welding heat and subsequent
rolling. In this case I slightly enlarge the upper curves or arches of the
corrugated beam on the outer sides thereof, as shown at t, t, Figure 16,
so that the overlapping edges p, p, of the capping R will take hold
thercon more firmly.
Figure 17 illustrates the capping R formed without a central flange 8,
Fig. 15, but secured upon the base beam by transverse bolts & engaging.
its overlapping edges, and which may be used with or without welding.
Figuro 18 illustrates the capping R when secured by vertical bolts
1, n.
I claim herein as my Invention the combination of an extended
capping plate R formed substantially as described with a longitudinally
2 grooved or corrugated beam, substantially in the manner and for the
purpose herein set forth.
'
W, Figures 19 and 20 (Sheet 3), is a steel ingot cast directly from
the furnace in a suitable mold in a form approaching that of the
cap plate R to be rolled therefrom as illustrated in the Drawings. The
cap plate R, Figures 14 to 18, is produced by rolling out the ingot W to..
the desired form.
I claim as my Invention the use of this form of ingot W as an
improvement in the process of producing steel cap plates R of the form
and for the purpose herein set forth.
In witness whereof, I, the said Richard Montgomery, have hereunto
set my hand and seal, this Tenth day of November, in the year'
Toad 1870
RICHARD MONTGOMERY: (L.S.)