IMPROVEMENTS IN FORGING AND ROLLING METALS APPLICABLE TO THE MANUFACTURE OF WHEELS, SPADES, SHOVELS, AXLES, BUFFERS, AND OTHER ARTICLES OF WROUGHT IRON
Year: 1860

page_text: ETTERS PATENT to John Henry Johnson, of 47, Lincoln's Inn Fields,
in the County of Middlesex, and of 166, Buchanan Street, in the City of
Glasgow, North Britain, Gentleman, for the Invention of "IMPROVEMENTS
IN FORGING AND ROLLING METALS APPLICABLE TO THE MANUFACTURE OF WHEELS,
SPADES, SHOVELS, AXLES, BUFFERS, AND OTHER ARTICLES OF WROUGHT IRON."
A communication from abroad by Messieurs H. Petin Gaudet and Com-
pany; of Paris, in the Empire of France, Engineers.
Sealed the 11th December 1860, and dated the 27th September 1860.
PROVISIONAL SPECIFICATION left by the said John Henry Johnson
at the Office of the Commissioners of Patents, with his Petition, on
the 27th September 1860.
I, JOHN HENRY JOHNSON, of 47, Lincoln's Inn Fields, in the County of
Middlesex, and of 166, Buchanan Street, in the City of Glasgow, North
Britain, Gentleman, do hereby declare the nature of the said Invention for
"IMPROVEMENTS IN FORGING AND ROLLING METALS APPLICABLE TO THE MANUFACTURE
OF WHEELS, SPADES, SHOVELS, AXLES, BUFFERS, AND OTHER ARTICLES OF WROUGHT
IRON," a communication from abroad by Messieurs. H. Petin Gaudet and
Company; of Paris, in the Empire of France, Engineers.
This Invention relates to a peculiar system or mode of shaping metals by
forging and rolling the same, which system or mode may be advantageously
employed in the manufacture of railway wheels and axles, buffer heads, door

page_text: .
hinges, the frames or holders for break locks, break levers, guard plates,
shovels, spades, trowels, scythes, and in general, all articles of a symmetrical
form.
.
The
According to this Invention it is proposed to employ suitably constructed
rolls according to the shape of the article to be produced, which rolls have a
progressive alternating motion imparted to them in lieu of a continuous
rotatory motion as heretofore. This progressive alternating motion is derived
from a vibrating lever keyed on to a rocking shaft, which also carries a large.
spur wheel for transmitting its motion to the gearing of the rolls.
vibrating lever is actuated by a rotating crank and connecting rod, and the
gradual progressive motion of the rolls is obtained by increasing gradually
the throw or stroke of the vibrating lever. This may be accomplished by
connecting the end of the connecting rod to a nut working on a screw spindle,
which extends along the lever and which is rotated a certain amount at each
stroke by a pair of bevel wheels and a reversing pall and spur wheel, the.
direction of rotation of the screw depending upon the position of the pall. As
the nut travels towards or from the free end of the lever it follows that the
stroke of such lever will be gradually diminished or increased, the lever being
thereby vertically lengthened or shortened, and this variation of motion is
imparted in a proportionate degree to the rolls, which receive a partial
circular reciprocating motion on their axes, but, which motion gradually
increases in extent at each stroke.
In making a solid railway wheel (that is to say, a wheel without spokes or
arms) according to this Invention, a rough flat blank of an oval or elongated
form is prepared by means of a suitable matrix under the steam hammer,
which matrix also forms a perforated boss thereon. This blank is placed on a
steel bar having a recess to receive the boss, and a central mandrill in that
recess which enters the hole in the boss. This bar is made to fit accurately
a groove in the lower roll, and is supported by two carrying rolls beneath it
one on each side of the lower roll. The upper roll is plain on its surface
for the purpose of imparting an even surface to the top side of the blank,
whilst the under face is also rolled even by those parts of the lower roll on
each side of the steel bar. As the blank is slightly oval, it follows that by the
time it is reduced to a sufficient thickness by the gradual approximation
of the rolls it will have expanded laterally to a sufficient degree to form a disc
or circular blank, the oval blank being introduced with its major axis parallel
to the axes of the rolls. The recess in the steel bar serves as a matrix for the
formation of the boss. The blank so formed is now dished in a matrix under
a steam hammer, and a pair of blanks thus prepared are then placed together

page_text: with their convex sides outwards, and having been heated are welded together
at their edges between suitable dies and a rim applied to their peripheries, such
rim being either welded thereon by dies for that purpose or rivetted thereon,
or the two sides of the wheel may be rivetted together in place of being welded,
as above described. A central mandrill is fitted into the lower matrix to
receive the boss of the wheel during the welding together of the two halves or
sides. In rolling axles the steel bar is dispensed with and each roll is so
grooved or channelled as to produce the shape of axle required. The blank is
first acted upon in the middle and the rolls vibrate more and more at each
partial rotation until the proper length of axle is obtained. For many articles
a plate with a matrix formed in it to receive the blank is passed between the
rolls, and the depth of the matrix may be greater than the actual thickness
of the article, in which case the upper roll should have a raised portion formed
upon it to enter the matrix, and fit accurately therein, by which means the
waste of metal by reason of its squeezing out at the edges of the matrix is
obviated.
SPECIFICATION in pursuance of the conditions of the Letters Patent, filed
by the said John Henry Johnson in the Great Seal Patent Office on
the 27th March 1861.
TO ALL TO WHOM THESE PRESENTS SHALL COME, I, JOHN
HENRY JOHNSON, of 47, Lincoln's Inn Fields, in the County of Middlesex, and
of 166, Buchanan Street, in the City of Glasgow, North Britain, Gentleman,
send greeting.
WHEREAS Her most Excellent Majesty Queen Victoria, by Her Letters
Patent, bearing date the Twenty-seventh day of September, in the year of our
Lord One thousand eight hundred and sixty, in the twenty-fourth year of Her.
reign, did, for Herself, Her heirs and successors, give and grant unto me,
the said John Henry Johnson, Her special license that I, the said John
Henry Johnson, my executors, administrators, and assigns, or such others
as I, the said John Henry Johnson, my executors, administrators, or assigns
should at any time agree with, and no others, from time to time and at
all times thereafter during the term therein expressed, should and lawfully.
might make, use, exercise, and vend, within the United Kingdom of Great
Britain and Ireland, the Channel Islands, and Isle of Man, an Invention
for "IMPROVEMENTS IN FORGING AND ROLLING METALS APPLICABLE TO THE MANU-
PACTURE OF WHEELS, SPADES, SHOVELS, AXLES, BUFFERS, AND OTHER ARTICLES OF

page_text: WROUGHT IRON," a communication from abroad by Messieurs H. Petin Gaudet
and Company, of Paris, in the Empire of France, upon the condition (amongst
others) that I, the said John Henry Johnson, my executors or administrators, by
an instrument in writing under my hand and seal, or under the band and
seal of one of them should. particularly describe and ascertain the nature
of the said Invention, and in what manner the same was to be performed,
and cause the same to be filed in. the Great Seal Patent Office, within
six calendar months next and immediately after the date of the said Letters
Patent.
NOW KNOW YE, that I, the said John Henry Johnson, do hereby
declare the nature of the said Invention, and in what manner the same, is
to be performed, to be particularly described and ascertained in and by the
following statement, reference being had to the accompanying Drawings and
to the letters and figures marked thereon, that is to say :-
:. The said Invention relates to a peculiar system or mode of shaping metals
by forging and rolling the same, which system or mode may be advantageously.
employed in the manufacture of railway wheels and axles, buffer heads, door
hinges, the frames or holders for break blocks, break levers, guard plates,
shovels, spades, trowels, scythes, and in general all articles of a symmetrical
form.
According to this Invention it is proposed to employ suitably constructed
rolls, according to the shape of the article to be produced, which rolls have a
progressive alternating motion imparted to them in lieu of a continuous
rotatory motion, as heretofore. This progressive alternating motion is derived
from a vibrating lever: keyed on to a rocking shaft, which also carries a large
spur wheel for transmitting its motion. to the gearing of the rolls. The
vibrating lever is actuated by a rotating crank and connecting rod, and the
gradual progressive motion of the rolls is obtained by increasing gradually the
throw or stroke of the vibrating lever. This may be accomplished by con-
necting the end of the connecting rod to a nut working on a screw spindle,"
which extends along the lever, and which is rotated a certain amount at each
stroke by 3 pair, of bevel wheels and a reversing pall and spur wheel, the
direction of rotation of the screw depending upon the position of the pall.. As
the nut travels towards or from the free end of the lever it follows that the
stroke of such lever will be gradually diminished or increased, the lever being
thereby vertically lengthened or shortened; and this variation of motion is
imparted in a proportionate degree to the rolls, which receive a partial circular
reciprocating motion on their axles, but which motion gradually increases in
extent at each stroke.

page_text: And in order that the said Invention may be fully understood, I shall now
proceed more particularly to describe the same, and for that purpose I shall
refer to the several Figures on the Sheet of Drawings hereunto annexed, the
same letters of reference indicating corresponding parts throughout all the
corresponding Figures.
In applying this system of rolling to the manufacture of a solid railway
wheel, for example, that is to say, a wheel made without arms or spokes, as
shown in Figures 2, 3, 4, and 5 of the annexed Sheet of Drawings, I first
prepare two halves of a wheel in the shape of two discs (Figure 5); these are
heated at the centre or boss, and are placed together in a matrix M, as shown
in the same Figure, and welded together at the line of junction m, n, by the
blows of a steam hanmer. In this matrix is fitted a mandrill, which is
cylindrical at the part A, B, corresponding to the interior of the nave or boss,
slightly tapered at the upper end above the nave, and conical also at the part
where it is fixed into the matrix, in which it is retained by a key at its lower
end, this key being withdrawn, so as to allow the mandrill to drop out when
the wheel is to be removed from the matrix. The two discs being thus
welded together, they are allowed to cool, and the rim is then applied. This
is effected in the following manner:-The rim C consists of a wrought-iron
ring of the section or outline shown at u, s, r, . After being heated to a
welding heat it is placed in the matrix, as shown by the red lines in Figure 5,
and the wheel adjusted thereon. A few blows of the hammer welds the rim
on to the periphery of the wheel, and simultaneously shapes the upper side of
the rim similar to the lower side, the upper die or matrix being suitably
formed for that purpose, as shown in the Drawing. The wheel, with a rim
so applied, is shewn at Figure 5 bis.
.
I may observe here that the central mandrill will not be required in the
operation above referred to.
If preferred, the two portions of the wheel may be welded together at the.
same time that the rim is formed, as shown in Figure 4, the rim forming a part
of the discs themselves. Or the two halves may be made, as shown in
Figure 2, and after the central boss has been welded, the edges of the discs"
may be secured together by rivets, and the rim C secured also by rivets.
the edges of the two discs may be rivetted on to the rim C, as shown in
Figure 3, in which case this rim is rolled to the section a, b, c, d, e, f.
Or
I shall now proceed to describe the method I adopt for making the discs A, B,
herein-before referred to as forming the two halves or sides of the wheel.
I first form a circular blank by means of a steam hammer and matrix or
otherwise having the shape shewn in elevation at a, b, c, d, Figure. 1, which

page_text: α,
b,
blank is heated and passed between the rolls A and B, such rolls being
gradually approximated until the blank is reduced to a thickness, say, of about
half an inch, care being taken to change the direction of the rolling by
rotating the blank partially after each passage through the rolls, in order to
preserve its circular form. These blanks are then cut to a perfect circle, and
are shaped or dished as shown, and provided with central bosses by means of
suitable dies and matrices. This peculiar system or mode of rolling discs
constitutes the essential feature of novelty in the manufacture of railway and
other disc. wheels. Of the rolls so employed one B is perfectly plain and
cylindrical, whilst the other A has a channel or sunk portion in its centre, the
centre of which corresponds to the outline or contour of the raised boss
in the centre of the blank, as will be readily understood on referring to
the Drawing Figure 1. This blank, in order to attain its proper thickness, is
passed several times through the rolls, which are brought nearer together at
each passage, the blank being turned about one-eighth of a revolution if it is
intended to pass it eight times through the rolls, or one-tenth if ten passes are
required, the object being to roll out the disc evenly in all directions, and so
preserve its circular outline. But it will be readily perceived that the sides
of the channel which forms the boss a, b, will leave corresponding marks; on
the inner surface of the blank, a fresh mark or ridge being formed at each
passage and change of position of the blank, forming in the end a number of
radiating ribs corresponding in number to the number of times the blank has
been passed through the rolls, and therefore it would necessitate an infinity of
passes before a plain and even surface could be obtained. Further, it is hardly
possible to present the blank to the rolls, so that its boss shall correspond
exactly to the channel or groove, and it is also almost impossible to turn the
blank each time the same distance. The internal face therefore of the blank
and of the boss would consequently present an irregular appearance. The
rolling apparatus has been therefore modified, so as to overcome these objec-
tions and enable a variety of articles to be constructed on the above-mentioned
principles. These rolls in place of rotating will in most cases reciprocate, but
with a progressive motion. Figures 6, 7, and 8 serve to illustrate this novel
system of rolling. The lower roll A is provided with a rectangular groove or
channel a, b, c, d, (Figure 7), in which is inserted an iron or steel bar X,
which must exactly fit the groove. Near the longitudinal centre of the bar X
is a recess or matrix e (Figures 7 and 8), the form of which corresponds
exactly with the exterior form of the nave or boss on one half of the wheel.
In the centre of this matrix there is a mandrill i, which is to be introduced
into the aperture in the boss. The upper roll B is plain, since the external

page_text: surface of the disc is intended to be plain and smooth. The bar X is sup-
ported on either side of the roll A by two supplementary rollers C and D, the
diameters of which are the same as the diameter of the roll A at the bottom of
the groove or channel a, b, c, d. This roll receives its motion from a large
spur wheel E, fixed on the shaft F (Figure 6), which also carries a lever arm
G; the wheel E gears into the pinion I keyed on to the axis of the roll A, and
itself gearing into a second pinion J keyed on to the axis of the roll B. The
opposite end of the axis of this last named roll carries a second spur wheel K,
which transmits motion to two pinions L, M, keyed into the respective -axis
of the rollers C and D. The diameters of the several wheels I, J, K, L,
and M are so calculated as to impart the desired speed to the different rolls of
the rolling mill. The shaft F of the large wheel E receives the alternating
progressive motion, above referred to, from any convenient prime mover in the
following manner :-The lever G receives its movement from a rotating crank
through the connecting rod N, (Figure 6), one end O of which is forked and
embraces a nut P, within which works a screw spindle Q, rotating in suitable
bearings at each end. One of these bearings is formed by the point of the
set screw S, which may be tightened up to any extent required. The screw
spindle carries near its lower extremity a bevel wheel T keyed thereon, and
gearing into a corresponding bevel wheel U keyed on to a shaft V, turning in a
bearing in the plummer block X'. On this same shaft V is also fitted a spur
wheel Y, which acts as a ratchet wheel, and into the teeth of which are
engaged the ends m or n, (as may be required), of the pall Z, (Figure 6bis).
According as one or other of the teeth m and n is in gear with the wheel Y,
the screw spindle Q will revolve either to the right or left, and. consequently
the nut P will rise or descend, thereby vertically lengthening or shortening.
the lever G, and diminishing or increasing the amount of motion of the wheel
E, and through it that of the rolls and rollers which support the bar X. In
all cases the radius of the lever is greater than that of the actuating crank, so
that it will never assume a position in a direct line with its actuating connect-
ing rod, or in other words, will never reach the dead centre; and as it is
requisite occasionally to impart a considerable amount of motion; to the rolls,
it is necessary that the wheel keyed on to the axis of the lever G.should be of
a larger diameter than those keyed on to the shafts of the rolls A, B, as will
be seen on referring to the Drawings. A rack might be obviously substituted
for the screw spindle Q in the lever G, one end of the rack being connected
to the connecting rod O, whilst the lower.portion of the rack is in. gear with
a spur pinion on the axis F. A ratchet wheel fixed on this axis would enable

page_text: -
the pinion to be turned in either direction, as herein-before described. If
desired, these appliances may be adapted to the actuating crank in place of to
the lever arm G, in which case the throw of the crank would be variable, and
the length of the lever remains always the same. In place of preparing a
round blank, as previously described, I prefer to make the blank of an oval or
oblong rectangular form with the corners cut off. In the centre of this blank
is förmed, by means of a steam hammer, a. perforated boss corresponding to
the half of the boss of the wheel. This blank so prepared is placed in the
bar X, (Figures 7 and 8), care,being taken to insert the boss into the cavity
or matrix in the bar destined to receive it, the larger. dimension of the blank
being in the direction of the generatrices of the rolls: A and B. The machine
is now, set in motion, the upper roll being progressively forced down, and as
fast as the blank 'decreases: in thickness its smaller diameter increases until it
finally assumes a circular or nearly circular form:
At Figures 9 and 10 I have represented a pair of rolls suitable for making
axles. A, A, are the shafts of the rolls, each carrying a spur wheel B, B',
gearing with the large wheel on the axis of the vibrating lever arm. These
two shafts carry also the shoulders C, C', against which bear the working parts
of the rolls D, D1, these last mentioned parts being securely fixed by means
of keys a and b. The working parts of the rolls are thus removeable at
pleasure, and may be. shaped to suit any article to be produced. The two
Figures represent the rolls adapted for nipping the axle in the middle of its
length when it is of the smallest diameter; the width of the semicircular
grooves or channels increasing up to the points C, C, which correspond to the
points e, e, at the thickest part of the axle, as shewn in Figure 10; the
remaining portion of the grooves, and consequently of the axle, remain cylin-
drical or parallel.
1
It is obvious that a square, octagonal, or other shaped axle may be equally
well produced by simply substituting rolls having grooves of a suitable form;
and; indeed, the same principle may be carried out in the manufacture of
various articles; some of which I have herein-before enumerated as examples,
by employing rolling and shaping surfaces adapted to produce the article
required. In rolling an axle it is nipped first at its centre, at which part it
should be about the same diameter as the grooves, so that the rolls will not
require to be further approximated. Motion is now imparted to the rolls, such
motion being very slight at first, and gradually increasing until the full throw
is attained, when the axle has been rolled out to its proper length. If it be
desired that the axle at the point where it is first nipped between the rolls

page_text: should not correspond to the exact shape of the grooves, it may be flattened
slightly, so that its breadth will be rather less than that of the grooves. Then
on approximating the rolls, the axle will be squeezed progressively at the
same time that it is lengthened. By making the rough bar of an oval section;
and placing it between the rolls with its longer diameter in a vertical position,
a perfectly round axle would be obtained by the action of the rolls thereon.
In making hinges for carriages and waggons (Figure 11) a plate or matrix
similar to that above described, and shewn in Figures 7 and 8 is used, but the
matrix corresponds exactly in shape to the three faces a bc, de f, ghi
(Figure 11) of the hinge. The upper roll will carry only a projection for
forming the contour e, j, k. If at the same time the matrix is provided with
a fixed piece to form the space l, it will be obvious that the hinge might be
entirely completed in the rolls, beyond the drilling of the requisite holes
therein for securing it to the waggon and for receiving the pin of the hinge.
Guard plates (Figure 12) are still more easily fashioned by this system.
The matrix is very simple, and the upper roll is perfectly plain. The-demi-
circumference a, b, c,. will be formed in the blank, the branches a, d, and c, e,
being short in proportion to the thickness of the metal, so that when the
piece has by rolling attained its proper thickness, the branches will have
assumed their desired length. In place of forming the matrix of a depth equal'
to the desired thickness of the article, it may be made considerably deeper
even than the rough blank to be finished; but in that case it is requisite to
have on the upper roll a projecting portion which will fit exactly the contour
of the matrix. By this arrangement the possibility of the metal exuding
laterally from the matrix when under pressure between the edge thereof, and
the surface of the upper roll is obviated..
:
C
Spades and shovels are made in the same manner as the guard plate above
described, but for greater economy of time and labor, the matrix is 'made to
produce the spades or shovels at one operation, the two being in a line with
each other, and formed simultaneosly as the rolls reciprocate over them!
When completed the article is separated or divided in the middle, and each
portion forming a spade or shovel blade. Suitable projections and cavities are
made on the upper roll and in the die or matrix for forming the sides of
edges of the shovel, or making other impressions or raised parts thereon. >
The manufacture of scythes presents no greater difficulties than the making
of spades, but as they are not symetrical in relation to a common centre line or
axis, that system which was adopted simply from motives of economy in making
spades, becomes in the manufacture of scythes a necessity, in other words; it

page_text: is requisite that two, at least, be made at one time; the two being united by
the blade, and separated afterwards by shears; the blades having the requisite
curvature imparted to them. The blanks from which the scythes are to be
made contain sufficient metal in them to form also the handle or socket of the
scythe, in the same manner that the spade blanks formed the sockets for the
spades. By using rolls of large diameter four scythes might be made at one
time. They would be united in pairs at the blades, and each pair would be
united either at the points or at the handles. In place of rolling the scythes
lengthwise, they may evidently be rolled crosswise or transversely. In that
case the rolls may be of small diameter. The blades of the two scythes should
be presented to the rolls in such a manner that the straight line of junction
between the two be parallel to the axes of the rolls, and the rolling action will
commence at this central line.
Trowels may be made in a precisely similar manner to spades, and much
more easily than scythes. They constitute, in fact, small spades, having stems
in lieu of sockets; and when two are rolled in one, they are separated at the
stems or handle, and the part is then turned up or curved to the proper form.
Should it be found difficult to make the matrices and prepare the blades of
scythes with the object of rolling them in pairs, they may be made singly.
The modifications required in matrix and mode of operating being of a simple
nature, and consist in forming the matrix deeper than the thickness of the
scythe blade. That portion of the matrix which corresponds to the back of
the scythe will be curved to suit the curvature of the blade. The upper roll
will also be provided with a raised portion corresponding to the matrix, and of
such a height as to impart the requisite thickness to the blade. The rolling
action will commence at the back of the scythe, and advance progressively
towards the blade. By this process also the handle may be formed simul-
taneously with the blade of the scythe, it being simply necessary to bend
suitably the portion of metal forming the handle. The rolling action should
be parallel to the width of the blade..
Having now described and particularly ascertained the nature of the said
Invention, and the manner in which the same is or may be used or carried
into effect, I would observe in conclusion, that what I consider to be novel and
original, and therefore claim as the Invention secured to me by the herein-
before in part recited Letters Patent is,
First, the system or mode of rolling and shaping metals, as herein-before
described.
Second, the general construction
arrangement
and combination of

page_text: machinery or apparatus for rolling and shaping metals, as herein-before
described.
In witness whereof, I, the said John Henry Johnson, have hereunto
set my band and seal, this Twenty-seventh day of March, One thousand
eight hundred and sixty-one.
J. HENRY JOHNSON. (L.S.)