Part 14

This machine affords a striking example of the application of the copying principle which is the fundamental feature of modern manufacturing processes. It would hardly be supposed possible, until the method had been explained, that articles in shape so unlike geometrical forms as gun-stocks, shoemakers’ lasts, &c., could be turned in a lathe. The mode in which this is accomplished is, however, very simple in idea, though in carrying that idea into practice much ingenious contrivance was required. The illustration, Fig. 35, represents a Blanchard’s lathe, very elegantly constructed by Messrs. Greenwood and Batley, of Leeds. The first obvious difference between an ordinary lathe and Blanchard’s invention is that in the former the work revolves rapidly and the cutting-tool is stationary, or only slowly shifts its position in order to act on fresh portions of the work, while in the latter the work is slowly rotated and the cutting-tools are made to revolve with very great velocity. Again, it will be observed that the headstock of the Blanchard lathe, instead of one, bears _two_ mandrels, having their axes parallel to each other. One of these carries the pattern, C, which in the figure has the exact shape of a gun-stock that is to be cut in the piece of wood mounted on the nearer spindle. One essential condition in the arrangement of the apparatus is that the pattern and the work having been fixed in similar and parallel positions, shall always continue so at every point of their revolutions. This is easily accomplished by placing exactly similar toothed wheels on the two axles, and causing these to be turned by one and the same smaller toothed wheel or pinion. The two axles must thus always turn round in the same direction and with exactly the same speed, so that the work which is attached to one, and the pattern which is fixed on the other, will always be in the same phase of their revolutions. If, for example, the part of the wood which is to form the upper part of the gun-stock is at the bottom, the corresponding part of the pattern will also be at the bottom, as in the figure, and both will turn round together, so that every part of each will be at every instant in a precisely similar position. The wood to be operated upon is, it must be understood, roughly shaped before it is put into the lathe. The toothed wheels and the pinion which drives them are in the figure hid from view by the casing, _h_, which covers them. The pinion receives the power from a strap passing over _f_. The cutters are shown at _e_; they are placed radially, like the spokes of a wheel, and have all their cutting edges at precisely one certain distance from the axis on which they revolve, so that they all travel through the same circle. These cutting-edges, it may be observed, are very narrow, almost pointed. The shaft carrying the cutters is driven at a very high speed, by means of a strap passing over _k_ and _i_. The number of revolutions made by the cutters in one second is usually more than thirty. The great peculiarity of the lathe consists in the manner in which the position of the cutters is made to vary. The axle which carries them rotates in a kind of frame, which can move backwards and forwards, so that the cutters may be readily put at any desired distance from the axis of the work. Their position is, however, always dependent on the pattern, for, fixed in a similar frame, _b_, which is connected with the former, is a small disc wheel, _a_, having precisely the same radius as that of the circle traced out by the cutters, and this disc is made by a strong spring to press against the pattern. The cutters, being fixed in the same rocking-frame which carries this guiding-wheel, must partake of all its backward and forward motions, and as the cutting-wheel and the guide-wheel are so arranged as to have always the same relative positions to the axes of the two headstocks, it follows that the edges of the cutters will trace out identically the same form as the circumference of the guiding-disc. The latter is, of course, not driven round, but simply turns slowly with the pattern by friction, for it is pressed firmly against the pattern by a spring or weight acting on the frame, in order that the cutters may be steadily maintained in their true, but ever-varying, position. The rocking-frame receives a slow longitudinal motion by means of the screw, _n_, so that the cutters are carried along the work, and the guide along the pattern.

The whole arrangement is self-acting, so that when once the pattern and the rough block of wood have been fixed in their positions, the machine completes the work, and produces an exact repetition of the shape of the pattern. It is plain that any kind of forms can be easily cut by this lathe, the only condition being that the surface of the pattern must not present any re-entering portions which the edge of the guide-wheel cannot follow. The machine is largely used for the purposes named above, and also for the manufacture of the spokes of carriage-wheels. The limits of this article will not permit of a description of the beautiful adjustments given to the mechanism in the example before us, particularly in the arrangement for driving the cutters in a framework combining lateral and longitudinal motions; but the intelligent reader may gather some hints of these by a careful inspection of the figure. The machine is sometimes made with the frame carrying the guide-wheel and cutters, not rocking but sliding in a direction transverse to the axes of the headstocks. It is extremely interesting to see the Blanchard lathe at work, and observe how perfectly and rapidly the curves and form of the patterns seem to grow, as it were, out of the rudely-shaped piece of wood, which, of course, contains a large excess of material, or, in the picturesque and expressive phrase of the workmen, _always gives the machine something to eat_.

_SAWING MACHINES._

With the exception of the last, all the machines hitherto described in the present article are distinguished by this—they are tools which are used to produce other machines of every kind. Without such implements it would be impossible to fashion the machines which are made to serve so many different ends. Another peculiarity of these tools has also been referred to, namely, that they are especially serviceable, and indeed essential, for the reproduction of others of the same class. Thus, the accurate leading-screw of the lathe is the means used to cut other accurate screws, which shall in their turn become the leading-screws of other lathes, and a lathe which forms a truly circular figure is a necessary implement for the construction of another lathe which shall also produce truly circular figures. In these tools, therefore, we find the copying principle, to which allusion has been already made, as the great feature of all machines; but in order to bring this principle still more clearly before the reader, we have described in the Blanchard Lathe a machine of a somewhat different class, because it embodied a very striking illustration of the principle in question. We are far from having described all the implements of the mechanical engineer, or even all the more interesting ones; for example, we have given no account of the powerful lathes in which great masses of iron are turned, or of the analogous machines, which, with so much accuracy, shape the internal surfaces of the cylinders of steam engines, of cannons, &c. The history of the steam engine tells us of the difficulties which Watt had to contend with in the construction of his cylinders, for no machine at that time existed capable of boring them with an approach to the precision which is now obtained.

The kind of general interest which attaches to the tools we have already described is not wanting in yet another class of machine-tools, namely, those employed in converting timber into the forms required to adapt it for the uses to which it is so extensively applied. And for popular illustration, this class of tools presents the special advantage of being readily understood as regards their purpose and mode of action, while their simplicity in these respects does not prevent them from showing the advantages of machine over hand labour. Everybody is familiar with the up-and-down movement of a common saw, and in the machine for sawing balks of timber into planks, represented in Fig. 36, this reciprocating motion is retained, but there are a number of saws fixed parallel to each other in a strong frame, at a distance corresponding to the thickness of the planks. The saws are not placed with their cutting edges quite upright, but these are a little more forward at the top, so that as they descend they cut into the wood, but move upwards without cutting, for the teeth then recede from the line of the previous cut, while in the meantime the balk is pushed forward ready for the next descent of the saw-frame. This pushing forward, or _feeding_, of the timber is accomplished by means of ratchet-wheels, which are made to revolve through a certain space after each descent of the saw-frame, and, by turning certain pinions, move forward the carriage on which the piece of timber is firmly fixed, so that when the blades of the saws are beginning the next descent they are already in contact with the edge of the former cut. To prevent the blades from moving with injurious friction in the saw-cuts, these last are made of somewhat greater width than the thickness of the blades, by the simple plan of bending the teeth a little on one side and on the other alternately. The rapidity with which the machine works, depends of course on the kind of wood operated upon, but it is not unusual for such a machine to make more than a hundred cuts in the minute. The figure shows the machine as deriving its motion by means of a strap passing over a drum, from shafting driven by a steam engine. This is the usual plan, but sometimes the steam power is applied directly, by fixing the piston-rod of a steam cylinder to the top of the saw-frame, and equalizing the motion by a fly-wheel on a shaft, turned by a crank and connecting-rod.

A very effective machine for cutting pieces of wood of moderate dimensions is the _Circular Saw_, represented in Fig. 37. Here there is a steel disc, having its rim formed into teeth; and the disc is made to revolve with very great speed, in some cases making as many as five hundred turns in a minute, or more than eight in a second. On the bench is an adjustable straight guide, or fence, and when this has been fixed, the workman has only to press the piece of wood against it, and push the wood at the same time towards the saw, which cuts it at a very rapid rate. Sometimes the circular saw is provided with apparatus by which the machine itself pushes the wood forwards, and the only attention required from the workman is the fixing of the wood upon the bench, and the setting of the machine in gear with the driving-shaft. Similar saws are used for squaring the ends of the iron rails for railways, two circular saws being fixed upon one axle at a distance apart equal to the length of the rails. The axle is driven at the rate of about 900 turns per minute, and the iron rail is brought up parallel to the axle, being mounted on a carriage, and still red hot, when the two ends are cut at the same time by the circular saws, the lower parts of which dip into troughs of water to keep them cool.

RAILWAYS.

Towards the end of last century, tramways formed by laying down narrow plates of iron, were in use at mines and collieries in several parts of England. These plates had usually a projection or flange on the inner edge, thus—L, in order to keep the waggons on the track, for the wheels themselves had no flange, but were of the kind used on ordinary roads. These flat tramways were found liable to become covered up with dirt and gravel, so that the benefit which ought to have been obtained from their smoothness was in a great measure lost. _Edge rails_ were, therefore, substituted, and the wheels were kept on the rails by having a _flange_ cast on the inner edge of the rim. The rails were then always made of cast iron, for, although they were very liable to break, the great cost of making them of wrought iron prevented that material from being used until 1820, when the method of forming rails of malleable iron by rolling came into use. The first time a tramway was used for the conveyance of passengers was in 1825, when the Stockton and Darlington Railway was opened—a length of thirty-seven miles. It appears that the carriages were at first drawn by horses, although locomotives were used on this and other colliery lines for dragging, at a slow rate, trains of mineral waggons. At that time engineers were exercising their ingenuity in overcoming a difficulty which never existed by devising plans for giving tractive power to the locomotive through the instrumentality of rack-work rails. It never occurred to them to first try whether the adhesion of the smooth wheel to the smooth rail was not sufficient for the purpose. During the first quarter of the present century the greater part of the goods and much passenger traffic was monopolized by the canals. It is quoted, as a proof of the careless manner in which this service was performed, that the transport of bales of cotton from Liverpool to Manchester sometimes occupied twice the length of time required in their voyage across the Atlantic. When an Act of Parliament authorizing the construction of a railway between Liverpool and Manchester was applied for, the canal companies succeeded in retarding, by their influence, the passing of that Act for two years. It was passed, however, in 1828, and the construction of the line was proceeded with. This line was at first intended only for the conveyance of goods, especially of cotton and cotton manufactures, and the waggons were to be drawn by horses. When the line was nearly finished the idea of employing horses was, at the instigation of Mr. George Stephenson, abandoned in favour of steam power. The directors were divided in opinion as to whether the carriage should be dragged by ropes wound on large drums by stationary engines, or whether locomotives should be employed. Finally, the latter plan was adopted, and it was also suggested that passengers might be carried. The directors offered a prize for the best locomotive, and the result has been already mentioned. In the light of our experience since that time, it is curious to read of the doubts then entertained by skilful engineers about the success of the locomotive. In a serious treatise on the subject, one eminent authority hoped “that he might not be confounded with those hot-brained enthusiasts who maintained the possibility of carriages being driven by a steam engine on a railway at such a speed as twelve miles an hour.” When the “Rocket” had accomplished the unprecedented velocity of twenty-nine miles an hour, and the railway was opened for passengers as well as goods, the thirty stage coaches daily plying between Liverpool and Manchester found their occupation gone, and all ceased to run except one, which had to depend on the roadside towns only, while the daily number of passengers between the two cities rose at once from 500 to 1,600. In that delightful book, Smiles’s “Life of George Stephenson,” may be found most interesting details of the difficulties attending the introduction of railways, especially with regard to the construction of this first important line. Mr. Smiles relates how the promoters of the scheme struggled against “vested interests;” how the canal proprietors, confident at first of a secure and continuous enjoyment of their monopoly, ridiculed the proposed railway, and continued their exorbitant charges and tardy conveyance, pocketing in profits the prime cost of their canal about every three years; how, roused into active opposition, they did all in their power to thwart the new scheme; how the Lord Derby and the Lord Sefton of that day, and other landowners, offered every resistance to the surveyors; how the Duke of Bridgewater’s farmers would not allow them to enter their fields, and the Duke’s gamekeepers had orders to shoot them; how even a clergyman threatened them with personal violence, and they had to do their work by stealth, while the reverend gentleman was conducting the services in his church; how newspaper and other writers declared that the locomotives would kill the birds, prevent cows from grazing and hens from laying, burn houses, and cause the extinction of the race of horses. All the civil engineers scouted the idea of a locomotive railway, and Stephenson was held up to derision as an ignoramus and a maniac by the “most eminent lawyers,” and the most advanced and “respectable” professional C.E.s of the time. An article appeared in the “Quarterly Review,” very favourable to the construction of railways, but remarking in reference to a proposed line between London and Woolwich: “What can be more palpably absurd and ridiculous than the prospect held out of locomotives travelling _twice as fast as stage coaches_! We should as soon expect the people of Woolwich to suffer themselves to be fired off upon one of Congreve’s _ricochet_ rockets as trust themselves to the mercy of a machine going at such a rate. We will back old Father Thames against the Woolwich Railway for any sum. We trust that Parliament will, in all railways it may sanction, limit the speed to _eight or nine miles an hour_, which we entirely agree with Mr. Sylvester is as great as can be ventured on with safety.” This passage, which reads so strangely now, may be seen in the “Quarterly Review” for March, 1825. But still more curious appear now the reports of the debates in Parliament, and of the evidence taken before the Parliamentary Committee, in which we find the opinions and fears of the best informed men of that period, and trace the frantic efforts of the holders of the “vested interests” to retain them, however obstructive of the public good.

When it has been decided to construct a railway between two places, the laying-out of the line is a subject requiring great consideration and the highest engineering skill—for the matter is, on account of the great cost, much more important than the setting-out of a common road. The idea of a perfect railroad is that of a straight and level line from one terminus to another; but there are many circumstances which prevent such an idea from being ever carried into practice. First, it is desirable that the line should pass through important towns situated near the route; and then the cost of making the roadway straight and level, in spite of natural obstacles, would be often so great, that to avoid it detours and inclines must be submitted to—the inconvenience and the increased length of road being balanced by the saving in the cost of construction. It is the business of the engineer who lays out the line to take all these circumstances into consideration, after he has made a careful survey of the country through which the line is to pass. The cost of making railways varies, of course, very much according to the number and extent of the tunnels, cuttings, embankments, or other works required. The average cost of each mile of railway in Great Britain may be stated as about £35,000. The road itself when the rails are laid down is called _the permanent way_, perhaps originally in distinction to the temporary tramways laid down by the contractors during the progress of the works. The permanent way is formed first of _ballast_, which is a layer of gravel, stone, or other carefully chosen material, about 2 ft. deep, spread over the roadway. Above the ballast and partly embedded in it are placed the _sleepers_, which is the name given to the pieces of timber on which the rails rest. These timbers are usually placed transversely—that is, across the direction of the rails, in the manner shown in Fig. 42. This figure also represents the form of rails most commonly adopted, and exhibits the mode in which they are fastened down to the sleepers by means of the iron _chairs_, _b_ _c_, the rail being firmly held in its place by an oak wedge, _d_. These wedges are driven in while the rails are maintained at precisely the required distance apart by the implement, _e f_, called a _cramp gauge_, the chairs having previously been securely attached to the sleepers by bolts or nails. The double ⟙ form of rail has several important advantages, such as its capability of being reversed when the upper surface is worn out, and the readiness with which the ends of the rails can be joined by means of _fish-plates_. These are shown in Fig. 43, where in a we are supposed to be looking down on the rails, and in B to be looking at them sideways. In Fig. 44 we have the rail and fish-plates in section. The holes in the rails through which the bolts pass are not round but oval, so that a certain amount of play is permitted to the ends of the rails.

It may easily be seen on looking at a line of rails that they are not laid with the ends quite touching each other, or, at least, they are not usually in contact. The reason of this is that space must be allowed for the expansion which takes place when a rise in the temperature occurs. If the rails are laid down when at the greatest temperature they are likely to be subject to, they may then be placed in actual contact; but in cold weather a space will be left by their contraction. For this reason it is usual when rails are laid to allow a certain interval; thus rails 20 ft. long laid when the temperature is 70°, are placed with their ends 1/20th of an inch apart, at 30° 1/10th of an inch apart, and so on. The neglect of this precaution has sometimes led to damage and accidents. A certain railway was opened in June, and after an excursion train had in the morning passed over it, the midday heat so expanded the iron, that the rails became in some places elevated 2 ft. above the level, and the sleepers were torn up; so that, in order to admit of the return of the train, the rails had to be hastily relaid in a kind of zigzag. In June, 1856, a train was thrown off the metals of the North-Eastern Railway, in consequence of the rails rising up through expansion.