AN IMPROVED METHOD OF AND APPARATUS FOR CONVERTING OLD RAILWAY- RAILS AND RAIL-ENDS INTO BILLETS OR PIECES FOR SALE OR FOR USE IN THE MANUFACTURE OF VARIOUS ARTICLES
Year: 1880

page_text: LETTERS PATENT to William Robert Lake, of the Firm of Haseltine, Lake, &
Co., Patent Agents, Southampton Buildings, London, for an Invention of "AN
IMPROVED METHOD OF AND APPARATUS FOR CONVERTING OLD RAILWAY-
RAILS AND RAIL-ENDS INTO BILLETS OR PIECES FOR SALE OR FOR USE IN
THE MANUFACTURE OF VARIOUS ARTICLES." A communication from abroad
by Stephen Warner Baldwin, of Yonkers, New York, United States of
America.
COMPLETE SPECIFICATION filed by the said William Robert Lake at the
Office of the Commissioners of Patents on the 15th June 1880.
WILLIAM ROBERT LAKE, of the Firm of Haseltine, Lake, & Co., Patent Agents,
Southampton Buildings, London. "AN IMPROVED METHOD OF AND APPARATUS
FOR CONVERTING OLD RAILWAY-RAILS AND RAIL-ENDS INTO BILLETS OR PIECES
A com-
FOR SALE OR FOR USE IN THE MANUFACTURE OF VARIOUS ARTICLES."
munication from abroad by Stephen Warner Baldwin, of Yonkers, New York,
United States of America.
Railway rail ends have heretofore been formed into merchantable "billets" or
pieces in various manners, but by reason of modern improvements in the manu-
facture of railway iron and in the form and relative proportions of the "foot,"
"web," and "head" of the rail, the utilization of rail-ends, except for reworking
into rails, has become almost impracticable. It is well known that formerly rail-
ends were of considerable length, say, from three to five feet, whereas at present
they seldom if ever exceed two feet at the most. Heretofore the longest of these
ends have been converted into "billets" by rolling operations, commencing either
with the rail end in its original form, or more commonly by first dividing it into three
longitudinal sections, viz., "head," "web," and "foot," or into two sections, one of
which contains the foot and the other the web and head, and then rolling these
sections separately. Only the long ends are capable of being profitably worked by
this sectional system, the shorter lengths having heretofore been reworked into
rails. The modern introduction of steel rails, together with the improved methods
of manufacture, tend still further to decrease the length of rail-end to about twelve
inches as a maximum, the rule being that they are much shorter than that, and
hence the sectional system of forming "billets" therefrom is impracticable, and the

page_text: incapacity of the metal for being welded on itself also renders it impracticable to
roll such short steel rail-ends direct from the original form, which might be possible,
although not profitable, with iron rail-ends of the same length. It is well known
that in working steel rail-ends the welding or re-incorporation or working together
of two scale surfaces in contact so as to attain a homogenous condition is impossible,
and therefore any mode of operation involving such contact of scale-surfaces would
inevitably produce "billets" containing flaws and scams, rendering them unfit for
general use in the manufacture of any kind of goods involving thin rolling and
requiring either strength or fair surface-finish. I am well aware that rolls have
been, heretofore devised for working old rails into sheets or plates commencing
upon the rail in its normal form, but such rolls have never been successfully used
in working "rail-ends."
The general object of this Invention is to economically transform old railway
rails and rail ends into "billets" of such a form as will render them readily available
for subsequent rolling operations or for convenient use in the manufacture of a
great variety of metal goods.
"
The special object of the said Invention is to economically produce rail "billets "
of superior quality, having reference to uniform density and freedom from scale-
seams, and flaws, and also to practically and profitably transform into merchantable
'billets" of a valuable bulk and weight steel rail-ends of a shorter length than
have been practically formed into "billets" under pre-existing methods.
My Invention mainly consists in subjecting the rail ends to compression or
percussion applied in lines at right angles to the plane of the web, while the rail
end is bodily immovable, but free to expand in all directions in the plane of the
web. In the use of the term "bodily immovable" I desire to be understood as
meaning that in the practice of this Invention there is no movement of the rail-end
considered as a whole during the application of pressure, and that although its
form is changed by the compressing operations, it occupies at the termination of
cach compression substantially the same position it occupied at the beginning
thereof.
A subordinate feature of the said Invention consists in subjecting the "foot" or
the head" of the rail or rail-end either simultaneously or consecutively to
compression or percussion applied in lines at right angles to the plane of the web,
while the web of the rail-end is firmly confined against lateral or longitudinal
movement.
The only method heretofore practised under which the rail-end in its normal
condition has been transformed into a "billet," as hereinbefore indicated, involved
the use of peculiarly grooved rollers fitted to operate on the foot and head of the
rail-end during the passage of the latter through the rolls. My novel method
differs mainly from the rolling operation in that I confine the rail end against all
bodily movement, whereas in the rolling operation the rail-end moves bodily through
the rolls. In operative results these methods differ in this respect, namely, that by
my method, while working the foot of the rail-end, no uneven crippling or folding
down can occur, because the rail-end is bodily immovable and firmly held so as to
assure a uniform upset. In rolling the least angular movement of the rail-end in
passing through the rolls is conducive to the very crippling or folding result I seek
to avoid, and further, my operation is more rapid and can therefore be fully effected
with less heat or with the heat contained in a freshly cut end; and, further, there
is less loss in scale by my operation than with rolling, there being a fresh scale at
every passage through the rolls, while with my process a single scale only is
developed, resulting in this respect alone in a saving of from two to three per cent.
' in scale loss.
According to this Invention I produce from a rail-end a "billet" without any
change of the "web" portion of the rail-end; I produce a "billet" from a rail-end
in its normal condition without rolling operations; also "billets" from steel rail-
ends in their normal form without liability of seams or laps therein; also from a
rail-end in its normal form a "billet " of the same or practically the same length as

page_text: the rail-end. These points will serve to illustrate the practical value of my
Invention, as well as the novelty involved therein as an improvement in working
rail-ends. In rolling, the effect is to prolong or longitudinally draw out the metal
in the head and the foot without a corresponding working of the web, and the
tendency is therefore to strain or weaken the metal at or near the lines of junction
between the web and and the foot and head respectively, so that the billet thus
formed is not uniformly solid and homogeneous.
Although I do not limit myself to any particular mechanism for effecting the
objects above set forth, my Invention also comprises certain means which have been
found to be practically valuable for attaining the results desired, that is to say, I
employ apparatus hereinafter described.
I provide a pair of dies which are longitudinally scored for the reception of the
opposite edges of the "foot" of a rail-end with mechanism for slowly advancing
said dies toward each other and upon an interposed rail-end, the scores serving the
double purpose of preventing the bodily movement of the rail-end, and also
preventing said "foot" of the rail-end from being crippled and folded upon itself or
on the "web."
Although I have shewn in the accompanying Drawings dies whereby this
operation has been successfully performed without the employment of means for
clamping the "web" of the rail-end, I prefer, for assuring the best results, that the
web be independently confined, and in that connection my Invention further
comprises in the combination with jaws for clamping a rail-end web, and suitable
mechanism for operating said jaws, a pair of dies scored to receive the edges of the
foot of the rail-end, and suitable mechanism for operating said dies.
This com-
bination of devices is capable only of operating upon the foot of the rail-end, and
for operating upon the head alone; my Invention further comprises the combination
with clamping jaws for holding a rail-end by its web of a pair of dies adapted to
reduce the head of a rail-end in a plane corresponding with that of the web, and
suitable mechanism for operating the jaws and dies. The comparative non-liability
of the head to be unevenly reduced enables these head-compressing dies to bo
capable of operating without a longitudinal score therein.
For simultaneously operating on the foot and head of the rail-end with separato
dies, my Invention further comprises the combination with a pair of longitudinally
scored dies; and a pair of head-working dies, of clamping jaws interposed between
the pairs of dies, and suitable mechanism for operating the dies and jaws.
Under the features of the said Invention thus far stated I do not limit myself
'to any particular operating mechanism, for I am well aware that it may be largely
varied in kind without materially affecting the proper operation of the dies alone,
or the dies and jaws combined, but I construct a complex press which may be :
operated by the application of steam or hydraulic pressure, and in that particular
connection my.Invention further comprises the combination with clamping jaws,
and one or two pairs of compressing dies, of a system of levers and a separate
steam or hydraulic operating cylinder for the jaws and for each pair of dies, whereby
the jaws may be controlled independently of either pair of dies, and each pair of
dies controlled independently of the other. It is obvious that the power required
for clamping will be less than is required for working either the head or the foot
of the rail end, and also that by reason of its greater bulk more power will be
required for working the head than for working the foot, and therefore I prefer
that each pair of dies and the jaws be separately operated. Moreover with the
separate "head" and "foot" dies it is desirable that the rail end be firmly clamped
before either of the dies commence their work. In this press I employ the scored
foot-dies, and also plain foot-dies which follow the operation of the scored dies to
complete the "billet."
:
The finishing dies operate in pairs, and I have so arranged them in my press
that having subjected the rail-end-to-compression with the scored foot dies-and-
inclined-or-curved-face-head dies, the partially compressed end may then be
moved along and placed in position to be acted upon by the finishing dies, and in

page_text: the foot) have been heretofore rolled with considerable success in work
rail-ends.
i
It is in working the "foot" c that the greatest difficulty has heretofore been
experienced, because of its being so nearly equal to or greater in bulk than the
web, its general resemblance to it in sectional form, and also to the rectangular and
central position occupied by it with relation to the web. In order to properly
control the metal in the foot, the pressure or percussion must be applied equally
and simultaneously at both edges, in a line at right angles to the plane of the web,
so as to properly locate the reduced metal. The least tipping or cramping of the
foot so as to cause its two sides or edges to close down in opposite directions would
result in the contact of scale-surfaces, and produce a seamed or "flawed " billet, and
it is therefore essential that the rail-end be firmly held against all bodily movement .
during the working of the foot.
1 prefer compression to percussion, because of the greater ease with which com-
pressing mechanism may be operated and controlled, but I have shown and
described dies for working the head and foot which may be operated in either
manner, it being understood that if percussion be employed, blows or strokes should
be simultaneously effected on opposite sides in order to attain the best results.
"
Tho
In Figure I have shewn in section dies A, illustrating such as have been
Successfully used in carrying out the main feature of this Invention.
longitudinal scores d are for the reception of the edges of the "foot," and it is
obvious that after they have firmly engaged with the rail-end, the latter can havo
no bodily movement, although free during the displacement of metal in the head
or foot to expand in all directions in the plane of the web. The advance of the
dies toward each other soon brings their "head faces" into contact with the
"head" of the rail end, and then both "foot" and "head are simultaneously
compressed, until said dies occupy the position indicated by dotted lines, and the.
"billet" is partially formed, as also similarly indicated. The dies slightly chill the
thin edges of the foot, which contributes to their rigidity, but the scores are so
bevelled at the sides as to admit of an easy lateral movement or displacement of the
The centre of
metal without liability of overlapping upon itself or on the "web.'
the "foot" having the greatest heat freely expands outward, and maintains this
convex outline to the finishing of the "billet," which is a matter of practical valuo
in subsequent rolling operations.
In Figure 5 I have shewn a pair of finishing dies B which have no longitudinal
scores, and which deliver the completed "billet," Figure 3. For working solid dies
of this character a very powerful press is required, and considerable care is also
requisite for the accurate delivery of the rail-end thereto by tho attendant, becauso
the rail-end should be so maintained in position that the edges of the foot shall
properly occupy the longitudinal scores d.
'
When separate foot and head dies are used I prefer that they may be accom-
panied by clamping jaws C, one form of which is shown in section in Figuro 6.
These have coincident faces f which correspond in sectional outline with the
sectional outline of the web of the rail-cuds to be worked, so as to firmly clamp tho
rail-end by its web. The jaws may be mounted and operated in various ways, one
method being hereinafter shewn.
The dies A', Figure 7, are for the initial working of the foot of the rail-end.
They are essentially provided with the longitudinal score d for receiving the
opposite edges of the foot c of the rail-end. These dies may be variously operated,
and those shown are provided with ears for connection, either with operating lovers,
as for compression, or with shoes for receiving blows thereon from a hammer, it
being understood that said dies bo so mounted in suitable guides, as to be confined
in their movement toward each other, to a line at true right angles to the plane of
the web of the rail end when clamped by the jaws. With these dies a full or
complete compression of the foot cannot be effected, because of the standing metal
which occupies the scores das shewn-in-the-partly-compressed-"-billet, Figure-2,
and therefore a pair of plain 'dies A³, as in Figure 8, are next relied upon for

page_text: completing the work. The standing metal which was formerly the edges of the foot is,
after the first compression, of sufficient beight to render it possible for the plain
dics to cripple or bend it to the one side or the other, and it will be seen that the
central portion of the foot of the rail is forced outward in the plane of the web, the
remaining portions being quite equally distributed on either side, with faces nearly
or quite parallel with each other, and with prolongations of the surfaces of the
web.
In Figure 9 two sets of head dies are shewn, of which the dies gare for the initial
operation and the dies for completion. It will be seen that the dies have
working faces which are slightly inclined, and that the outer edges thereof are
farther removed from the dotted central line shown than the inner edges thereof,
whereby the metal of the head, as its form is changed, is forced or drawn outward,
leaving that portion of the "billet," after the first compression, with flaring sides,
as is shewn in Figure 2. The finishing dies h have straight faces, which complete
the drawing operation on the head and develope the parallel surfaces at that portion
of the "billet," as shown in Figure 3.
In Figure 10 the clamping jaws, the scored foot-dies A', Figure 7, and the head-
dies g of Figuro 9 are shewn in their proper relative positions, with a rail-end
interposed. The jaws are first set, so as to firmly hold the rail-end against all bodily
movement, and then the head and foot dies are simultaneously or consecutively
operated in pairs to transform the rail-end into the form shewn in Figure 2, after
which the dies A' and complete the operation, they being shewn in their proper
relative position in Figure 11. The dies and jaws shewn are capable of being
operated in various ways without departing from the main feature of iny Invention,
but for economic working much depends upon the operative mechanism employed,
as well as upon certain matters of arrangement, as will be hereinafter fully set
forth.
In Figure 12 I have shown the solid dies A provided with clamping jaws C¹,
which occupy recesses in the jaws and are backed up by powerful springs, and so
far project from said dies as to enable them to engage with and firmly clamp the
rail end by its web before the dies commence their work.
Considered as a whole, my improved press may be termed a triple press, in that
it has three separate points for the independent application of power to clamping
jaws, "foot" dies, and “head” dies. I will first describe the clamping jaws and
their operating mechanism:-The jaws C are located longitudinally and centrally a
in a suitably strong and heavy frame D. As the lower jaw need not be movable it
is mounted firmly upon the frame at each end, and centrally supported or braced by
a post . The upper jaw is movable, and should bo limited to a truly vertical
movement by guides, but in this machine no separate guides are employed, because
the coincident surfaces of the movable bars 1 and E on which compressing dies
are fixed or mounted mainly perform the guiding function, although the upper jaw
is centrally provided on its upper surface with square laterally projecting studs k
which occupy vertical slots in both of said bars, the jaw and bars operating in a
measure therefore as vertical guides for each other.
On the upper front end of the machine is a clamping jaw-operating cylinder F
provided with a piston and a rod, to which movement is imparted by steam or
water under pressure, delivered to and discharged from the cylinder by valve-
mechanism operated automatically or otherwise in a manner too well known to
require detailed Drawings or description. The upper jaw is suspended from the top
of the frame by means of a series of jointed toggles ³ connected by means of a 5
horizontal bar m', which at its front end is jointed to the end of a toggle-lever m³
baving a fixed fulcruin at m³ in a bracket projecting from the frame and connected
by a vertical link m to piston-rod 1, so that when the latter is lifted by its piston
the upper jaw is forced into clamping relations with the lower or fixed jaw, for
securely holding an interposed rail-end by its web. The pair of scored foot-dies A¹
are each mounted on a movable bar E, both of which bars are guided by contact
with the frame of the machine at each end and with the coincident surfaces of the

page_text: jaws C, and centrally by the square studs & hereinbefore referred to. On one side
of the top of the frame, centrally located longitudinally, is a "foot "-die-operating
cylinder G provided, like the jaw-operating cylinder herein before described, with
valve-mechanism, piston, and a long piston rod l', which is connected with both die-
bars E by means of two links n, two bell-crank levers n', two horizontal bars n³,
and the two series of toggles n³: The upper die-bar E is suspended by its toggles n³
from the top of the frame, and the lower die-bar E is supported by its toggles n³,
which bear with their pivots in the bed of the frame. It will readily be seen that
the upward movement of the piston-rod will cause the two dies A¹ to approach
each other for compression, and that the downward movement of the said rod will
cause them to separate. These same die-bars E also carry the finishing foot-dies A²,
Baid bars being twice the length of the dies, which abut endwise with each other
=
midway of the bar.
•
The head-working dies g and h are similarly mounted on die-bars E', which are
connected with their cylinder G-by its piston rod and other links, levers, bars, and
toggles, as already described, in connection with the foot-dies. The connection of
the links to the piston-rods should be adjustable, or those parts should be otherwiso
so constructed as to admit of more or less capacity for adjustment, whereby the
jaws or dies may be variably opened. The degree of compression will vary with
the pressure of steam or water within the cylinders, and that can be readily governed
through well known valve-mechanism.
The jaws and dies being separately operated the proper clamping of the rail-end
may be attained prior to the operation of the dies, and the latter may be simul-
taneously operated, as is preferable in most cases; or they can be separately
operated, as, for instance, if ever desirable, a rail-end may be first sectionally
divided by separating the head or the foot from the web, leaving the web with
either the foot or the head to be worked, in which case the proper dies need only
be employed leaving the others idle. The solid dies, Figures 4, 5, and 12, may be
used in this press by removing therefrom the clamping jaws C and their operative
mechanism, and having each set of die-toggles properly connected to the upper
and lower dies respectively; in which case the die-cylinders G and C' should be
provided with a single set of valve-mechanism common to both cylinders. I would
prefer, however, for the solid dies a single cylinder with sufficient area of piston tỏ
'perform the required work.
'
When the apparatus is designed for service at some particular rail-mill the length
of the dies should be sufficient to work the longest ends common to that mill; but
of whatever length the dies may be they can be used on ends longer than they are
or on old rails, by the intermittent advance of the rail into the machine, its
construction being such that it can as safely operate upon one short end between
either set of dies, as it can simultaneously operate with all its dies upon a rail-end
which is as long as the machine itself. It will readily be seen that if my apparatus
be located closely adjacent to the saw of a rail-mill, a red hot end, however
short, may be put directly into the dies, one succeeded by another and pushed-
forward by it, so that the finished "billets" will drop from the rear end of the
machine; or if the supply of ends be not sufficiently rapid for that purpose each
rail-end may be pushed through from the front to the rear dies, and thence pushed
separately from the machine. I contemplate the use of well known valve-
mechanism by which the jaws and dies will be automatically operated in proper
closing and opening succession, so that'a tender will only be required for inserting
the rail-ends at the front of the machine.
Having thus fully described the said Invention as communicated to mo by my
foreign correspondent, and the manner of performing the same, I wish it under-
stood that I claim,→
First. The improved method of converting the ends of railway rails into
merchantable "billets or pieces, by subjecting them to compression or percussion
applied-in lines at right angles-to-the-plane-of-the-"web" while the rail-end is
confined against bodily movement, substantially as above described.

page_text: "
Second. The improved method of converting the ends of railway rails into
merchantable "billets" or pieces by subjecting the" foot or the "head" of the
rail-end, or both of them, either simultaneously of consecutively, to compression or
percussion applied in lines at right angles to the plane of the web of the rail-end
while the web of the rail-end is firmly confined against all lateral or longitudinal
movement, substantially as described and for the purposes specified.
Third. The combination with jaws for clamping a rail-end by its "web," and
suitable mechanism for operating said jaws, of a pair of dies scored to receive the
edges of the "foot" of a rail-end, and suitable mechanism for operating said dies
for upsetting the "foot," substantially as described for the purpose specified.
Fourth. The combination with clamping jaws for holding a rail-end by its
web," of a pair of dies adapted to reduce the "head' of a rail-end in a plane
corresponding with that of the "web," and suitable mechanism for operating the
jaws and dies, substantially as described for the purpose specified.
Fifth. The combination with a pair of longitudinally scored foot "-dics and a
pair of "head"-working dies, of clamping jaws interposed between them, and
suitable mechanism for operating the jaws and dies, substantially as described and
for the purpose specified.
"
Sixth. The combination with clamping jaws, and one or more pairs of com-
pressing dies for working rail-ends into "billets," of a system of levers and a
separate steam or hydraulic operating cylinder for the jaws and for each pair of
dies, substantially as described, whereby the jaws and the pairs of dies may be
separately operated, as above set forth and for the purpose described.
Seventh. The combination with suitable operating mechanism, a pair of clamping
jaws adapted to firmly clamp a rail or rail-end by its "web," a pair of longi-
tudinally-scored "foot" dies, and a pair of inclined faced "head" dies, of a pair of
finishing "foot"-dies and a pair of finishing "head"-dies, substantially as described
for the purpose specified.
Eighth. The combination with suitable operating mechanism, a pair of initial
dies and a pair of finishing dies for working on the "foot" or "head" of a rail or
rail end, of clamping jaws common to all the dies, substantially as described,
whereby one of the jaws may operate as a bed on which a partially formed "billet "
or pieco may be supported while being pushed from one pair of dies to the other,
as above set forth.
Ninth. Tho combination with suitable operating mechanism and clamping jaws
of four sets of dies simultaneously operated, substantially as described, whereby the
"foot" and "head" of a rail or rail-end may be partially worked in the forming of
a "billet" or piece by two sets of dies while the finishing operation is performed
by the other two sets of dies, as herein set forth.
In witness whereof, I, the said William Robert Lake, have hereunto set my
hand and scal, this Fifteenth day of June, in the year of our Lord One
thousand eight hundred and eighty.